Software Global Customer Conference

Transcription

1 Intergraph Process, Power & Marine Smart Engineering from Concept to Operations Software Global Customer Conference Presenter: Paras Trivedi - Frank Joop Product Owner SPP&ID/SPPE Executive Director Global Business Development 10/13/2014

2 Process, Power & Marine Division The SmartPlant Concept The Process Connection Detailed Design Construction Lowering Operational Risks Summary 2

3 Harmonization and Extension ISO Export SP P&ID SP P&ID SPPE SPI SmartPlant P&ID SmartPlant Instrumentation SmartPlant Electrical SmartPlant P&ID Engineer SPI SmartPlant P&ID Engineering Integrity SmartSketch external editor SmartPlant Explorer SP P&ID E SPI Operational Excellence SP P&ID EI SP P&ID DV PDMS Others S 3 D SPEL SPEL SmartPlant Isometrics SP Explorer SmartSketch /S P O

4 The SmartPlant Solution

5 Value-Add Basis Engineering is in a given scope and schedule to go from assumptions and ideas to an asbuilt facility that is safe, reliable and efficient. Making the right decisions early in the 13% to Impact/lower the cost/risk in the 87% 37% EPC $ split scope and schedule = Deliverables/productivity assumptions and ideas = Change management/case studies safe, reliable and efficient = Best practices in engineering and operations 6% 7% 50% Engineering Design Materials Construction

6 From 2D to 2D Model Differentiator Design integrity and quality validation early on Validation P&ID Smart Engineering Model Instrumentation Electrical Connecting the dots = engineering/design tasks Workflow, standards, rule checking, templates, single tool set, Flexibility in resourcing (core base team and added resources based on project demand) Workshare to utilize domain expertise and JVs

7 The Relationship Spider Web Engineering is a Team Sport Key is to: Create Maintain Manage Leverage (Rules) And more.

8 Connecting the Dots Creating specifications Wiring Composite Drawings Cable Routing Process Cases Installation Details Electrical Distribution Create New Tags Scope-Task-Solution-Deliverable Termination Design More Tasks

9 Task-Based Engineering Get Ready to Go to Work

10 The Process Connection

11 Overview of Engineering Project Workflow Conceptual Front-End Engineering Design & Construction Technology & Design Basis Development Business Review Scope Definition Contractor Selection Engineering Procurement Construction PFD Material Balance Conceptual layout Cost estimate Equipment List P&ID UFD Equipment Datasheets Mechanical Design Line List Instrument Data Plot plan / GA s Logic diagrams Pipe & other specs As Built Documentation

12 Lifecycle cost reduction opportunity Total Project Cost Significance of Conceptual Design 30% 40% 2% 15% 5% 2% Conceptual Design 12% Detailed Design 44% Procurement Construction Commissioning SPPE can play a strategic role in the early decision making The opportunity cost and risk to influence/improve asset performance is at its lowest during conceptual & detailed design

13 Key Challenges in Conceptual Design Consistency Reusability Accuracy Auditing Conceptual Design Optimization Intelligent Deliverables Flexibility Jump Start Detailed Design Long lead Item Planning Compressed Schedules Change Management Accounting Safety Data Security Risk Management Margins

14 SmartPlant Engineering & Schematics PDMS ISO Export SP P&ID SP P&ID SPPE SPI SPI external editor SP P&ID E SPI Operational Excellence SP P&ID EI SP P&ID DV Others S 3 D SPEL SPEL SP Explorer SmartSketch /S P O

15 Introducing SmartPlant Process Engineering (SPPE) A post-simulation, conceptual design level, data-centric engineering tool that will allow process engineers to rapidly develop an optimized and intelligent Conceptual level Front-End Engineering Design (FEED) basis using industry standards A practical solution that will join the SmartPlant Enterprise family to Address the functional requirements of Conceptual design Address the business drivers in the FEED Projects Provide continuity to support Detailed Design and Operations

