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  • WH

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    SmartPlant

    Spoolgen Plus

    Piping Productivity for Fabricators and Constructors

  • SmartPlant Spoolgen Plus

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    Contents

    1. Introduction ................................................................................................................. 1

    2. Work Process Modernization ...................................................................................... 3

    2.1. Piping Data Transfer from 3D Plant Design to Construction ........................................................... 4

    3. SmartPlant Spoolgen Plus .......................................................................................... 6

    3.1. Overview .......................................................................................................................................... 6

    3.2. Goals ............................................................................................................................................... 7

    3.3. Business Benefits ............................................................................................................................ 7

    4. SmartPlant Spoolgen .................................................................................................. 9

    4.1. Overview .......................................................................................................................................... 9

    4.2. Work Process ................................................................................................................................ 10

    4.3. Key Capabilities ............................................................................................................................. 13

    4.3.1. Integrated Workflow Management ....................................................................................... 13

    4.3.2. Automatic Deliverables ........................................................................................................ 13

    4.3.3. Bills of Materials ................................................................................................................... 13

    4.3.4. Piping Reports ...................................................................................................................... 13

    4.3.5. Replay .................................................................................................................................. 14

    4.3.6. Repeatability ........................................................................................................................ 14

    4.3.7. Integrated 3D Visualization .................................................................................................. 14

    4.3.8. Cut and Paste ...................................................................................................................... 14

    4.3.9. Elbow to Bend Conversion ................................................................................................... 14

    4.3.10. Weld Gaps ......................................................................................................................... 15

    4.3.11. Work Content Measurements ............................................................................................ 15

    4.3.12. Flat Spools ......................................................................................................................... 15

    4.4. Business Benefits .......................................................................................................................... 15

    4.4.1. Productivity ........................................................................................................................... 15

    4.4.2. Efficiency .............................................................................................................................. 16

    4.4.3. Accuracy .............................................................................................................................. 16

    4.4.4. Consistency .......................................................................................................................... 16

    4.4.5. Quality Assurance ................................................................................................................ 16

    5. SmartPlant Isometrics ............................................................................................... 17

    5.1. Overview ........................................................................................................................................ 17

    5.2. Business Benefits .......................................................................................................................... 18

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    6. Spoolgen-Piping ........................................................................................................ 20

    6.1. Overview ........................................................................................................................................ 20

    6.2. Work Process ................................................................................................................................ 21

    6.3. Key Capabilities ............................................................................................................................. 22

    6.3.1. Automatic Classification of Pipelines According to ASME/PED .......................................... 23

    6.3.2. Weld Management ............................................................................................................... 26

    6.3.3. Automatic Production of Final QA Documentation .............................................................. 28

    6.4. Business Benefits .......................................................................................................................... 29

    7. Sample QA and Final Handover Documentation ....................................................... 30

    8. Conclusion ................................................................................................................ 36

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    1. Introduction

    Figure 1: Engineering projects that include piping involve the main stages of Design, Fabrication, Construction (Erection), and Operations to varying degrees.

    Engineering projects that include piping involve the main stages of Design, Fabrication, Construction (Erection), and Operations. But as Figure 1 shows, each project is different with more or less work performed in the engineering office, the fabrication workshop, and the construction site. But all projects face two major challenges:

    Procure and assemble materials in time to efficiently fabricate piping spools in a workshop to the required engineering and quality assurance standards

    Deliver those spools, together with any erection items needed to complete the assembly, to the site in a sensible sequence

    These challenges are complicated by the fact that complex chains of primary and secondary contractors and sub-contractors are involved.

    To be successful in this task, various companies need to:

    Effectively plan and prepare work packages (drawings and reports)

    Efficiently utilize all available resources machinery, materials, and man-power

    Make decisions that optimize spooling for efficient shop fabrication and safe field erection

    Procure materials on time, and cost-effectively

    Operate materials management proficiently in-house and at the site

    Measure work progress and productivity to control costs and schedule

    Monitor and control application of welding procedures and assess welder performance

    Manage the impact of piping revisions on production

    Reduce the potential for error and avoid unnecessary rework

    Perform quality assurance (NDT) to relevant standards

    Meet ever more demanding delivery deadlines set by the contract or client

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    There is an increasing demand within the process, power, and marine industries to work smarter, and not just during the engineering and detail design project phases, but also during downstream procurement and construction phases, and even extending into the operations and maintenance phase of the life cycle.

