intergraph process, power & marine smart engineering...

10/13/2014

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

2

Process, Power & Marine Division

The SmartPlant Concept

The Process Connection

Detailed Design

Construction

Lowering Operational Risks

Summary

Harmonization and Extension

–SmartPlant P&ID

–SmartPlant Instrumentation

–SmartPlant Electrical

–SmartPlant P&ID Engineer

–SmartPlant P&ID Engineering Integrity

–SmartSketch

–SmartPlant Explorer

–SmartPlant Isometrics

SP P&ID

SPI

–SPEL

SP Explorer

SPI external editor

SPI Operational

Excellence

ISO 15926 Export

SmartSketch

PDMS

Others

S

3

D

/S

P

O

SP P&ID E SP P&ID EI SP P&ID

DV

SP P&ID

SPI

SPEL

SPPE

../../../Events/Spain P2C2/Modify Platform Elevation 2.avi

The SmartPlant Solution

Value-Add Basis

Engineering is in a given scope and schedule to go from assumptions and ideas to an as-built facility that is safe, reliable and efficient.

Making the right decisions early in the 13%

to Impact/lower the cost/risk in the 87%

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%

37%

EPC $ split

Engineering

Design

Materials

Construction

From 2D to 2D Model

Differentiator

Design integrity and quality validation early on

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

–Smart Engineering

–Model

Instrumentation

Validation

Electrical

P&ID

Engineering is a Team Sport

The Relationship Spider Web

Key is to:

– Create

– Maintain

– Manage

– Leverage (Rules)

And more………………….

Connecting the Dots

Creating specifications

Wiring

Composite Drawings

Cable Routing

Process Cases

Installation Details

Electrical Distribution

Create New Tags

Termination Design

More Tasks…

Scope-Task-Solution-Deliverable

Task-Based Engineering

Get Ready to Go to Work

The Process Connection

Overview of Engineering Project Workflow

Technology &

Design Basis

Development

Business

Review

Scope

Definition

Contractor

Selection

Engineering

Procurement

Construction

Conceptual Front-End Engineering Design & 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

Cost estimate

As Built

Documentation

Significance of Conceptual Design

The opportunity cost and risk to influence/improve asset performance

is at its lowest during conceptual & detailed design

2%

2%

40%

Detailed

Design

Procurement Construction Commissioning Conceptual

Design

Tota

l Pro

ject

Co

st

30%

15%

5%

12%

44%

Lif

ecyc

le c

ost

red

uct

ion

op

po

rtu

nit

y

SPPE can play a strategic role in the early decision making

Key Challenges in Conceptual Design

Consistency

Accuracy

Accounting

Safety

Conceptual

Design

Optimization

Change

Management

Data Security

Reusability

Intelligent

Deliverables

Auditing Flexibility

Margins

Compressed

Schedules

Risk

Management

Long lead

Item Planning

Jump Start

Detailed

Design

SmartPlant Engineering & Schematics

SP P&ID

SPI

–SPEL

SP Explorer

SPI external editor

SPI Operational

Excellence

ISO 15926 Export

SmartSketch

PDMS

Others S

3

D

/S

P

O


DV

SP P&ID

SPI

SPEL

SPPE


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

–C

on

ce

ptu

al

Des

ign

Conceptual Design with SPPE

Process

Simulation

– Detailed

Design

SPPE

Case

Management

Assorted

Equipment &

Stream

Sizing

Applications

Equipment

Datasheets PFD

Creation

Cost

Estimating

Equipment &

Stream

Lists

Other SP

Detail design

applications

Key Features and Work Processes in SPPE

Change Management

Intelligent

Deliverables

Case Management Importing

Simulations

Interface with Layout

Preliminary Pipe

Sizing

Preliminary

Equipment Sizing

Interface with Cost

Estimate

Rules Management

Detail Design Audit Tracking

Security

Interfacing with Multiple Simulation Tools

SPPE

Simulation

Case

Management PFD

Creation

Equipment &

Stream

Lists Translation

Rules

Management

SPPE Simulation Tool Simulation

Case

Unit Operation

Streamline

Unit Operation Process Data

Equipment Class

Temperature/ Thermodynamic Properties

Pressure

Flow rates/Residence time/Volume

Fluid Phases

Composition Properties

Streamline Process Data

Connectivity (from/to)

Temperature

Pressure

Flow rates

Fluid Phases


Simulation

Case Equipment 1

Equipment 2

Equipment Process Data

Equipment Type

Temperature/ Thermodynamic Properties

Pressure

Flow rates/Residence time/Volume

Fluid Phases


Pipeline Process Data

Connectivity (from/to)