16 Conce ptual Design Conceptual Design with SPPE Process Simulation Case Management Equipment & Stream Lists Detailed Design Assorted Equipment & Stream Sizing Applications Equipment Datasheets PFD Creation Cost Estimating SPPE Other SP Detail design applications

17 Key Features and Work Processes in SPPE Case Management Importing Simulations Security Rules Management Preliminary Equipment Sizing Preliminary Pipe Sizing Interface with Layout Interface with Cost Estimate Intelligent Deliverables Audit Tracking Detail Design Change Management

18 Interfacing with Multiple Simulation Tools Rules Management Translation Simulation Case Management Equipment & Stream Lists PFD Creation SPPE

19 Intelligent Rules-Based Transition from Simulation to SPPE Technology Simulation Case Unit Operation Simulation Tool Unit Operation Process Data Equipment Class Temperature/ Thermodynamic Properties Pressure Flow rates/residence time/volume Fluid Phases Composition Properties Import Technology Simulation Case Equipment 1 Equipment 2 Equipment Process Data SPPE Equipment Type Temperature/ Thermodynamic Properties Pressure Flow rates/residence time/volume Fluid Phases Composition Properties Streamline Streamline Process Data Connectivity (from/to) Temperature Pressure Flow rates Fluid Phases Composition Properties Pipeline Pipeline Process Data Connectivity (from/to) Temperature Pressure Flow rates Fluid Phases Composition Properties

20 20 Case management: Generating Design Bases One Topology For Each Selected Process Technology Simulation Case 1 Equipment 1 Simulation Case 2 Equipment 1 Simulation Case 3 Equipment1 Simulation Case 4 Unit Equipment1 Operation1 Hybrid Case Equipment1 1 Duplicated Case Equipment 1 Equipment 2V Equipment 2 Equipment 2 Unit Equipment Operation 2 2 Equipment 2 Equipment 2H Streamline 1 Streamline 1 Streamline 1 Streamline 1 Streamline 1 Streamline 1 Streamline 2 Streamline 2 Streamline 2 Streamline 2 Streamline 2 Streamline 2 Streamline 3 Streamline 3 Streamline 3 Streamline 3 Streamline 3 Streamline 3 Streamline 4 Streamline 4 Streamline 4 Streamline 4 Streamline 4 Streamline 4

21 Case management: Source of Preliminary Design Data External Tools Equipment Sizing Tool(s) Vendor Data SPPE case Equipment 1 Equipment 2 SPPE Equipment Process Data Temperature / Thermodynamic Properties Pressure Flow rates Residence time / Volume Fluid Phases Composition Properties Prelim. Equipment Design Data Equipment Class Equipment Size / Dimensions Equipment Model Information Model No. Type Capacity Performance Data Pipe Sizing Tool(s) Pipeline Pipeline Process Data Temperature Pressure Flow rates Fluid Phases Composition Properties Prelim. Pipeline Design Data (1 st Iteration minimal h information) Pipe Size Pipe Class Pipe Material Properties / Spec Insulation data

22 Finalist Case Management: 3D Level Optimization Layout (3D) SPPE External Tools Project A Layout Option 1A Layout Option 2A Layout Option 3A Updated Equipment Data Equipment Class Equipment Size / Dimensions Equipment Model Information Location coordinates Updated Pipeline Data Pipe Size Pipe Class Pipe Material / Spec Insulation data Pipe Route Length Pipe Route Coordinates Elevation changes Updated Major Equipment List (MEL) Updated Pipeline List Optimize Optimize Design Case Equipment1 Equipment 2 Pipeline 1 Pipeline 2 Pipeline 3 Pipeline 4 Optimize Optimize Optimize Optimize Equipment Sizing Tool(s) Vendor Data Pipe Sizing Tool(s) Cost estimate Tool(s)

