Early Decision Engineering with SmartPlant Schematics

Transcription

1 Process, Power and Marine Division Early Decision Engineering with SmartPlant Schematics Intergraph September 16, 2009 Agenda Introduction of the team Objective of the session The Scope Success Criteria Process Design Control System Design Electrical Design Conclusions 1

2 Team & Objectives Show the additional value of rule drive integrate engineering solution Enabling to make earlier design decision and create quality and consistent data for down stream use Improve productivity Open and flexibility to comply with project/customers demands The Team Rene van Strien, CBI Process Design John Dressel, Fluor Control System Design Scott Hendrickson, Burns & McDonnell Electrical Design Challenges & Opportunities Competitive environment Shorter project cycles Joint ventures Complex projects (process technical) Risk management Engineering data for Operations Innovation is the Single Most Important Condition to Transform the Crisis into an Opportunity 2

3 Opportunities Innovative solutions Rule driven Open to add complementary solutions Automate design Drive consistency in the design and deliverables Break down silo s Be a winner, offer added value Ability to use the data in operations P&ID Piping Instrumentation Equipment Electrical Scope Workflow setting (for this session limited to process, instr. and electr.) The scope Create the P&ID in a work shared environment Add the controls Add the pump/ electrical distribution Pump Motor Unit Controls 3

4 Success Criteria The bottom line Faster plant productivity improvement Minimized downtime Reduced engineering efforts & costs Up to-date plant documentation Enabled through Better collaboration (intra- and inter-company) Faster access to all relevant engineering information Management of change Re-use of designs Design automation Accurate material quantification, purchasing and delivery Optimized construction Automated update of plant documentation Process Design First Step in the work process Create the P&ID using best practices Leveraging the engineering capabilities Validate the design 4

5 Introduction SmartPlant P&ID experience list: Over 10 years BDEP, Feed and EPC projects Small (about 30 dwg) to large (over 500 dwg) projects Basis for this presentation: Current Feed project Client: Staatsolie, Suriname Refinery Complex incl. Licensor packages About 300 dwgs CB&I - 9 Global Execution Capabilities Ft. Saskatchewan Calgary Everett Niagara-on-the-Lake Plainfield San Francisco Bloomfield San Luis Obispo Pittsburgh Los Angeles Dallas New Castle The Woodlands Tyler Atlanta Beaumont Houston Caracas Puerto Ordaz The Hague Moscow London Brno Beijing Tokyo Cairo Al Khobar Doha Ajman New Delhi Shanghai Dubai Bangkok Singapore Manila Secunda Perth Brisbane Sydney CB&I

6 SmartPlant P&ID Engineering Drawings are developed by Process Engineers Typical hookups / Assemblies Rule configuration System editing MOPEX projects using Connected Workshare Consistent basis for symbols, rules Database synchronization o Consistency on interfaces Access to drawings not in own office CB&I - 11 Reports Deliverable reports Drawing list Line list Check / Consistency reports Inconsistency report Valve list Interface reports Instrument export MTO export CB&I

7 AVI Performing the Task CB&I - 13 Conclusions SmartPlant P&ID Benefits Consistency of data On the drawings Between offices Between drawings and related reports Between SmartPlant P&ID and other applications (e.g. SmartPlant Instrumentation) Efficiency SmartPlant P&ID requirement Not to be used as CAD application Configuration of rules CB&I

8 Completing the Process Design Key ypoints Use of assemblies (best practice) The rules and validation helps to avoid iterations and facilitates faster execution The data centric approach allowed to query for the changes made and helps MOC Let me ask you.. Audience Poll... The creation of the intelligent PID takes more time than creating PID with traditional CAD like AutoCAD. A) Yes, much more time B) Yes, a little more time C) They are about the same D) No, it takes less time E) I don't know 8

9 Control System Design Next step in the work process Adding the controls Creating the specifications and wiring Creating the deliverables to buy, install, test and later maintain Control System Design Next step in the Project Work Process Interfacing SPI with SmartPlant Foundation Applications Indexing Control Systems and Instrumentation Systems Specifying and Sizing of Control Valves and Instruments Defining the Control System Wiring and Signals Creating deliverables to purchase, install, test t and later maintain the Instrument Control Systems John Dressel Principal Control Systems Application Specialist 9

