Process, Power and Marine Division John Sanins John Sanins Director, Global Business Development Director, Global Business Development Intergraph UK & I 2008 18 th November 2008 S S trategies for Fast trategies for Fast - - Tracking Conceptual Tracking Conceptual Plant Studies using SmartPlant Layout Plant Studies using SmartPlant Layout
38
Embed
Strategies for Fast-Tracking Conceptual Plant Studies ... · Strategies for Fast-Tracking Conceptual Plant Studies using SmartPlant Layout. ... Integrated Process/ Plant Model ...
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Process, Power and Marine Division
John SaninsJohn SaninsDirector, Global Business DevelopmentDirector, Global Business Development
Intergraph UK & I 200818th November 2008
SStrategies for Fasttrategies for Fast--Tracking Conceptual Tracking Conceptual Plant Studies using SmartPlant LayoutPlant Studies using SmartPlant Layout
Process, Power and Marine Division
SStrategies for Fasttrategies for Fast--TrackingTrackingConceptual Plant StudiesConceptual Plant Studies
Conceptual Plant Engineering – Intergraph’s Perspective;– Business Drivers, Challenges & Opportunities Today …– Industry Best Practice – General Observations– Current Work Practices & Workflows – an EPC’s View– Strategy Options to support Conceptual Plant Design & Layout– Intergraph's Approach
Conceptual Plant Engineering – Intergraph’s Perspective;– Business Drivers, Challenges & Opportunities Today …– Case Study; The Dow Chemical Company– Industry Best Practice – General Observations– Current Work Practices & Workflows – an EPC’s View– Strategy Options to support Conceptual Plant Design & Layout– Intergraph's Approach
Business Challenges Business Challenges ……Opportunities to Change?Opportunities to Change?
““ …… over 80% of a projectover 80% of a project’’s total cost are committed withins total cost are committed withinthe first 20% of the total projectthe first 20% of the total project’’s design time s design time …”…”
Pro
fit
Time
FasterStart‐up
TraditionalStart‐up
CapitalCost Savings
FasterProfitability
IncreasedProfit
Traditional Project Cost/Breakeven Curve
Digital Plant Project Cost/Breakeven Curve
Co
st
ReducedCapital Spend
CapitalCost Savings
ConceptualDesign
DetailedDesign
Fabrication &Construction
Commission& Test Plant Operations & Maintenance
According to a Construction Industry Institute studyof 53 major projects, projects which included the most effort on conceptual plant studies averaged:
The The opportunity costopportunity cost to influence & improve asset performance is at its to influence & improve asset performance is at its lowestlowest during the during the early stages of conceptual & detailed designearly stages of conceptual & detailed design
Business Opportunity Business Opportunity ……Potential Impact on projectsPotential Impact on projectsLayoutLayout
2%2%
2%2%
40%40%
DetailedDesign
Procurement Construction CommissioningConceptualDesign
Some Observations Some Observations ……From the EPC’s Perspective:
Boundaries between Conceptual Studies (traditional layout), FEED & Design continue to blur to support more fully integrated, complex projectsCommercial/ contractual basis supporting project execution strategies continues to poise challenges on projects
From the Owner/ Operator’s Perspective …Major opportunity to influence overall CAPEX/ OPEXContinued pressures to reduce schedule(time to market) & cost without any compromise to plant quality, integrity, safety & the environmentCapital Investments continue to get larger on a global scale ~ increasing number of ‘Mega-Projects’
How to manage the resulting challenges moving froma functional (PFD) to technical (P&ID) design, into plant layout …
SmartPlant Layout …Intergraph’s latest solution optimized for preliminary 3D conceptual plant layout
– Early plant layout, iteration & optimization– Proposal/ tender/ RFQ/ RFP development– More accurate/ early design estimates– Not intended as a “piping designer”
Scope …Tools for optimization of plant layout;
– Layout design case management– Selected equipment, piping, structure,
