strategies for fast-tracking conceptual plant studies ... · strategies for fast-tracking...

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


SStrategies for Fasttrategies for Fast--TrackingTrackingConceptual Plant StudiesConceptual Plant Studies

September, 2008September, 2008

© 2008. Intergraph Corporation. All Rights Reserved. 3

Introduction Introduction ……

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

• SmartPlant Layout Positioning & Overview• Optimized conceptual plant layout workflow

using SmartPlant Layout integratedwith Aspen Tech Applications

• Business Value

– Q & A

– Summary & Close

LayoutLayout


Introduction Introduction ……

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

• SmartPlant Layout Positioning & Overview• Optimized conceptual plant layout workflow

using SmartPlant Layout integratedwith Aspen Tech Applications

• Business Value

– Q & A– Summary & Close

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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:

• 20% Lower Engineering costs• 39% Schedule reduction• 15% Plant Utilization/ Capacity increase

compared to projects that spent the least effort on conceptual plant design studies as part of pre-project planning.

Plant Hand-over

Plant Lifecycle

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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

Total

Project

Cost

30%

15%

5%

12%12%

44%44%

Lifecycle cost red

uctio

n op

portun

ity


User Case Study User Case Study ……

The Dow Chemical CompanyThe Dow Chemical Company


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 …

LayoutLayout


Det

aile

d D

esig

nD

etai

led

Des

ign

Det

aile

d D

esig

n

Heat & MaterialBalance

Heat & MaterialHeat & MaterialBalanceBalance

PFDPFDPFD

EvaluationEvaluationEvaluation

ProcessConfiguration& Simulation

ProcessProcessConfigurationConfiguration& Simulation& Simulation

Estimationand Cost

EstimationEstimationand Costand Cost

ProcessDatasheetsProcessProcess

DatasheetsDatasheets

EquipmentList

EquipmentEquipmentListList

An EPC View Today An EPC View Today ……Current Work Process/ Work FlowCurrent Work Process/ Work Flow

EquipmentDatasheetsEquipmentEquipmentDatasheetsDatasheets

P&ID’s 3D Plant Model


Det

aile

d D

esig

nD

etai

led

Des

ign

Det

aile

d D

esig

n

Heat & MaterialBalance

Heat & MaterialHeat & MaterialBalanceBalance

PFDPFDPFD

EvaluationEvaluationEvaluation

ProcessConfiguration& Simulation

ProcessProcessConfigurationConfiguration& Simulation& Simulation

Estimationand Cost

EstimationEstimationand Costand Cost

ProcessDatasheetsProcessProcess

DatasheetsDatasheets

EquipmentDatasheetsEquipmentEquipmentDatasheetsDatasheets

P&ID’s 3D Plant Model

Solution Mapping toSolution Mapping toWork Process/ Work FlowWork Process/ Work Flow

EquipmentList

EquipmentEquipmentListList


Conceptual Plant DesignConceptual Plant DesignLayout Strategies & OptionsLayout Strategies & Options

Layout Strategy Estimation Basis#1. 2D CAD-based Plot Plans Internal Rates/ Historical Data

#2. ‘Simplified’ 3D Plant Model Internal Rates/ Historical Data

#3. Integrated Process/ Plant Model Linked to Cost Estimation Software

Observations Comments 2D CAD-based Plot Plans ‘The way we’ve traditionally done it …’

Simplified 3D Plant Model ’If the customer is prepared to pay for it …’

Integrated Process/ Plant Model ‘Who will gain the overall benefits?’

Sound familiar …?

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Paper-based Drawing Layouts/2D Studies; Simplified 3D CAD Models

Undertaking Conceptual Plant Layouts~ Design Cases ~ using 3D plant layout toolsIntegrated with process design

CurrentApproach:

AlternateApproach:

So, Where should 3D Plant Modeling start?So, Where should 3D Plant Modeling start?