    Competitive companies increasingly strive for shorter processing times and lower operating costs. This has led many to adopt new methods that offer optimum quality and cost efficiency and therefore maximum cost savings, without distracting them from their core business or being overly onerous to operate and gain the resulting benefits.

    Intergraph meets industry demands by offering an integrated piping solution SmartPlant

    Spoolgen

    Plus that satisfies various order fulfillment scenarios in the scope of pipeline fabrication, construction, and maintenance projects. With an emphasis on the drivers and financial demands of the business, but aiming to deliver organizational performance improvements, piping contractors can realize productivity gains and efficiency savings by replacing their outdated working methods with a continuous digital chain that encompasses engineering, detail engineering, manufacturing, installation, and maintenance.

    The key to success is a standard format for piping data that can be easily transferred between various companies working on the digital chain. This standard format eventually delivers accurate and timely information into overarching corporate systems, such as SmartPlant Construction and SmartPlant Materials, that are used to manage the whole project.

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    2. Work Process Modernization

    Owner operators will normally specify the use of, and small-to-medium engineering design contractors and large EPCs will typically use, a variety of process engineering and 3D plant design tools to execute projects. Its unrealistic, and simply far too expensive, for any piping contractor to have all of these systems in-house, so the piping contractor will usually default to working in the lowest common denominator with paper and Microsoft

    Excel

    being commonly employed.

    Figure 2: A common, paper-based work process involves all projects and service activities in parallel.

    A key benefit of SmartPlant Spoolgen Plus is its ability to work electronically with piping design data produced by all of the leading and most popular process engineering and 3D plant design systems.

    Figure 3 shows how SmartPlant Spoolgen Plus replaces an outdated, inefficient paper and Excel-based work process with an automated, efficient digital-based work process that enables the piping contractor to work with many different clients using many different design systems.

    Figure 3: A modern, efficient, digital-based work process supports piping information and data received from many different systems and clients.

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    Piping contractors who choose SmartPlant Spoolgen Plus to modernize their work processes can expect to benefit from:

    Faster work preparation

    More efficient resource utilization

    Improved internal and external communications

    Shortened production hold-ups due to effective change management

    Elimination of islands of duplicated information

    More accurate materials procurement

    Improved materials delivery schedules

    Better materials management

    Reduced errors and rework

    Increased accuracy and quality

    Lower operating costs

    Shortened project schedules

    Meeting of tight delivery schedules

    Fewer construction delays

    Enhanced business reputation

    Satisfied clients leading to repeat business

    Further efficiencies are also possible through the integration of other business processes and other third-party vendor systems used in the organization.

    2.1. Piping Data Transfer from 3D Plant Design to Construction

    As Figure 4 shows, most of the worlds 3D plant design systems use Intergraph ISOGEN to

    automatically create piping design isometrics. ISOGEN receives a data file containing a description of the pipeline to be documented. The software then automatically lays out the drawing and creates the material takeoff based on the information in this file. The exact form the drawing takes the style of dimensioning or the units of coordinates, for example is determined by a set of controls.

    ISOGEN creates a piping isometric drawing using the selected CAD format AutoCAD, MicroStation,

    or Intergraph SmartSketch but the information used to create that drawing is contained in the IDF/

    PCF data file created by the plant design system.

    Figure 4: ISOGEN is widely used by all leading plant design solutions.

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    This file is one of two types:

    ISOGEN Data File (IDF) is used by traditional systems, such as Intergraph PDS

    and AVEVA PDMS

    Piping Component File (PCF) is used by all recent systems, such as Intergraph SmartPlant 3D and CADWorx

    Plant Professional

    IDFs/PCFs are the primary input to SmartPlant Spoolgen Plus, and are usually transmitted electronically to the fabricator. This ensures a seamless handover of design data with no loss or corruption of design information.

