Digital design workflows to reduce non-conformances in the power industry Mark Upston Senior Director 1 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated 2018 Bentley Systems, Incorporated
2017 USA Energy Infrastructure Report Card What is the Gap? https://www.infrastructurereportcard.org/wp-content/uploads/2017/01/energy-final.pdf 2 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Recommendations to Improve USA Power Infrastructure 3 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Brownfield Plant Projects Design Challenges Determining as-built conditions Evaluating engineering integrity of existing facility Evaluating and selecting facility expansion alternatives (new design) Coordinating new proposed design with on-site conditions Coordinating progress across teams, offices, and disciplines 4 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Bentley Solving Multi-Discipline Team Collaboration 5 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
AGENDA With the digital data integration of design and analysis applications across key engineering disciplines like structural and piping, companies are abandoning traditional paper workflows and managing engineering projects more efficiently and with less risk. Engineering content can be easily managed in a central distributed document management system for handover and operational asset management. Digital data transfer of structural and piping design engineering information and richly integrated design models for asset management Improved 3D Visualization and digital clash detection to avoid costly nonconformances See how integrated design analysis applications are being used to manage ageing assets on brownfield projects Q&A 6 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Brownfield Project: Laser Scan to 3D Modeling to Engineering Analysis for Checking Structural Integrity 7 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Where is Structural Integrity Needed Most? Area $Billions / Year Drinking Water / Sewage 36 Petrochemical 3.7 Oil & Gas 1.4 Pulp & Paper 6.0 Electrical Utilities 6.9 Bridges 8.3 Gas & Liquid Pipelines 7.0 Source: 2002 Report http://www.nace.org/publications/cost-of-corrosion-study/ 8 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Brownfield Projects Industry Problem Plant Pipe Racks are failing with increasing downtime leading to significant production losses Corrosion is Everywhere! The Structural Integrity is deteriorating due to age and corrosion Plant has been in operation for over 20 years. Pipe racks are failing due to increased loads. As operations have increased further steel and pipe work has been added. There are no 3D models available for the structure. The only viable solution is As Built capture. 9 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Brownfield Projects Design Solution Aging Plants Integrated Design Models using STAAD for Structural and AutoPIPE for Piping LaserScan 10 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Brownfield Projects Design Solution Aging Plants Integrated Design Models using STAAD for Structural and AutoPIPE for Piping 3D CAD model e.g. OpenPlant Engineering Analysis (STAAD & AutoPIPE) Optioneering (Scenario Services) LaserScan 11 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Bentley Solution Model and Analyze Failing Structures Descartes Advanced point cloud data processing Pipe centrelines modelled with one click from point cloud data ProStructures 3D modelling environment for structural steel and metal work Modelling from 300 databases and International Standards Open Plant Modeler 3D Plant design and modelling Attachment of point cloud data for pipe modelling STAAD.Pro Analyze and design virtually any type of structure. Steel, concrete, timber, and aluminum design codes from all International Standards AutoPIPE Advanced Analysis Features for Varied Piping Environments Interface with AutoPIPE Vessel, STAAD.Pro, Plant Design CAD Systems, and ProjectWise 12 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Design Integrity and Asset Management ProjectWise Document Management 1 5 4 3 2 6 AssetWise Reliability Server RBI SIM Assessment 13 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated Engineering Analysis