23 Units Plant Graphical Deliverables: PFDs and Prelim. P&IDs Optimized Design Case Equipment1 Equipment 2 Systems Areas Area Specific PFD Plant Specific PFD Area Specific PFD Area Specific PFD Area Specific Prelim. P&ID Area Specific Prelim. P&ID Area Specific Prelim. P&ID Pipeline 1 Pipeline 2 Pipeline 3 Pipeline 4 Unit Specific PFD System Specific PFD Unit Specific PFD System Specific PFD Unit Specific PFD System Specific PFD Unit Specific PFD System Specific PFD Unit Specific Prelim. P&ID System Specific Prelim. P&ID Unit Specific Prelim. P&ID System Specific Prelim. P&ID Unit Specific Prelim. P&ID System Specific Prelim. P&ID Unit Specific Prelim. P&ID System Specific Prelim. P&ID 23

24 Heat Mass Balance Tables

25 Reports, Datasheets, and Data Exchange Media Preliminary Data for Datasheets SPPE Equipment Process Data (From Simulation) Temperature / Thermodynamic Properties Pressure Flow rates Residence time / Volume Fluid Phases Composition Properties Equipment Preliminary Design Data (From External Data Treatment) Equipment Class Equipment Size / Dimensions Equipment Model Information Model No. Type Capacity Performance Data Pipeline Process Data (From Simulation) Temperature Pressure Flow rates Fluid Phases Composition Properties Preliminary Pipeline Design Data (1 st Iteration minimal h information) Pipe Size Pipe Class Pipe Material / Spec Insulation data Pipe Material Properties

26 Detailed Design

27 SmartPlant Engineering & Schematics ISO Export SP P&ID SP P&ID SPPE SPI SPI external editor SP P&ID E SPI Operational/ex cellence SP P&ID EI SP P&ID DV PDMSOth ers S 3 D SPEL SPEL SP Explorer SmartSketch /S P O

28 The Project Creating the plant process model Challenges Fast track Change management Iterative design Share engineering data downstream SmartPlant Engineering & Schematics

29 SmartPlant P&ID at Work Verified Engineering Data SmartPlant Engineering & Schematics

30 Post-P&ID Analyses: Engineering Integrity Assurance Adding Understanding to the P&ID Uses a knowledge to apply real world view on the P&ID Translates the P&ID from distinct mechanical items to process system Reads a P&ID like a human Understands the context. SmartPlant Engineering & Schematics

31 Results: Passed and Not Passed SmartPlant Engineering & Schematics

32 Accessing Supporting Design Data During the Design Engineers and Designers spend over 50% of their time looking for data Third Party Validation tools Rules API Project P&ID Rules Rules Allocated Tag Number Pipe Specification SmartPlant Engineering & Schematics

33 Physical Design (3D) Flow sheet transposition P&ID topology and specifications drive the physical design (3D) Select systems from P&ID to place in design Compare P&ID with 3D model Yellow off routed and placed plant items Consistency between logical and physical design SP P&ID PDS S3D PDMS SmartPlant Engineering & Schematics

34 The Project Design the Control System Challenges Data consistency Change management Interface with automation vendors Deliverables SmartPlant Engineering & Schematics

35 Controlling the Plant P&ID Expansion to Instrument Index List FICA Functional Definition FE FY FT FC FT FV FI FA FE SmartPlant Engineering & Schematics Physical Definition

36 No. PART NO QUANTITY E P SIZE DE EN SCHEDULE OR RATING BY DATE REVISION VENDOR TYPE MATERIAL MNFR./MODEL INSTRUMENTATION HOOK-UP CLIENT: PROJECT: DXF FILE : DESCRIPTION TAG NUMBERS DEMO_SPI70 SHEET: 1 OF 1 &DWG_FILE_NAME DWG. NO.: CV (H_646MT.SYM / SmartSketch) REV. / / / / / / / / / / &ITEM_UDF.1 CV (H_646MT.SYM / SmartSketch) VALVES Process Data Calc. Sheets Spec Sheet Profibus Network Designer JB Layout Single Source for all Control System Fieldbus Designer Instrument Index Tasks and Deliverables Cable Schedules Enhanced Smart Loop INSTR. AIR HEADER 36 SmartPlant Engineering & Schematics Installation Details Plan & Equipment Layouts Wiring Block Diagram