    Figure 5: Electronic data transfer supports the efficient and accurate exchange of information with procurement and construction management solutions.

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    3. SmartPlant Spoolgen Plus

    3.1. Overview SmartPlant Spoolgen Plus provides maximum flexibility and unparalleled ease of use for the efficient management and intelligent reuse of process engineering and physical piping data, whether used for:

    Major CAPEX projects Where the project scope covers hundreds or even thousands of pipe spools produced either for a single project or for multiple projects over the course of the business year

    Projects requiring fewer numbers of pipe spools For example, those needed for the rapid execution of time-critical, small-scale brownfield piping modification projects, where plant downtime needs to kept to an absolute minimum

    SmartPlant Spoolgen Plus is bundled into three distinct parts:

    Figure 6: SmartPlant Spoolgen Plus boosts productivity for pipe construction and maintenance projects.

    SmartPlant Spoolgen Plus supports the typical scope of common pipe construction and maintenance projects, such as:

    Greenfield

    New plant constructions

    Plant expansions and extensions

    Brownfield

    Revamps and retrofits

    Maintenance and repairs

    Modifications and debottlenecking

    Turnarounds and shutdowns

    Inspection

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    3.2. Goals The solution meets a variety of goals, such as the abilities to:

    Offer openness and interoperability with client design systems

    Benefit from ease of use and operation

    Enable productivity and efficiency gains

    Support project schedule reduction

    Deliver project cost reduction

    Enhance and assure attainment of quality

    Enable a digital data handover to the client

    Help the business win repeat orders

    3.3. Business Benefits The business benefits provided by SmartPlant Spoolgen Plus are extensive and include:

    Improved workflows

    Flexible toolset supports both greenfield construction and brownfield maintenance projects

    Solution accommodates both paper and electronic data input

    Project execution is improved thanks to enhanced communication between QA/QC and welding department, and shop and field personnel, supported by a user-friendly, easily understood graphical user interface

    Productivity and efficiency grow due to toolset ease of use and electronic data exchange

    Integration with accounting, procurement, and other business systems reduces the need for duplicate data entry into disparate systems

    Configurable shop, field, sub-contractor, and QA documentation is produced automatically

    Performance monitoring of welder effectiveness identifies sub-standard welders

    Electronic handling of material and welder certificates avoids moving paper certificates between sites

    Impact of piping revisions on production is more easily managed and efficiently dealt with due to change management (standard functionality)

    On-demand reporting of progress and status information, required by management and other stakeholders, is easily produced

    Higher data quality and standards compliance

    Automated, configurable, rule-driven work process supports adherence to engineering and QA standards

    Reduced manual data entry leads to fewer data errors, omissions, and mistakes

    Accurate, high quality, electronic design data means less rework

    Comprehensive weld management, including weld traceability, ensures welding procedures and protocols are observed

    Data validation prevents duplicated and unqualified data from entering the work process, avoiding confusion in the shop or at the field

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    Time and cost savings

    Solution offers greater than 50 percent time savings in work preparation effort, equating to an average time saved between two to four hours per pipeline manufactured

    Project schedules are shortened due to fast work preparation supported by drawing and report automation

    Project costs are reduced thanks to eliminating CAD drafting from the work process

    High-quality deliverables are produced in minutes, not hours, thanks to industry-standard ISOGEN drawing automation

    Bulk MTOs are produced in minutes, not days, due to the elimination of manual counting

    Enhanced client relations

    High quality, as-built isometric deliverables are produced quickly and easily for handover to clients

    Quality handover deliverables enhance business reputation and client relationships

    Cost and schedule savings provide a competitive advantage when bidding for projects

    Solution offers the opportunity to broaden your customer base

    Solution supports business expansion and growth along with participation in larger fabrication projects, at home or abroad

    Client satisfaction increases due to pipe spools being delivered on schedule or sooner, enabling facilities to be brought online quicker