2D CAD/ Drafting & simplified 3D Modeling2D CAD/ Drafting & simplified 3D Modeling 3D Plant Design/ Modeling3D Plant Design/ Modeling

LayoutLayout

Feasibility/Concept

Feed EngineeringProcurement/Construction/ Commissioning

Operations/ Maintenance


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

IntroductionIntroductionLayoutLayout


ObjectivesObjectives

Targeted at Front End Engineering DesignStarting point …

Process Flow Diagram ~ PFD

Plot size & shape ~ 2D CAD-based drawings

Facilitate layout evolution, evaluation& plant optimisation …

Plant areas & zonesEquipment placementPipe routesStructural requirements – Pipe Racks

Input to cost estimationRollover into detail design

Find the minimum evaluation cost

Avoid obstructions

Utilise Pipe Racks & Zones

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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

SmartPlant3D

SmartPlant3D

P&IDs

• PFD’s• Equipment

Data Sheets• Equipment

Lists• Stream

Data Sheets

ZyqadZyqad

SmartPlantP&ID

SmartPlantP&ID

SmartPlantLayout

SmartPlantLayout

K-BaseK-Base

• P&IDs • Reports

• Piping MTO• Structural MTO

• Correlated P&IDs

• Piping Data


Pip

ing

Pip

ing

Str

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Ele

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Dra

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&D

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Rep

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Sp

ace

Sp

ace

Man

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uip

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Fu

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& F

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Cata

log

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Cata

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CommonCommon

Gri

ds

Gri

ds

Han

gers

Han

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& S

up

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& S

up

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Syst

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Sp

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& S

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Project Setup& Reference Data

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

production

LayoutLayoutLayoutLayoutToolsTools

3D Modeling3D ModelingToolsTools

ReferenceReferenceDataData

ArchitectureArchitectureLayoutLayout


Optimized SmartPlant Layout WorkspaceLayout Tools:

– Define Connections– Limit Path– Auto Route

Modeling Tools:– Place Equipment– Place Zones– Place Pipe & Components– Place Structural

Reference Data (OOTB):– Layout Equipment– Pipe Auto-router Rules– Layout Piping Specifications– Code Lists– Layout Drawing & Report Templates

Layout

Zones

Equipment

Piping

WorkflowWorkflowLayout Task/ Reference DataLayout Task/ Reference Data

User‐Configurable/Extendible

User‐Configurable/Extendible

LayoutLayout


DefineSite Grid,

Plant Zones& Pipe Racks

DefineSite Grid,


Create/ Position Equipment


Define / ImportPipe Runs


Auto-RoutePipe Runs

Auto-RoutePipe Runs

Adjust Layout(Optimization)


Document Design Case


LayoutOK?

LayoutOK?

Yes

No

WorkflowWorkflowLayout Workflow/ OverviewLayout Workflow/ OverviewLayoutLayout


Intelligent ‘Smart’ Grid Wizard assistsinitial site layoutDynamic creation of Pipe Racks

– Identical to SmartPlant 3D Structure

Equipment placed from SmartPlant Layout reference data catalog

– Based on identical SmartPlant 3D Equipment objects

WorkflowWorkflowDefine Site Grid, Pipe RacksDefine Site Grid, Pipe Racks& Zones; Position Equipment& Zones; Position EquipmentLayoutLayout


Piping can be placed in the 3D modelfrom various sources;

– SmartPlant P&ID• Import of line connection data & correlation

– 3D Model• User routes piping & then applies rules• Auto-routing pipe

– Spreadsheet• Import of line & connection data from Excel

Connectivity between;– Equipment origins– Equipment bounding boxes– Equipment nozzles– 3D points– Connection zones– Runs

WorkflowWorkflowDefine & Import Pipe RunsDefine & Import Pipe RunsLayoutLayout


Goal is to find the minimum cost route while avoiding obstructions …

… resulting route driven by space objects(3D volumes& zones) initially created in theSmartPlant Layout 3D model …

- 3D Volumes & Zones(with special attributes)

• Attraction• Pipe Rack

– ‘Via’ zones• Avoidance• Connection

– Obstructions– SmartPlant Layout 3D Plant Objects

Pipe AutoPipe Auto--router Theoryrouter Theory

User‐Configurable/Rules

User‐Configurable/Rules

LayoutLayout


Vessel

Equipment

#5. Attraction Zone#6. Via Zone

#4.Avoidance

Zone

#1. Connection Zone #2. PipeRack Zone

#3.Interference Volume

RulesRules‘‘ForcingForcing’’ the Routethe Route

#7. SmartPlant Layout 3D Plant Objects

LayoutLayout


Pipe Rack Zone (Cost Factor 0.2)Pipe Rack Zone (Cost Factor 0.2)