37 Enhanced Smart Loops True presentation of the design Automatically created No template SmartPlant Engineering & Schematics

38 Dimensional Data Interface Interface to PDS and S3D that enables instrument dimensional data to be imported directly into the 3D model Key Benefits Improved model accuracy = improved constructability Eliminates redundant data entry Allows rapid propagation of changes Improves quality of deliverables SmartPlant Engineering & Schematics

39 The Project Designing Power Distribution System Challenges Late in project schedule Fast track design Deliverables with consistent data Cable management SmartPlant Engineering & Schematics

40 SmartPlant Electrical at Work SmartPlant Engineering & Schematics

41 Single Line Diagram Generated from SPEL SmartPlant Engineering & Schematics 41

42 Cable Routing Round tripping between SPEL and S3D SPEL define to-from and cable type plus initial size Actual routing and length determined in automatic cable routing in S3D Actual length fed back to SPEL for size validation Automatic drum allocation and management Reduce cable waste Improve pulling activities/schedule SmartPlant Engineering & Schematics

43 Constructing the Plant

44 Construction Readiness Ready Moderately Ready Not Ready -10% +4% +28% +60%

45 3D Models PDMS SmartMarine PDS S3D MHE Tekla SmartPlant Engineering & Schematics

46 Just View Look in Animation Time Ahead Materials Schedules with Schedule Find WP that start in 1, 3, or 8 weeks.

47 Executive Dashboard SmartPlant Engineering & Schematics

48 Lowering the Operational Risks

49 SmartPlant Engineering & Schematics ISO Export SP P&ID SP P&ID SPPE SPI SPI external editor SP P&ID E SPI Operational/ex cellence SP P&ID EI SP P&ID DV PDMSOth ers S 3 D SPEL SPEL SP Explorer SmartSketch /S P O

50 Engineering & Design Basis for Operations Process Maint. ERP Document Mgt Existing Plant Operations Systems DCS Reliability SHE CAD Engineering 2014 SmartPlant Engineering & Schematic 2012 Engineering & Design Basis

51 LDAR on Site SmartPlant Engineering & Schematics

52 LDAR Managed by SP P&ID (SECCO China) SmartPlant Engineering & Schematics

53 SmartPlant Process Safety SmartPlant Process Safety Engine Knowledge base Interactive visualisation on P&ID to navigate and support brainstorming Results database Hazop Meeting manager Full, auditable record Comprehensive Consistent - Up to 50% time & cost reduction SmartPlant Engineering & Schematics

54 SmartPlant Process Safety Automatically Detects Cause-Consequence Scenarios SmartPlant Engineering & Schematics

55 Area Classification SmartPlant Engineering & Schematics Defined areas where an explosive condition is or can occur that can course explosions

56 Smart Safety in Action Engineering firms and plant owners can transfer their engineering, operational and safety relevant know-how into the rulesbased design systems. Rules, embedded in the design systems, help to optimize the design and to reduce the number of design errors. Rules work as watch dogs who won t allow non-compliant design or unauthorized design modifications. Rules-based Area Classification in S3D Ensure right and safe design from the start SmartPlant Engineering & Schematics

57 P&ID to Training/Simulation Model Automatically convert the current/asbuilt SP P&ID into Operator training models DCS MMI s Simulation model for advanced controls Validate KPI s more 57

58 Calibration of a Temperature Transmitter 2014 SmartPlant Engineering & Schematic 2012

59 Tag Out Lock Out Automatically find all block valves to isolate equipment for maintenance or emergency shutdown

60 Summary

61 Summary SmartPlant Engineering & Schematic offering: Different/innovative approach to create design and deliverables In crease productivity and business value Increase consistency and design quality Change control Integration Rules drive and validation at design time Automation of tasks Fit for engineering & Operations And more

62 Integrating the Engineering Enterprise June 2014