    Clients receive added value through electronic handover of high-quality, highly accurate electronic piping isometrics that can be reused in operations and maintenance activities for example, to produce isometrics for inspection

    Automation presents an opportunity to re-evaluate how projects are priced, enabling more attractive bids to be submitted for future tenders

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    4. SmartPlant Spoolgen

    4.1. Overview

    SmartPlant Spoolgen is a proven, industrial-strength application that enables the automatic creation of piping isometric drawings for fabrication and erection from the design created during the detail design phase of a process, power, or marine engineering project. The technology is based on ISOGEN, the industry-standard software for automated piping isometric generation, and has been deployed successfully on all sizes of plant engineering projects in every region of the world. Today, more than 370 companies worldwide use SmartPlant Spoolgen to automate their pipe fabrication and erection work process.

    Figure 7: SmartPlant Spoolgen offers an easy-to-use interface.

    SmartPlant Spoolgen is fast and accurate because it eliminates the need to redraw isometrics and manually re-create material take-offs, dramatically shortening the work preparation lead-time in terms of drawing production and bulk material calculations.

    SmartPlant Spoolgen boosts productivity because no CAD skills are needed to produce deliverables. It employs ISOGEN to create high-quality pipe spool drawings in many different formats automatically and without CAD drafting. AutoCAD, MicroStation, and Intergraph SmartSketch outputs are supported.

    If spool drawings are not utilized by the shop, SmartPlant Spoolgen can instead be used to produce full pipeline isometrics containing all required manufacturing and test information, configured in accordance with company standards and working practices.

    SmartPlant Spoolgen is not a design system. Changes to the source (IDF/PCF) data that it processes are strictly controlled to maintain the original design integrity. This helps to eliminate transcription errors and ensures that the design intent is faithfully preserved throughout the fabrication and erection phases.

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    4.2. Work Process

    SmartPlant Spoolgen can work with data (IDF/PCF) from almost any plant design system Intergraph SmartPlant 3D, PDS, and CADWorx; AVEVA PDMS; and Bentley AutoPLANT and PlantSpace are all supported.

    Take advantage of a variety of powerful configuration and customization options that ensure the solution will fit smoothly into any existing piping construction or piping maintenance work process.

    Individuals who understand the work processes employed and capabilities of the fabrication workshop environment are empowered to make the right decisions concerning how a pipeline should be spooled for efficient fabrication and transportation, and later, safe erection.

    Without altering the original pipe design, and without the need for redrafting or re-entry of material data, SmartPlant Spoolgen provides a workflow environment for fabrication and erection information to be added to piping designs by the appropriate people at the appropriate time. This enables the creation of new drawings containing all required information to fabricate and erect a pipeline to be produced.

    Figure 8: SmartPlant Spoolgen fits smoothly into your work process.

    The software includes an integrated workflow database that prevents users from working on the same pipeline and keeps a record of every pipeline received in to the project. This record enables the software to detect piping revisions when they are received from the engineering design contractor. The replay of edits made to the previous version of the pipeline is automatically added to the latest revision, eliminating duplication of effort and saving time and cost.

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    After import, pipelines are checked out for work to be performed on them. Thanks to simple editing functionality, users interact with the pipeline on-screen to add all required fabrication and erection detailing.

    Additional information is easily and quickly added using familiar Microsoft Windows-type point-and-click

    and drag-and-drop editing techniques. This additional information includes:

    Annotations

    Flow arrows

    Floor and wall symbols

    Reference dimensions

    Supports and associated welds

    Field fit allowances

    Additional materials (pipe, plate, etc.)

    Detail sketches used to convey assembly instructions pictorially

    Other data can be quickly introduced to the pipeline using the powerful Get External Data feature, such as:

    Pipeline attribute data held in a line list

    Other manufacturing-specific data such as non-destructive testing and heat treatment information typically not present in the original IDF/PCF input data files

    This ensures that all information required to fabricate, test, and erect the pipe spools is present on the final drawing deliverables, and is included in any piping reports.