10 SPI - SP-P&ID Interface The SPI SP_PID interface is a correlation process that transfers Instrument Tag related data and data modifications from the P&ID to SPI Tags that are in both SPI and SP_PID will correlate to each other without having to import new Instrument Tag numbers into SPI This will allow SPI users to create the Instrument index in SPI before the P&ID is published and maintain the SPI automation capabilities without having SPI data overwritten This interface allows MOC between tags on the P&ID and SPI with the P&ID being the master source of change throughout the project PUBLISH PUBLISH DO NOT RETREVE RETREVE SmartPlant User Interface SPI Explorer Interfaces with Module Work Area Window Allows navigation to all Tag, Loop, & Wiring Properties Allows access to all SPI Documents Allows access to all primary support tables Powerful Menu Functions for Editing, Duplication and Generation of Documents and Data 10

11 Instrument Index Module Index Add, Edit or Duplicate Tag Number or Loop Properties Displays Loop association for Tags Access to primary support tables with pick lists for data consistency Additional data for SPEL power requirements Access to User Defined Custom Tables Instrument Index Module The Instrument Type Table contains entries for every type of instrument that is expected to be used on a project. Instruments are grouped by Process Function Each different technology is given a separate Description The Profile defines the SPI Automation 11

12 Instrument Index Module Instrument Type Profile defines the Tag Automation Functions Automation Functions Instrument Specifications Define Spec Form Populate Spec from Template Automatic Loop Creation Process Data Workflow Populate Support Tables Initialize Device Wiring Define I/O Type Define Signal Cable Define Connection Type Define Material Requirements Define Dimensional Data for Piping for SP3D interface Instrument Index Module Query Wizard for User Defined Index Browse and Browser Views Full Index Command Menu for data editing Drop down Data Windows for pick lists Create User Browser views of Spec Sheets and Process Data Automatic Report and Export of query data from Browser Linked access to external and internal documents for full document management 12

13 Instrument Spec Module Instrument Specification Form for each Spec Type Edit Forms in SPI Drop Down Data Windows External Form Editor Multi-Item forms Multi-Sheet forms Revision control Show data from Index table Link directly to Process Data Export Specs to Excel or Intergraph External Editor Interfaces with Vendor Sizing and Selection Software Process & Calculation Module Handles multiple Process Cases Fluid properties lookup Data entered by Tag or Line Unit of Measure conversion Copy data from other Tags Additional Properties Base Conditions Alarm / Trip Settings User Defined Fields Workflow control Process datasheets with Revisions Process datasheets with Revisions Process Calculation Module Control Valve Sizing Relief Valve Sizing Flow Meter Sizing Thermowell Parameters 13

14 SmartPlant Wiring Module Handles Conventional and Foundation Fieldbus wiring matrix Drag and drop cables to terminals for connection with automatic signal propagation Allows simultaneous Field and DCS side wiring Automated Junction box wiring with pre-loading DCS I/O loading and built in DCS manufacturer interfaces Automatic or manual cross wiring and continuity checking Generates Wiring and Loop Diagrams with Revisions SmartPlant Loop Module Automatic Loop Generation Enhanced SmartLoop True CAD documents User configurable Interactive with database Save in CAD file formats AutoCAD & Microstation Automatic Loop Generation Completely configurable Can use existing or client Blocks or Cells Saved in native formats SPI Loop Wiring and DCS I/O data is handed over to the Owner Operator for Plant Maintenance and Asset Management 14

15 SmartPlant Loop Module Automatic Loop Generation Enhanced SmartLoop True CAD documents User configurable Interactive with database Save in CAD file formats AutoCAD & Microstation Automatic Loop Generation Completely configurable Can use existing or client Blocks or Cells Saved in native formats SPI Loop Wiring and DCS I/O data is handed over to the Owner Operator for Plant Maintenance and Asset Management SmartPlant Loop Module Fieldbus Segment Diagrams and Fieldbus Loops True CAD document User configurable Interactive with database Save in CAD file formats May be annotated Uses SmartSketch RAD graphic engine 15

16 SmartPlant Instrumentation Interfaces SmartPlant Foundation Interface allows Data Sharing to SmartPlant t Applications Work Sharing via Citrix allows real time global access to the SPI database over the Web Vendor Interfaces for Data Sharing to instrument sizing, selection and DCS programs Controls in place Key ypoints Getting the instruments from P&ID Browser are central data and task management to make sure all is completed Deliverables view from that data Consistency thru the complete document set Cover all CS tasks Data is available for operations (calibration, maintenance, revamps, etc Let me ask you.. 16