Benefits Assets that are structurally at risk can be identified quickly and accurately. Accurate modeling of as built assets Integrate brownfield project extensions to existing plant Reusable 3D intelligent plant and analysis models for future Plant sustainability Use of existing tools and design resources already in house Rapid Efficiency savings as high as 75% compared to traditional design methods 14 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Power Plants Using Integrated Design Technology 200MW - Coal-Fired Power Plant Philippines Doosan Heavy Industries 600MW Gas Power Plant Cairo Projenia S.r.l 50% Reduction in interference checking 80% Reduction in Site Non-conformances 95% on-time delivery 15% Design time savings, Faster Erection Schedule just 14.5 months and Clash Free 15 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Power Plants Using Integrated Design Technology Biomass - ESI Inc of Tennessee 42MW Gas-Turbine Power - Giprotyumenneftegaz STAAD Pro and AutoPIPE saved ESI a combined 700 resource hours on the project The integrated software facilitated exchange of information among disciplines, reducing mistakes and automating processes such as collision detection and generation of specifications and estimates. The time savings reduced costs by about 15%. 16 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Power Plants Using Integrated Design Technology 582MW Clean Coal Plant Mississippi Southern Company 375MW Combined Cycle Plant in India L&T & Sargent Lundy AutoPlant was configured for each engineering discipline and all models were managed through a controlled workflow in ProjectWise. eb Data Quality Manager enabled efficient asset location and transfer of approx. 75,000 vendor assets and design information vital to construction, operation and maintenance As a result, the startup and commissioning group will save nearly 6000 man-hours. The team used Microstation, Bentley Navigator, Structural Modeler and STAAD.Pro for integrated analysis ad modeling which enabled engineers to identify hindrances and optimize the layout in the turbine building. These efficiencies reduced engineering cycle time by 8%. 17 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Power Plants Using Integrated Design Technology 540MW Sewaren 7 Combined Cycle Plant New Jersey, Black & Veatch Flue Gas Desulfurization Plant in North Carolina Utility Engineering Design Teams shared information using i-models which improved multi-disciplined collaboration. Bentley Navigators view and review capabilities provided self service in the clash detection and model review processes by putting the software in every project professionals hands. 18 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated Designs were changed in the model before procurement errors and installation conflicts, which helped minimize interferences and eliminate redesign and construction rework. Additionally, the project team conducted weekly model reviews with the client using an up to date and accurate design model via the internet
A Brownfield Plant Retrofit Project Design Integrity Check 19 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
The As-Built System AutoPIPE Stress analysis of piping system Piping in isolation (no structure) Acceptable stresses in piping Export to STAAD.Pro using pipelink format STAAD.Pro Read in pipe support locations and applied reactions from pipelink Analyze structure and run design code checks on steel members All members pass checks AutoPIPE STAAD.Pro 20 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Revise Piping System and Investigate AutoPIPE Upsize main lines from ø350 to ø450 Rerun stress analysis Verify piping design passes Pipe stresses Equipment e.g. pump loads Support design Update Pipelink data exchange file for use in structural analysis design in STAAD.Pro 350 mm Dia. 450 mm Dia. 21 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Revise Piping System and Investigate STAAD.Pro Read in updated pipelink file Rerun analysis and code checks The revised piping imparts higher forces on portions of the structure Some members now fail code checks Add bracing to add stiffness and strength Rerun the analysis and design All members now pass code checks 22 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated Before After (Braces Added)
Revised System - Combined Piping-Structure AutoPIPE Read updated pipelink structure into AutoPIPE Includes revised structure designed in STAAD.Pro Re-run stress analysis as final check Check possible increase in pipe support loads and pump loads 23 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
3D Clash Detection 24 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Evaluating Model for Clashes AutoPIPE AutoPIPE Publish AutoPIPE model to i-model Optionally consider deformed geometry Upload to Bentley Cloud Services project Bentley Navigator Create a clash detection job Identify specific clashes Leave markups so other team members can easily review and update Bentley Navigator 25 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Case Study Hot Operation Clashes Samcheok Green Power Unit 1 and 2, South Korea KEPCO Engineering & Construction Company 2x1,000MW Ultra Supercritical Thermal Power Plant Samcheok, South Korea Image Courtesy of KEPCO E&C Samcheok Green Power Unit 1 and 2 Project, Be Inspired 2014 26 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Case Study Hot Operation Clashes The Solution Run Full 3D Clash Detection of AutoPIPE 3D Hot deflected DGN model in Bentley Navigator, or MicroStation or OpenPlant LP Bypass Line 3 Critical Hot Clashes Identified during Design Phase Warm Up Line KEPCO Engineering & Construction Company 2x1,000MW Ultra Supercritical Thermal Power Plant Samcheok, South Korea 27 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated Image Courtesy of KEPCO E&C Samcheok Green Power Unit 1 and 2 Project, Be Inspired 2014
