digital design workflows to reduce non-conformances...
TRANSCRIPT
1 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated © 2018 Bentley Systems, Incorporated
Digital design workflows to reduce non-conformances in the power industry
Mark Upston – Senior Director
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2017 USA Energy Infrastructure Report Card – What is the Gap?
https://www.infrastructurereportcard.org/wp-content/uploads/2017/01/Energy-Final.pdf
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Recommendations to Improve USA Power Infrastructure
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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
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Bentley Solving Multi-Discipline Team Collaboration
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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 non-conformances
– See how integrated design analysis applications are being used to manage ageing assets on brownfield projects
Q&A
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Brownfield Project: Laser Scan to 3D Modeling to Engineering Analysis for Checking Structural Integrity
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Where is Structural Integrity Needed Most?
Source: 2002 Report http://www.nace.org/Publications/Cost-of-Corrosion-Study/
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
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• 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.
Brownfield Projects – Industry Problem
Plant Pipe Racks are failing with increasing downtime
leading to significant production losses
Corrosion is
Everywhere!
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Brownfield Projects – Design Solution
• Aging Plants – Integrated Design Models using STAAD for Structural and AutoPIPE for Piping
LaserScan
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Brownfield Projects – Design Solution
• Aging Plants – Integrated Design Models using STAAD for Structural and AutoPIPE for Piping
LaserScan
3D CAD
model e.g.
OpenPlant
Engineering
Analysis
(STAAD &
AutoPIPE)
Optioneering
(Scenario
Services)
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▪ 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
Bentley Solution – Model and Analyze Failing Structures
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Design Integrity and Asset Management
43
AssetWise Reliability
Server
RBI SIM Assessment
ProjectWiseDocument Management
6
1
2
5
Engineering Analysis
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Integrate brownfield project
extensions to existing plant
Reusable 3D intelligent plant
and analysis models for
future Plant sustainability
Accurate modeling of ‘as built’ assets
Use of existing tools and design
resources already in house
Rapid Efficiency savings as
high as 75% compared to
traditional design methods
Assets that are structurally at risk can be
identified quickly and accurately.
Benefits
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Power Plants Using Integrated Design Technology
200MW - Coal-Fired Power Plant – PhilippinesDoosan Heavy Industries
600MW Gas Power Plant – CairoProjenia 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”
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Power Plants Using Integrated Design Technology
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%.
Biomass - ESI Inc of Tennessee 42MW Gas-Turbine Power - Giprotyumenneftegaz
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Power Plants Using Integrated Design Technology
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%.
582MW Clean Coal Plant – Mississippi Southern Company
375MW Combined Cycle Plant in India –L&T & Sargent Lundy
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Power Plants Using Integrated Design Technology
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.
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
540MW Sewaren 7 Combined Cycle Plant New Jersey, Black & Veatch
Flue Gas Desulfurization Plant in North Carolina Utility Engineering
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A Brownfield Plant Retrofit Project – Design Integrity Check
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The As-Built System
AutoPIPE– Stress analysis of piping system
– Piping in isolation (no structure)
– Acceptable stresses in piping
– Export to STAAD.Pro using pipelinkformat
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
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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.
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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
BeforeAfter
(Braces Added)
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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
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Evaluating Model for Clashes
AutoPIPE– Publish AutoPIPE model to i-model
– Optionally consider deformedgeometry
– 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
AutoPIPE
Bentley Navigator
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Case Study – Hot Operation Clashes
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
Samcheok Green Power Unit 1 and 2, South Korea
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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
KEPCO Engineering & Construction Company
2x1,000MW Ultra Supercritical Thermal Power Plant
Samcheok, South Korea
LP Bypass Line
Warm Up Line
Image Courtesy of KEPCO E&C Samcheok Green Power
Unit 1 and 2 Project, Be Inspired 2014
3 Critical Hot Clashes Identified
during Design Phase
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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 non-conformances
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Engineering Document Management Using ProjectWise and Asset Reliability
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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
ProjectWise
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Structural Integrity Dashboard in Asset Management System
• Asset Summary & Health
• SIM KPI’s: RSR, Inspection Compliance, CP Readings, Anomalies, Trends
• Role specific
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Assets – Navigate by Hierarchy, Map, Listing
• GIS Interface
• Select and report on assets and equipment
• Surface Alarms and KPIs
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How does Immersive Asset Reliability help?
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Asset Performance
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.
T&D Implementation of Asset Risk at Indianapolis Power & Light
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Reality Modelling – Capture
Point Clouds➢ Traditional Laser Scanning Technology.
Photogrammetry➢ 3D meshes created from photos.
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Photogrammetry – 3D Reality Mesh Models
Aligning new designs
with existing conditions
Inspecting operational assets
Managing
information
Richer Information Models are available with 4D
(Time), 5D (Cost) and 6D (Operations Management)
Capturing the
context
Better understanding
via 3D is great!
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What is the level of 3D Detail with Photogrammetry?
➢ Drone – Falcon 8
➢ Camera – Nikon D810
➢ Capture - 4500 Photos
➢ Processing- 2 Hours
Chemical Plant
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
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Reality Modeling
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
Analysis of Transmission Tower, South Korea, GeoINT
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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
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Mobile 3D Visualizations and Interactive Inspections
Visualize 3D i-Models Punchlist of Issues
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Thank you for Attending…
Q&A
Product Management: Mark Upston
Marketing: Samantha Langdeau