    Once all required edits and additions have been made, spool isometrics (or full isometrics if preferred) are automatically produced in seconds. These isometrics contain just the information needed to efficiently manufacture the pipe spool in the fabrication shop, such as spool materials, cutting, welding, and NDT data. The pipeline is automatically split into a number of new drawing deliverables without any manual effort required.

    Figure 9: Spool isometrics are automatically produced in seconds.

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    Erection isometrics can also be produced. These depict how the spools for each pipeline need to be assembled together to build the entire pipeline at the construction site, including all required erection material items for hook-up.

    Figure 10: This shows Sheet #1 of an erection isometric.

    Figure 11: This close-up of Sheet #1 shows weld and spool numbering and the location of field welds.

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    Decisions are made during detail design specifying how a pipe should be spooled. These spooling decisions are often later changed by the piping contractor to:

    Suit the capabilities of the workshop

    Accommodate the skills of the workforce

    Take account of feedback received from the construction site stating that field welds need to be made in alternate locations to those originally specified by the piping designer to avoid possible difficulties during erection

    SmartPlant Spoolgens most fundamental purpose is to enable the piping contractor to change the location of field welds, then produce new drawings showing the new locations (as shown in the lower right corner of Figure 11).

    4.3. Key Capabilities

    4.3.1. Integrated Workflow Management

    The integrated workflow database keeps a record of every pipeline (IDF/PCF) received into the project. It identifies pipeline revisions and triggers the Replay (automatic edit) function. The database also prevents users from working on the same pipeline. This ensures that duplicate drawings are not produced or inadvertently issued to the shop.

    4.3.2. Automatic Deliverables

    High-quality, consistently presented, industry-standard ISOGEN isometric drawing deliverables are produced automatically without manual intervention and require no further manual editing or touch-ups. Drawing deliverables are automatically generated in accordance with customer presentation and content needs, resulting in:

    Significant time savings

    Assured accuracy and quality during the manufacturing process

    Reduced need for rework

    4.3.3. Bills of Materials

    Fabrication and erection materials are separated automatically no manual counting is necessary. Any additional material items edited into the pipe are automatically accumulated and listed under the BOM section of the drawing. The items are also output to the material control report for costing, procurement, and material management purposes.

    4.3.4. Piping Reports

    Detailed piping reports are produced automatically from the piping data without any manual effort needed. The content of most reports is user-definable. These reports include:

    Welding

    Cutting

    Spool information

    Assembly (welded and bolted joints)

    Bending and cutting

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    4.3.5. Replay

    The pipeline can be automatically re-edited to include edits (spooling decisions) previously made to the original or previous revision. These edits are automatically repeated on the latest piping revision received from the engineering design contractor, saving time and cost.

    4.3.6. Repeatability

    Repeatability maintains data between revisions, generating the following benefits:

    Weld and part numbers are not duplicated or re-used if previously cancelled, because they no longer exist

    Isometric split points and spool numbers ensure the same number of drawings with the same spool numbers are produced

    4.3.7. Integrated 3D Visualization

    The integrated 3D view displays a true-scale, 3D view of every pipeline showing its relative position with respect to all other pipelines. This enables better spooling decisions to be made and easier determination of which pipelines need to be spooled in sequence based on construction needs.

    4.3.8. Cut and Paste

    Cut and paste enables the content of individual spool pieces to be altered. This optimizes spooling for the shop or field. For example, it might be necessary for components that exist at the boundary of a pipeline to be included in the next connected pipeline. Cut and paste functionality promotes the manufacturing of better defined spool pieces.

    4.3.9. Elbow to Bend Conversion

    If permitted under contract, elbows can be converted to equivalent pipe bend geometry. For example, a 1.5D elbow can be replaced with a 1.5D pipe bend. This enables cost-effective pipe bending techniques and available machine tools to be utilized in the manufacturing process. Note that this capability is only functional if configured.