Temperature

Pressure

Flow rates

Fluid Phases


Pipeline

Import

Technology Technology

Intelligent Rules-Based Transition from Simulation to SPPE

One Topology For Each Selected Process Technology

Simulation Case

1

Equipment 1

Equipment 2V

Streamline 1

Streamline 2

Streamline 3

Streamline 4

Simulation Case

2

Equipment 1

Equipment 2

Streamline 1

Streamline 2

Streamline 3

Streamline 4

Simulation Case

3

Equipment1

Equipment 2

Streamline 1

Streamline 2

Streamline 3

Streamline 4

Simulation Case

4

Unit Operation1

Unit Operation 2

Streamline 1

Streamline 2

Streamline 3

Streamline 4

Simulation Case

4 Equipment1

Equipment 2

Streamline 1

Streamline 2

Streamline 3

Streamline 4

Hybrid Case

Case management: Generating Design Bases

Equipment 1

Equipment 2

Streamline 1

Streamline 2

Streamline 3

Streamline 4

Streamline 1

Streamline 4

Equipment1

20

Duplicated Case

Equipment 1

Equipment 2H

Streamline 1

Streamline 2

Streamline 3

Streamline 4

SPPE External Tools

Equipment

Sizing Tool(s)

Pipe Sizing

Tool(s)

SPPE case

Equipment 1

Equipment 2


Temperature / Thermodynamic

Properties

Pressure

Flow rates

Residence time / Volume

Fluid Phases



Temperature

Pressure

Flow rates

Fluid Phases


Pipeline

Vendor Data

Prelim. Equipment Design Data

Equipment Class

Equipment Size / Dimensions

Prelim. Pipeline Design Data

(1st Iteration – minimal ∆h

information)

Pipe Size

Pipe Class

Pipe Material / Spec

Insulation data

Equipment Model Information

Model No.

Type

Capacity

Performance Data

Pipe Material Properties

Case management: Source of Preliminary Design Data

SPPE

Design Case

Equipment1

Equipment 2

Layout (3D)

Project A

Layout

Option 1A

Layout

Option 3A

Fin

alis

t

Layout

Option 2A

Updated Equipment

Data

Equipment Class

Equipment Size /

Dimensions

Equipment Model

Information

Location coordinates

Updated Pipeline Data

Pipe Size

Pipe Class


Insulation data

Pipe Route Length

Pipe Route Coordinates

Elevation changes

Updated

Major

Equipment

List

(MEL)

Updated

Pipeline

List

Optimize

Optimize

External Tools

Equipment

Sizing Tool(s)

Pipe Sizing

Tool(s)

Vendor Data Optimize

Optimize

Optimize

Optimize

Case Management: 3D Level Optimization

Cost estimate

Tool(s)

Pipeline 1

Pipeline 2

Pipeline 3

Pipeline 4

Pla

nt

Sys

tem

s A

reas

Uni

ts

Optimized

Design Case Equipment1

Equipment 2

Pipeline 1

Pipeline 2

Pipeline 3

Pipeline 4

Graphical Deliverables: PFDs and Prelim. P&IDs

System

Specific

Prelim.

P&ID

System

Specific

Prelim.

P&ID

System

Specific

Prelim.

P&ID

System

Specific

Prelim.

P&ID

Unit Specific

Prelim.

P&ID

Unit Specific

Prelim.

P&ID

Unit Specific

Prelim.

P&ID

Unit Specific

Prelim.

P&ID

Area

Specific

Prelim.

P&ID

Area

Specific

Prelim.

P&ID

Area

Specific

Prelim.

P&ID

System

Specific

PFD

System

Specific

PFD

System

Specific

PFD

System

Specific

PFD

Unit

Specific

PFD

Unit

Specific

PFD

Unit

Specific

PFD

Unit

Specific

PFD

Area

Specific

PFD

Area

Specific

PFD

Area

Specific

PFD

Plant

Specific

PFD

23

Heat Mass Balance Tables

Reports, Datasheets, and Data Exchange Media

– SPPE


(From Simulation)

Temperature / Thermodynamic Properties

Pressure

Flow rates

Residence time / Volume

Fluid Phases


Equipment Preliminary Design Data

(From External Data Treatment)

Equipment Class

Equipment Size / Dimensions

Preliminary Pipeline Design Data (1st

Iteration – minimal ∆h information)

Pipe Size

Pipe Class


Insulation data


(From Simulation)

Temperature

Pressure

Flow rates

Fluid Phases


Preliminary Data for Datasheets

Equipment Model Information

Model No.

Type

Capacity

Performance Data

• Pipe Material Properties

Detailed Design


SP P&ID

SPI

–SPEL

SP Explorer

SPI external editor

SPI Operational/ex

cellence

ISO 15926 Export

SmartSketch

PDMSOth

ers

S

3

D

/S

P

O


DV

SP P&ID

SPI

SPEL

SPPE



The Project Creating the plant process model

Challenges

• Fast track

• Change management

• Iterative design

• Share engineering data

downstream


SmartPlant P&ID at Work

Verified

Engineering Data


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.


