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SmartPlant ® 3D Materials Handling Taylor D. Cole Taylor D. Cole Vice President, Intergraph Vice President, Intergraph Global Metals & Mining Industry Global Metals & Mining Industry

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  • SmartPlant 3D Materials Handling

    Taylor D. ColeTaylor D. ColeVice President, IntergraphVice President, IntergraphGlobal Metals & Mining Industry Global Metals & Mining Industry

  • 676872

    2007 2015

    3544

    54 66

    2007 2012 2017 2022

    1926

    33 38

    2007 2012 2017 2022

    8441136

    1421 1624

    2007 2012 2017 2022

    Global Outlook - Commodities

    Source: Rio Tinto May and July 2008. Million MT per annum demand forecast.

    Global Seaborne Iron Ore Global Copper

    Global Aluminum Global Seaborne Coal

    2 X 2 X

    2 X 1.3X

  • Materials Handling Problem

    Time to Market Solution:Work-sharing Skilled Resources

    Higher Productivity and Quality for Same Hours

    Re-use of Design

    Reduce Interfaces and Re-work

    Supply Chain Efficiency Vendor Integrated

    Problem

    2008 2015

    Prod

    uctio

    n

    Time to Market

    Demand

    Supply

    Enablers:Technology: Intergraph SmartPlant Enterprise Workflow: Front-end Loaded and Rule Based

    Standardisation: Intelligent Re-usable Catalogue

    Leverage: Synergies with Other Industries

    Accuracy: Total Installed Schedule and CostOptimise: Layout, Pre-assembly, Design Stds

    Safety: Reviews: Hazop, Constructability, O&M

    Knowledge: Asset Lifecycle and Re-use

    Benefits:

  • 4

    Business Values for Change

    over 80% of a projectover 80% of a projects total cost are committed withins total cost are committed withinthe first 20% of the total projectthe first 20% of the total projects design time s design time

    Profit

    Time

    FasterStartup

    TraditionalStartup

    CapitalCostSavings

    FasterProfitability

    IncreasedProfit

    TraditionalProjectCost/BreakevenCurve

    DigitalPlantProjectCost/BreakevenCurve

    Cost

    ReducedCapitalSpend

    CapitalCostSavings

    ConceptualDesign

    DetailedDesign

    Fabrication &Construction

    Commission& Test Plant Operations & Maintenance

    According to a Construction Industry Institute study of 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

  • Intelligent Design Reduce Time on Task

    Comparison Microstation

    Old technology [1980s]

    Fantastic change for the time

    PDS Newer technology

    Faster design time improvement over Microstation

    SmartPlant 3D Latest technological advance

    Data base engineering

    Significant improvement over PDS in design time

    Improved integration between disciplines

  • Proof of Concept Project Background / Purpose / Status

    Problem industry demand and resource supply needs a step change solution

    Document centric (2D) project delivery compared to Process Industries

    Proof of Concept initiates the step change

    Industry requirements specifiedSolution concepts established and tested

    Initiated solution configuration and developmentConcept proved - confidence to continue

    Pilot project for project readinessobjective

  • SmartPlant 3D Materials Handling Benefits for Projects and Assets

    Schedule

    Standardisation

    Workflow

    Interfaces

    Productivity

    Cost

    Optimisation

    Re-use

    Wastage

    Rework

    Risk

    Work-share

    Tracking

    Forecasting

    Integration

    Safety

    Reviews

    Pre-assembly

    Simulation

    Education

    Knowledge Management and Re-use

    Handover and Asset Lifecycle

  • SmartPlant 3D Materials Handling Conveyor Design Workflow

    Curren

    t Scena

    rio Pr

    ofile & D

    ata She

    et Draw

    ing

    Solutio

    n Con

    veyor &

    Parts C

    atalogu

    e Specif

    ication

  • SmartPlant 3D Materials Handling Chute Catalogue Workflow

    Curren

    t Scena

    rio C

    hute A

    rrangem

    ent Dra

    wing

    Solutio

    n 3Di

    Design

    to Catal

    ogue an

    d Re-us

    e

  • SmartPlant 3D Materials Handling Benefits for Projects and Assets

    Schedule

    Standardisation

    Workflow

    Interfaces

    Productivity

    Cost

    Optimisation

    Re-use

    Wastage

    Rework

    Risk

    Work-share

    Tracking

    Forecasting

    Integration

    Safety

    Reviews

    Pre-assembly

    Simulation

    Education

    Knowledge Management and Re-use

    Handover and Asset Lifecycle

  • SmartPlant 3D Materials Handling Knowledge Management & Re-use

    Critical Information Transfer

    Design

    Operate

    Commission

    Build

    Critical Feedback Loop

    Critical Feedback Loop

    Critical Information Transfer

    Critical Information Transfer

  • SmartPlant 3D Materials Handling Knowledge Management & Re-use

    Design

    Operate

    Commission

    Build

    SmartPlant Foundation

    Application Integration

    Engineering Data Handover

    Engineering Information Management

  • SmartPlant 3D Materials Handling Handover & Asset Lifecycle

    By establishing a holistic strategy for plant asset lifecycle management, Owner Operators can

    manage their assets for short and long term

    profitability rather than the traditional sweat the

    assets strategies

    Measurable Value Expedited Commissioning & Startup (2-3% of TIC) - through expedited commissioning & start-up

    resulting from as-built data validation, transformation & loading into operating systems Minimized Plant As-Built Verification (1-2% of TIC annually) - through auditable plant asset

    information management of change Reduced Production Loss (0.2-0.5% of revenue annually) through elimination of unplanned

    outages as a result of decisions based upon inadequate / incomplete plant data Increased Turnaround Intervals (20% annually) Through application of reliability in design and

    asset performance management principals

  • SmartPlant Enterprise Financial Benefits

    Base W/ SPE ChangeSales (Revenue) 1,000 1,020 +2.0%Less:Operating CostDepreciation

    - 500- 100

    - 494.7- 85

    -3.0%-15%

    Operating Profit 400 440.3 +10.1%

    Base Scenario Savings / Revenue Improvement w/ SPE

    CAPEX Savings: -15% - Initial and Depreciation

    OPEX Savings: -3% annually

    Revenue Increase: +2.0% annually and 7 to 10% earlier project completion (approximately +20% revenue increase in Y1 on a three year CAPEX project life).

  • SmartPlant 3D Materials Handling Next Steps

    Pilot Project Australia Q4 2008

    BETA Version Q1 / Q2 2009

    Commercial Version SmartPlant 3D v9 Release

  • Materials Handling Solution

    Questions?

    Taylor D. ColeVice President, Intergraph Global Metals and [email protected]

    mailto:[email protected]

    SmartPlant 3D Materials Handling Global Outlook - CommoditiesMaterials Handling ProblemBusiness Values for ChangeIntelligent DesignReduce Time on TaskProof of Concept ProjectBackground / Purpose / StatusSmartPlant 3D Materials HandlingBenefits for Projects and AssetsSmartPlant 3D Materials HandlingConveyor Design WorkflowSmartPlant 3D Materials HandlingChute Catalogue WorkflowSmartPlant 3D Materials HandlingBenefits for Projects and AssetsSmartPlant 3D Materials HandlingKnowledge Management & Re-useSmartPlant 3D Materials HandlingKnowledge Management & Re-useSmartPlant 3D Materials HandlingHandover & Asset LifecycleSmartPlant EnterpriseFinancial BenefitsSmartPlant 3D Materials HandlingNext StepsMaterials Handling Solution