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    4.3.10. Weld Gaps

    Pipe fabrication requires accurate cut length information to ensure the dimensional accuracy of individual pipe spools and to avoid unnecessary material wastage. EPCs usually dont model welds in the plant design system. When theyre not modeled, ISOGEN (an integral part of the solution) will imply welds when IDFs/PCFs are imported into SmartPlant Spoolgen by performing the following actions:

    1. Automatically determines the correct weld types between the various inline fittings and pipe

    2. Creates weld components

    3. Sets an appropriate weld root gap (if the WeldGap feature is activated)

    4. Numbers and prefixes each weld according to customer-configured rules

    5. Calculates accurate pipe cut-lengths

    6. Lists pipe cut-lengths under the cut list section of the drawing

    4.3.11. Work Content Measurements

    Automatic calculation of work content measurements can be automatically calculated, such as:

    Surface area

    Weights

    Center of gravity

    Weld Dia. Inch

    These measurements are highly accurate since they are based on the original 3D piping design data. In combination with the Get External Data feature, Weld Dia. Inch is configurable per company standards, enabling accurate pricing of the welding work effort required for each weld on each individual spool piece.

    4.3.12. Flat Spools

    Drawings can be produced showing spools in their laid-down orientation rather than their erected orientation, making it easier for the shop to understand complex angles and flange rotations.

    4.4. Business Benefits

    4.4.1. Productivity

    When drafting spool sheets in systems like AutoCAD or MicroStation, it can take the average drafter from one to four hours per spool sheet, which means a typical pipeline consisting of eight spools might take at least one man-day to produce all required drawings.

    In comparison, a set of spool drawings from a single design isometric (IDF/PCF) can be created in 15 minutes or less using SmartPlant Spoolgen. All you need to do is mark up the locations of field welds. The spooling algorithm in combination with ISOGEN drawing automation does the rest. No drafting is required. As a result, companies have reported a tenfold improvement in drawing productivity.

    SmartPlant Spoolgen offers many possibilities for data automation. Users have found that up to 95 percent of their manual data entry work (such as the addition of welding testing requirements) can be eliminated by taking advantage of these powerful automation features.

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    4.4.2. Efficiency

    SmartPlant Spoolgen boosts efficiency because it enables you to employ relatively unskilled or junior engineering resources, yet still create high-quality drawings and reports. Users do not need a detailed knowledge of CAD to use SmartPlant Spoolgen.

    The drawings and reports created in SmartPlant Spoolgen could, in many cases, be generated by the EPC during the detailed engineering design phase. However, this is often an inefficient use of expensive 3D plant design software and engineering resources. Until a fabrication contractor is selected, details of the workshop capacity and capability are unknown, so it may be impossible to create fabrication drawings until just before they are needed. In this scenario, SmartPlant Spoolgen enables the optimal use of engineering and other resources.

    4.4.3. Accuracy

    Deliverables accuracy is achieved by eliminating the possibility of transcription error. Data supplied from the design contractor is preserved through the SmartPlant Spoolgen workflow. For example, when a single design isometric is split into multiple spool sheets, the material take- off is automatically divided so the correct material is assigned to each sheet. Erection material is not shown on individual spool sheets, but can be separately reported.

    Likewise, dimensions are protected from the possibility of inadvertent error. SmartPlant Spoolgen users cannot change the basic engineering design by accidentally deleting or editing pipeline components. This minimizes manual checking, saving time and increasing accuracy.

    4.4.4. Consistency

    Many companies report that a significant benefit of using SmartPlant Spoolgen is the consistency of the output. In contrast, when manual or CAD-based drafting is used, the individual style of the draftsman can vary considerably from drawing to drawing and project to project. SmartPlant Spoolgen is completely automated. This means you can configure all drawings so they have a consistent presentation. This helps improve communication between engineering and the fabrication shop, and also the personnel working at and receiving the spools at the construction site.

    4.4.5. Quality Assurance

    SmartPlant Spoolgen provides a number of features that help ensure a high-quality work process. The built-in workflow database automatically tracks all revisions of every pipeline. This enables the fabricator to quickly identify changes between revisions and detect errors and inconsistencies in the data supplied by the design contractor. For example, you can easily determine if the delivered drawing does not match the data from which it was apparently derived.