17 Audience Poll... Capabilities to create user defined rules and automate data entry based on external data collection will increase productivity. A) Yes, by at least 30% B) Yes, by less than 30% C) No, it does not make a difference D) I don't know Electrical Design Last step in this workflow Powering the system with best practices Electrical distribution design Making sure it is a safe and reliable design addition thru validation (ETAP) 17

18 Electrical Design Experience with SmartPlant Electrical Standard electrical design tool in Energy Global Practice Executed 10 projects over last 3 years Used by Electrical Engineers Changes experienced using SmartPlant Electrical Reduction in CAD personnel required for One-Lines, Schematics and Wiring Diagrams Reduction in Engineering time required to cross check deliverables More consistent deliverables with use of reference data and design rules Closer integration i with other disciplinesi Singular workflow that will work with small and large projects Show the new workflow Workflow used on large coal plant with 1500 loads Managed 1000 schematics in SmartPlant Electrical Gathering Load Information Loads created automatically using two methods Integrated environment using SmartPlant Foundation 250 motors and heaters created from SmartPlant P&ID s 250 instruments requiring power from SmartPlant Instrumentation Imported vendor loads using SmartPlant Electrical Import Manager 1000 loads including motors, heaters and local panels 18

19 Leveraging Reference Data Profiles Profiles are the data representation of an electrical schematic Allow to quickly and consistently create all information needed to manage deliverables Start from Switchgear and MCC Schematics Unique loads are easily handled by using most accurate profile and making the unique change Reapply profile options to handle changes in design Look Up Tables Customize tables to look up any number of inputs and fill in incomplete data with any number of outputs Batch Apply Profile Use tablular editor to apply profiles to all similar loads at one time Building Reference Data Example Motor with Space Heater Voltage Ratings Terminals Circuit i Information DCS I/O Terminal Strips Control Cables Circuit Internals Disconnect Circuit Breaker Control Transformer Contactor Solid State Overload Ground Fault Relay 19

20 Building Electrical Network Build electrical power distribution network quickly using drag and drop methods Duplicate electrical networks from any project using Reference Electrical Engineer Use batch load association based on preliminary load assignments Creates circuit based on load profile Automatically connects power cable and load to circuit Use Electrical l Engineer window to graphically view electrical l network Validate bus loading with SmartPlant Electrical and quickly move loads to balance electrical network 20

21 SmartPlant Instrumentation Interface Publish information for Control System Engineer Cable and power source for instruments requiring power DCS I/O from Switchgear and MCC schematics Retrieve partitioned DCS I/O with complete termination information Connect control cables based on I/O cabinet information Generate Preliminary Deliverables Workflow quickly and consistently creates all deliverables from single data entry. One-Lines MCC or Switchgear Schematics Cable Schedule Equipment Schedule Material Lists 21

22 SmartPlant 3D Interface Publish Cable Schedule to SmartPlant 3D for automatic cable routing and validating raceway design Retrieve cable routing path and length from SmartPlant 3D Perform voltage drop calculations based on routed length Automatically resize and replace cables Finishing Up Publish electrical network to ETAP (bi-directional interface) Perform Arc Flash Analysis Assign work packages to all major equipment Propagate work packages using rules to equipment internals, cables and I/O Create and Manage Final Deliverables Revisions are archived for comparison or viewing if design conditions change Automatically cloud changes on graphical reports Creates Excel report listing changes from last revision 22

23 Completing the Design Key Points Getting the data from the P&ID Fast and consistent configuring of the motor load designs using best practice design Data entry validations Validation of loads and cables Deliverables view of the design data Let me ask you.. Audience Poll... How much time can be saved by avoiding the inconsistencies across the documents produced in the electrical discipline? A) More than 30% B) Less than 30% C) None D) I don t know 23

24 Conclusion Integrated rules driven design enables: Fast track project execution Work sharing Reduce risks Management of change Reduction of revision iterations due to data validation Deliverables consistent Faster time to production Data hand over to Operations Q&A 24

25 Test Drive Try SP P&ID and SP Isometrics at your desk just using the web browser. Testdrive.Intergraph.com 6 pre-defined workflows 24 hours try if the application would run locally The recording of the webinar and additional information can be found at: Process, Power and Marine Division The Future of Engineering Today 25