Summary Highlights These Case Studies highlights the speed and accuracy of a solution to evaluate structural integrity of aging plants Benefits: Coupled analysis provides more accurate, cost effective seismic designs Explore alternative design options quickly with efficiency savings A structural integrity solution can verify remaining life and easy to adjust for design modifications 3D-Models help coordinate on and off-site assembly and fabrication of brownfield projects and reducing site nonconformances 28 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Engineering Document Management Using ProjectWise and Asset Reliability 29 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Engineering Document Management using ProjectWise "With ProjectWise we can easily manage over 9,000 transmittals and 20,000 technical documents in a single repository. Also, it s easy for the EPC subcontractor to collect the related documents/drawings for closed-out reports. ProjectWise has shortened the preparing time of closed-out reports." Bao Jia Chen, Project Manager, CPC Corporation ProjectWise industry leading global engineering content and collaboration server Optimized for engineering software integration, model management, drawing management, large file management, review and markup Link from Asset Reliability providing access to models, drawings, specifications, inspections, etc 30 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated ProjectWise
Structural Integrity Dashboard in Asset Management System Asset Summary & Health SIM KPI s: RSR, Inspection Compliance, CP Readings, Anomalies, Trends Role specific 31 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Assets Navigate by Hierarchy, Map, Listing GIS Interface Select and report on assets and equipment Surface Alarms and KPIs 32 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
How does Immersive Asset Reliability help? 33 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Asset Performance T&D Implementation of Asset Risk at Indianapolis Power & Light IPL used Bentley's AssetWise Asset Reliability to track specific indicators and indicator states for manholes, vaults. network transformers. and network protectors The team used the application to calculate an overall health score for each asset based on weighted values To date, monitoring 300,000 indicators for 20,000 assets and associated work order priorities has decreased equipment failures the network from 49 in 2011 to 15 2016 Substation transformer failures followed a similar downward trend. 34 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Digital Surveys of Existing Assets 35 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Reality Modelling Capture Point Clouds Traditional Laser Scanning Technology. Photogrammetry 3D meshes created from photos. 36 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Photogrammetry 3D Reality Mesh Models Capturing the context Aligning new designs with existing conditions Managing information Inspecting operational assets Better understanding via 3D is great! 37 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated Richer Information Models are available with 4D (Time), 5D (Cost) and 6D (Operations Management)
What is the level of 3D Detail with Photogrammetry? Chemical Plant Drone Falcon 8 Camera Nikon D810 Capture - 4500 Photos Processing- 2 Hours https://www.youtube.com/watch?v=o4xgf8 883dU Not only a dimension but a window into the condition of your asset! Allow 3D Coordination on Brownfield Projects with Ease 38 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Reality Modeling Analysis of Transmission Tower, South Korea, GeoINT Aerial Photogrammetry and ContextCapture reduced resource hours required for surveying on site, improving safety and enabling the team to build realistic 3D Mesh at 30% of actual project costs and deliver the final model in just two weeks 39 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Office to Site Coordination 40 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Bentley Cloud Services ProjectWise Project Share File Sharing Share models and files Notify teams members automatically when files are added or revised Issues Resolution Review punchlist items created in Navigator Coordinate status of each markup 41 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Mobile 3D Visualizations and Interactive Inspections Visualize 3D i-models Punchlist of Issues 42 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated
Thank you for Attending Q&A Product Management: Mark Upston Mark.Upston@Bentley.com Marketing: Samantha Langdeau Samantha.Langdeau@bentley.com 43 WWW.BENTLEY.COM 2018 Bentley Systems, Incorporated