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    5. SmartPlant Isometrics

    5.1. Overview

    SmartPlant Isometrics is a simple-to-use yet powerful pipe-sketching application and is included as part of SmartPlant Spoolgen. This application is used if new pipeline data must be generated, or if minor changes are required to existing pipelines to reflect as-built conditions, such as to:

    Add vents or drains

    Modify the design to resolve construction clashes

    Many piping contractors receive some of their work in hardcopy (paper) form. When isometrics have to be redrawn, or a hand-drawn field sketch needs to be turned into a high-quality deliverable suitable for fabrication, SmartPlant Isometrics can rapidly and accurately replicate the original hardcopy in electronic form. This can be subsequently processed using SmartPlant Spoolgen to perform a variety of tasks, such as to:

    Change elbows to bends

    Introduce weld gaps

    Add field welds to define spool breaks

    Automatically produce spool drawings or any other required drawing and report deliverables

    This means a single workflow supports both electronic and hardcopy inputs.

    Figure 12: The SmartPlant Isometrics user interface shows sketched and 3D pipeline views.

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    SmartPlant Isometrics and SmartPlant Spoolgen are built on the same technology platform. Both utilize ISOGEN to produce piping isometrics, meaning both can be interfaced with Intergraphs Piping Controlling Database (PICODA) to exchange information bi-directionally.

    Information can be exchanged in two ways. The first method is through the exchange of ISOGEN reports. Another option is data integration provided by the Get External Data feature. This feature will link data contained in external data sources, such as a line list in a spreadsheet or database. The final deliverables will include the process information contained in the external data sources.

    5.2. Business Benefits

    SmartPlant Isometrics extends the functionality of SmartPlant Spoolgen by providing design and pipe editing capabilities. It is particularly beneficial when used on brownfield projects. SmartPlant Isometrics offers a variety of benefits:

    Possible 75-percent time savings in isometric production when compared with manually drafting isometrics using 2D CAD (AutoCAD or MicroStation)

    2D CAD or drafting skills not required to operate the software or to produce drawing deliverables

    Rapid creation of high-quality piping isometrics (PCF input for SmartPlant Spoolgen) from hand-drawn paper field sketches

    Production of complete piping system circuit drawings for inclusion in hydrostatic pressure test packages

    Software can be deployed to the construction site to produce new drawings required to deal with clash problems

    Solution can be deployed to the operating plant to document the current as-built situation prior to making the required design change in the software needed to repair, replace, or alter an existing pipe

    Specification-based design assures dimensional accuracy and ensures fewer material and erection errors

    New isometrics (PCF input for SmartPlant Spoolgen) can be quickly and easily created from client-supplied paper drawings

    High-quality, consistently presented as-built isometrics for client handover show the before (existing) and after (modified) details, replacing poor quality marked-up paper isometrics used previously

    Insulation and heat tracing design is supported, including automatic generation of bills of quantities required for installation

    Newly created isometrics or modified (edited) isometrics (imported IDF/PCFs) can be supplied electronically to the client to support the piping inspection or other site-based piping engineering work processes

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    Figure 13 shows a simple example of a marked-up, as-built isometric produced by SmartPlant Isometrics. Detailing can be in accordance with industry practice and is fully configurable.

    Figure 13: This marked-up, as-built isometric was produced by SmartPlant Isometrics.

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    6. Spoolgen-Piping

    6.1. Overview

    Spoolgen-Piping is a solution that was born out of piping construction industry practice. Originally developed over a period of 10 years by Hertel-Enning, a German piping construction company, the technology (previously known as Pipe Control Database [PICODA]) and intellectual property are now owned by Intergraph. Together with SmartPlant Spoolgen and SmartPlant Isometrics, Spoolgen-Piping forms a core component of SmartPlant Spoolgen Plus.

    Spoolgen-Piping is a database solution for piping management. It is a flexible and scalable integration platform for all business processes and technical issues in the framework of piping construction and maintenance, with a particular focus on welding and quality assurance.