space management commands– Selected local drawings and reports– Interfaces with cost estimation– Pipe Auto-Routing … Powered by Alias I-Route
Simulation/ Process Design/ 3D Layout/ EstimationSimulation/ Process Design/ 3D Layout/ EstimationData Oriented Integration WorkflowData Oriented Integration Workflow
Today …
Future …
K-BaseK-Base
• PFD’s• Equipment Data Sheets• Equipment Lists (published as Equipment Data Sheets)• Stream Data Sheets (published as Equipment Data Sheets)
• 3D Model & Data • ISO Drawings• Ortho Drawings• Reports
SmartPlant3D
SmartPlant3D
P&IDs
• PFD’s• Equipment
Data Sheets• Equipment
Lists• Stream
Data Sheets
ZyqadZyqad
SmartPlantP&ID
SmartPlantP&ID
SmartPlantLayout
SmartPlantLayout
• P&IDs • Reports
• Piping MTO• Structural MTO
• Correlated P&IDs
• PFD’s• Equipment Data Sheets• Equipment Lists (published as Equipment Data Sheets)• Stream Data Sheets (published as Equipment Data Sheets)
• 3D Model & Data • ISO Drawings• Ortho Drawings• Reports
Design Aids Multi-discipline 3D Modeling Ortho/ ISO Drawings& Reports
Str
uct
ura
l A
naly
sis
Str
uct
ura
l A
naly
sis
3D Interference Detection3D Interference Detection
SmartPlant Layout – Stand-Alone Product– Based on Intergraph’s SmartPlant 3D (full license)– Pipe Auto-Routing powered by Alias I-Route engine– Optimized for rapid plant layout, MTO reporting & drawing
• Branch GapThe separation between adjacent branches connecting to the same header. If the branch gap value is greater than the in line length, this value will take precedence.
• Pipe Air GapThe separation required between adjacent pipes.If the Piping Materials Class has butt welded joints, the nominal pipe diameter (NPD) & this value determines the pipe separation.Where adjacent pipes have different NPD sizes, the separation is half that for pipe 1 plus half that for pipe 2.
Can be either SmartPlant Layout specific specsCan be either SmartPlant Layout specific specsor or ““standardstandard”” SmartPlant 3D SpecsSmartPlant 3D Specs
• Defines Piping Specifications used in Layout… ‘Generic’ ~ limited ~ specifications of basic piping components
Allows definition of Layout Equipment, its dimensions, Allows definition of Layout Equipment, its dimensions, location & orientation for use in alternate scenarioslocation & orientation for use in alternate scenarios
• Defines Equipment in Layout… can be saved and reused
Optimize layout through adjustments to site grid(s), pipe racks, zones& equipment positionAlternatives (Design Cases) for equipment & volume position- parameters can be saved & recalledResults can viewed …
– On-screen– Via intelligent orthographic drawings– Via intelligent reports
Direct integration via SmartPlant Review for layoutwalk-thru. & visualization
Output for cost estimation;Aspen Icarus™ (Kbase)
– Pipe/ Fittings– Steel
WorkflowWorkflowOptimization/ Case ManagementOptimization/ Case Management
– Improved preliminary designs– Increased estimate accuracy based on actual
layout– Higher Quailty Proposals
leading to …
10% reduction in concept development man-hours90% reduction in material estimate man-hours10-20% reduction in detailed design manhours5-10% reduction in total plant installed costReduction in materials requirements
“… Strong points include compatibility with SmartPlant 3D, user‐friendliness & easy to configure & learn …”
“… a good replacement for our current 3D plant layout solution …”
“… the equipment task, input definition of pipeline data, rules setup & connectivity were easy to use ”
“ …no other product on the market today (is capable of) producing a FEED model from withina detailed design solution integrated to process & cost estimating tools …”
SmartPlant Layout Customer Comments:
“… Strong points include compatibility with SmartPlant 3D, user‐friendliness & easy to configure & learn …”
“… a good replacement for our current 3D plant layout solution …”
“… the equipment task, input definition of pipeline data, rules setup & connectivity were easy to use ”
“ …no other product on the market today (is capable of) producing a FEED model from withina detailed design solution integrated to process & cost estimating tools …”