Results: Passed and Not Passed


Accessing Supporting Design Data During the Design

Engineers and Designers spend over 50% of their time looking for data

Project P&ID

Pipe

Specification

Allocated

Tag

Number

Third

Party

Validation

tools

Rules

Rules Rules

API


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 PDS S3D PDMS

SP P&ID


The Project

Design the Control System Challenges

• Data consistency

• Change management

• Interface with automation vendors

• Deliverables


Controlling the Plant

FICA FE Functional Definition

FV

FY FT

FI

FA

FT

FE

FC

Physical Definition

P&ID Expansion to Instrument

Index List


INST

R. A

IR H

EADE

R

P

E

EN

DE

VENDOR302315 461

MNFR./MODEL

DESCRIPTIONMATERIALTYPE

RATINGOR

SCHEDULE

SIZEQUANTITYNo.

PART

INSTRUMENTATION HOOK-UP

CLIENT:

PROJECT:

NO

SHEET:

DWG. NO.: REV.DXF FILE :BY DATE REVISION

OF

TAG NUMBERS

/

/

/

/

/

/

/

/

/

/

CV (H_646MT.SYM / SmartSketch)

VALVES

&ITEM_UDF.1

DEMO_SPI70

&DWG_FILE_NAME CV (H_646MT.SYM / SmartSketch)

1 1

–36

Spec Sheet Process Data Calc. Sheets

Plan & Equipment Layouts

Enhanced Smart Loop

Installation Details

Fieldbus Designer

Cable Schedules

JB Layout

Wiring Block Diagram

Profibus Network Designer

Instrument Index Single Source for all Control System

Tasks and Deliverables


Enhanced Smart Loops

–True presentation of the design

–Automatically created

–No template


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


The Project Designing Power Distribution System Challenges

• Late in project schedule

• Fast track design

• Deliverables with consistent data

• Cable management


SmartPlant Electrical at Work

SmartPlant Engineering & Schematics –41

Single Line Diagram Generated from SPEL


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

Constructing the Plant

Construction Readiness

• Ready • Moderately Ready • Not Ready

-10% +4% +28% +60%

IPA Independent Project Analysis study of over 12,000 projects


–••••••••••••••••••••••••PDS•••••••••• –••••••••••••••••••••••••PDMS•••••••••• –••••••••••••••••••••••••S3D••••••••• –••••••••••••••••••••••••SmartMarine•••••••• –••••••••••••••••••••••••MHE•••••••••• –••••••••••••••••••••••••Tekla••••••••

3D Models

Look Ahead Schedules Just in Time Materials

– Find WP that start in 1,

3, or 8 weeks.

View Animation with Schedule


Executive Dashboard

Customized Exec Dashboard.mp4

Lowering the Operational Risks


SP P&ID

SPI

–SPEL

SP Explorer

SPI external editor

SPI Operational/ex

cellence

ISO 15926 Export

SmartSketch

PDMSOth

ers

S

3

D

/S

P

O


DV

SP P&ID

SPI

SPEL

SPPE


2014 SmartPlant Engineering & Schematic 2012

Engineering & Design Basis for Operations

Process Maint. ERP Document

Mgt DCS

Reliability SHE CAD Engineering

Engineering

&

Design

Basis

Existing Plant Operations Systems


LDAR on Site


LDAR Managed by SP P&ID (SECCO China)


SmartPlant Process Safety

SmartPlant

Process Safety

Engine

Knowledge

base

Results

database

Hazop

Meeting manager

Interactive

visualisation on P&ID

to navigate and

support brainstorming

Full, auditable record

Comprehensive

Consistent

- Up to 50% time & cost reduction


SmartPlant Process Safety Automatically Detects

Cause-Consequence Scenarios


Area Classification

Defined areas where an explosive

condition is or can occur that can

course explosions


Rules-based Area Classification in S3D

Ensure right and safe design from the start

Smart Safety in Action

Engineering firms and plant owners can

transfer their engineering, operational and

safety relevant know-how into the rules-

based 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.

57

P&ID to Training/Simulation Model

Automatically convert the current/as-

built SP P&ID into

– Operator training models

– DCS MMI’s

– Simulation model for advanced controls

– Validate KPI’s

– more

2014 SmartPlant Engineering & Schematic 2012

Calibration of a Temperature Transmitter

Tag Out Lock Out

Automatically find all block valves to isolate equipment for maintenance or emergency

shutdown

Summary

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……………

June 2014

Integrating the

Engineering

Enterprise…

intergraph process, power & marine smart engineering...

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