Eqp AEqp A EqpB

EqpB

Free Space (Cost Factor 1)

X

Y

Pipe routed through the rack if :

[X * 1] > [ (Y * 2) + (X * 0.2)]

Pipe AutoPipe Auto--router Theoryrouter TheoryLayoutLayout


Auto-router defines minimum cost routes, while …– Complying with defined zones– Avoiding obstructions– Complying with rules

Routes driven by space elements in 3D model …– Zones

• Attraction• Pipe Rack• Avoidance• Connection

– Other obstructions/objects

Routes driven by rules …– Branch gap– Air gap– Standout– Etc.

PipeAir Gap

Standout

Branch Gap

WorkflowWorkflowAutoAuto--Route Pipe RunsRoute Pipe RunsLayoutLayout


Branch Gap

• 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.

RulesRulesBranch GapBranch GapLayoutLayout


= a Routing Parameter

• 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.

Pipe Air Gap

RulesRulesPipe Air GapPipe Air GapLayoutLayout


Standout10cm + Min Pipe

Length

RulesRulesStandoutStandoutLayoutLayout


Pipe Specs Pipe Specs Piping PartsPiping Parts

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

RulesRulesLayout Piping SpecificationLayout Piping SpecificationLayoutLayout


Rack SpacingRack Spacing Cost FactorsCost Factors

• Defines spacing of pipes… Defines cost factors – straight vs. bends

RulesRulesRack Spacing & Cost FactorsRack Spacing & Cost FactorsLayoutLayout


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

RulesRulesLayout EquipmentLayout EquipmentLayoutLayout


WorkflowWorkflowInitial Starting PointInitial Starting Point

Initial Layouts & Sketches~ P&ID & Plan Layout

Initial ‘Intelligent’ SmartPlant P&ID

LayoutLayout


DefineSite Grid,


DefineSite Grid,






Auto-RoutePipe Runs

Auto-RoutePipe Runs





LayoutOK?

LayoutOK?

Yes

NoTender Layout Drawing(s)

MTO Reports (Pipe, Piping Components, Structure)

Design Case Alternatives

Design Case Comparison/Analysis Reports (MS Excel)

MS Excel report export to3rd Party Estimation Tools

Initial Equipment List(s)/ P&ID(s) Preliminary P&ID’s

Initial Line List(s)

Initial Layouts & Sketches

WorkflowWorkflowLayout Workflow/ OverviewLayout Workflow/ OverviewLayoutLayout


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

COST ESTIMATIONKbase

LayoutLayout


SmartPlant Layout 3D data (MS Excel reports) are importedinto Aspen Technology’s Kbase for cost evaluation

WorkflowWorkflowCost Estimation with KbaseCost Estimation with Kbase

SmartPlantLayoutLine ListReport

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Speed & quality improvements compared tomanually drafted layouts;

– 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

ValueValueConceptual Plant Layout Benefits Conceptual Plant Layout Benefits

SmartPlant Layout SmartPlant Layout –– Design Layout Design Layout (Case) (Case) AlternativesAlternatives

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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 …”

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 …”


Summary & CloseSummary & Close


SummarySummary

SmartPlant Layout is a new, standalone solution for conceptual 3D plant layout & designfor use by the EPC OR the Plant Owner!

Preliminary 3D plant layout benefits are well documented compared to manual methods …

– Significant modeling/ layout productivity– Data integration,– Layout optimization– Conceptual layout quality improvements

When integrated with SmartPlant 3D &SmartPlant P&ID …

SmartPlant Layout delivers furtherincremental benefits to your projects …

– Conceptual/ preliminary designs seamlesslyevolve into early detailed design phase

– Improved preliminary cost estimates– Over 85% reduction in re-modeling man-hours

during the conceptual design phase– Over 90% reduction in model data reuse from

proposal to initial detailed design phase of project– Improved design quality – Lower administrative burden

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Integrating the Engineering Enterprise…

strategies for fast-tracking conceptual plant studies ... · strategies for fast-tracking...

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