process, power and marine division early decision ... · 9/17/2009 1 process, power and marine...

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Process, Power and Marine Division

Early Decision Engineering with SmartPlant Schematics

Intergraph

September 16, 2009

Agenda

Introduction of the team

Objective of the session Objective of the session

The Scope

Success Criteria

Process Design

Control System Design

© 2009. Intergraph Corporation. All Rights Reserved.


Electrical Design

Conclusions

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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


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Opportunities

Innovative solutions

R l d i 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 Ability to use the data in operations


PipingInstrumentation

Equipment

Electrical

P&ID

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

Pump Motor

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Success Criteria

The bottom line– Faster plant productivity improvement

Minimized downtime– 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– Management of change

– Re-use of designs

– Design automation

– Accurate material quantification, purchasing and delivery

– Optimized construction

– Automated update of plant documentation© 2009. Intergraph Corporation. All Rights Reserved.

Process Design

First Step in the work processp p– Create the P&ID using best practices

– Leveraging the engineering capabilities

– Validate the design


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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

© CB&I - 9

C e t Staatso e, Su a e

– Refinery Complex incl. Licensor packages

– About 300 dwgs

Global Execution Capabilities

Ft. Saskatchewan

C l

The Hague

MoscowCalgary

Everett

San FranciscoSan Luis Obispo

Los AngelesThe Woodlands

HoustonBeaumontTyler

Dallas

Plainfield

AtlantaNew Castle

BloomfieldPittsburgh

Niagara-on-the-Lake

Caracas

Puerto Ordaz

LondonMoscow

Brno

Cairo

Al KhobarDoha

AjmanDubai

New Delhi

Bangkok

Beijing

Tokyo

Shanghai

Manila

Singapore

© CB&I - 10

Perth Brisbane

Sydney

Secunda

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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

© CB&I - 11

atabase sy c o at o

– Consistency on interfaces

– Access to drawings not in own office

Reports

• Deliverable reports– Drawing list

– Line list

• Check / Consistency reports– Inconsistency report

– Valve list

© CB&I - 12

• Interface reports– Instrument export

– MTO export

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AVI

Performing the Task

© CB&I - 13

g

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

© CB&I - 14

• SmartPlant P&ID requirement• Not to be used as CAD application

• Configuration of rules

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Completing the Process Design

Key pointsy p– 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 CADtime than creating PID with traditional CAD like AutoCAD.

A) Yes, much more time

B) Yes, a little more time

C) They are about the sameC) ey a e about t e sa e

D) No, it takes less time

E) I don't know

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Next step in the work processp p– Adding the controls

– Creating the specifications and wiring

– Creating the deliverables to buy, install, test and later maintain



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

C ti d li bl t h i t ll t t d l t– Creating deliverables to purchase, install, test and later maintain the Instrument Control Systems


John DresselPrincipal Control Systems Application Specialist

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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 SPIhaving 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

RETREVEDO NOT

RETREVE

SmartPlant User Interface SPI Explorer Interfaces with Module Work Area Window

Allows navigation to all Tag, Loop, &to all Tag, Loop, & Wiring Properties

Allows access to all SPI Documents

Allows access to all primary support tables

Powerful MenuPowerful Menu Functions for Editing, Duplication and Generation of Documents and Data

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Instrument Index Module

Index Add, Edit or Duplicate Tag Number or Loop Properties

Displays Loop association for Tagsassociation for Tags

Access to primary support tables with pick lists for data consistency

Additional data for SPEL power requirementsrequirements

Access to User Defined Custom Tables


The Instrument Type Table contains entries for every type of instrument that is expected to be used on a project.

Instruments areInstruments are grouped by Process Function

Each different technology is given a separate Description

The Profile definesThe Profile defines the SPI Automation

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Instrument Type Profile defines the Tag Automation Functions

Automation Functions Instrument SpecificationsInstrument Specifications

– Define Spec Form

– Populate Spec from Template

Automatic Loop Creation

Process Data Workflow

Populate Support Tables

Initialize Device Wiring

– Define I/O TypeDefine 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

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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 RevisionsProcess datasheets with Revisions

Process Calculation Module– Control Valve Sizing

– Relief Valve Sizing

– Flow Meter Sizing

– Thermowell Parameters

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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

f– User configurable

– Interactive with database

– Save in CAD file formats

AutoCAD & Microstation Automatic Loop Generation

– Completely configurable

– Can use existing or client Blocks or CellsBlocks 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

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SmartPlant Loop Module Automatic Loop Generation

Enhanced SmartLoop

– True CAD documents

f– User configurable



AutoCAD & Microstation Automatic Loop Generation

– Completely configurable

– Can use existing or client Blocks or CellsBlocks 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



– May be annotated

– Uses SmartSketch RAD graphic enginegraphic engine

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SmartPlant Instrumentation Interfaces

SmartPlant Foundation Interface allows Data Sh i t S tPl tSharing to SmartPlant Applications

Work Sharing via Citrix allows real time global access to the SPI database over the Web

Vendor Interfaces for D t Sh i tData Sharing to instrument sizing, selection and DCS programs

Controls in place

Key pointsy p– 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…..


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Audience Poll...

Capabilities to create user defined rules and pautomate 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 workflowp– Powering the system with best practices

– Electrical distribution design

– Making sure it is a safe and reliable design addition thru validation (ETAP)


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Electrical Design Experience with SmartPlant Electrical

– Standard electrical design tool in Energy Global Practice

Executed 10 projects over last 3 years– 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

Cl i i i h h di i li– Closer integration with other disciplines

– 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


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Leveraging Reference Data Profiles

– Profiles are the data representation of an electrical schematic

Allow to quickly and consistently create all information needed to manage– 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 TablesCustomize tables to look up any number of inputs and fill in incomplete data– 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

Ci i I f i Circuit Information DCS I/O Terminal Strips Control Cables Circuit Internals

Disconnect Circuit Breaker Control Transformer Contactor


Contactor Solid State Overload Ground Fault Relay

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Building Electrical Network Build electrical power distribution network quickly using drag

and drop methods

f 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

U El t i l E i i d t hi ll i l t i l Use Electrical Engineer window to graphically view electrical network

Validate bus loading with SmartPlant Electrical and quickly move loads to balance electrical network



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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.

O Li– One-Lines

– MCC or Switchgear Schematics

– Cable Schedule

– Equipment Schedule

– Material Lists


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SmartPlant 3D Interface

Publish Cable Schedule to SmartPlant 3D for automatic cable routing and validating raceway design

f S 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

A i k k t ll j i t 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


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Completing the Design

Key Pointsy– 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 y ginconsistencies across the documents produced in the electrical discipline?

A) More than 30%

B) Less than 30%

C) None

D) I don’t know

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Conclusion

Integrated rules driven design enables:g g– Fast track project execution

– Work sharing

– Reduce risks

– Management of change

– Reduction of revision iterations due to data validationReduction of revision iterations due to data validation

– Deliverables consistent

– Faster time to production

– Data hand over to Operations


Q&A


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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:

http://www.intergraph.com/ppm/engsch.aspx

Process, Power and Marine Division

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