    Figure 14: The PICODA main menu offers a series of options.

    Working in conjunction with SmartPlant Spoolgen (greenfield projects) or SmartPlant Isometrics (brownfield projects), Spoolgen-Piping helps you to:

    Accelerate the execution of piping projects

    Reduce costs without compromising quality or accuracy

    Secure value creation

    Ensure a short-term return on investment

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    Spoolgen-Pipings broad scope supports project management, such as:

    Material handling

    Purchasing

    Logistics

    Project controlling

    Quality management

    Change management

    Moreover, intelligent, as-built digital data is delivered from the solution when the project concludes. This data provides an electronic data handover to the facility owner operator, enabling further benefits, including:

    Significant reductions in piping maintenance costs

    Improved reliability during the operational life cycle

    6.2. Work Process

    Figure 15 provides an overview of the general workflow in projects. Data is transferred electronically between the various project phases, including a handover of as-built digital data to operations and maintenance.

    Figure 15: SmartPlant Spoolgen Plus enables electronic data exchange and workflow in projects.

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    The main inputs to Spoolgen-Piping include:

    Process information Typically received via a line list in spreadsheet or database format, this is produced by process engineering design tools like SmartPlant P&ID

    Isometric information Materials, valves, instruments, welds, spools, supports, etc. are received from the design isometrics (IDF/PCFs), which are imported and processed through SmartPlant Spoolgen or SmartPlant Isometrics

    6.3. Key Capabilities

    Spoolgen-Piping offers an excellent value proposition with a variety of general capabilities, as shown in Table 1.

    Capability Types of data supported

    Work preparation

    Spooling

    Fabrication details

    Material assignment and reservation

    Documentation

    Requirement specifications

    Progress management

    Spools

    Welds

    Supports

    Valves

    Inch dia.

    Weight

    Length

    Calculation factors

    NDT management

    Scope specification

    Test plan

    NDT order management

    Sub-contractor documents

    Welding management & documentation

    WPS

    Heat number

    Certificates

    Repairs and extensions

    Welder performance

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    Capability Types of data supported

    Constructability reports

    Material

    Spools

    Supports

    Valves

    Scaffolding

    Punch list

    Pressure circuit management

    Planning

    Valve handling

    Documentation

    Punch list management Fabrication

    Erection phases

    Material management Bulk MTO lists

    Material balances

    Cost accounting Fabrication materials

    Erection materials

    Change management

    Pipeline

    Spool

    Weld revision handling

    Table 1: PICODA provides a variety of general capabilities, such as the ones listed here.

    Spoolgen-Pipings most important capabilities are described in the following sections.

    6.3.1. Automatic Classification of Pipelines According to ASME/PED

    Spoolgen-Piping is initially populated with data imported from a line list. It consists of the process data for each pipeline, such as:

    Fluid

    Pressure

    Temperature

    Pipeline material

    This information enables Spoolgen-Piping to automatically classify every pipeline according to the American Society of Mechanical Engineers (ASME), the European Pressure Equipment Directive (PED 97/23/EC), or other engineering and quality assurance standards.

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    Figure 16: This pipeline is classified in accordance with PED.

    Figure 17 shows a pictorial representation of the classification according to PED for the currently selected pipeline.

    Figure 17: This pipeline is classified according to PED.

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    The classification also determines the testing and inspection requirements and QA documentation needed to satisfy ASME/PED.

    Figure 18 shows the testing requirements that must be passed prior to pipeline handover.

    Figure 18: The confirmation of handover test is offered by Spoolgen-Piping.

    Figure 19 shows the final testing requirements for the pipeline.

    Figure 19: PICODA presents a confirmation of final testing.

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    6.3.2. Weld Management

    Welding processes are particularly important for any piping contractor. Spoolgen-Welding promotes the management of welds associated with those processes.

    Spoolgen-Welding is a module included in the SmartPlant Spoolgen Plus bundle, as shown in Figure 20. The module manages all aspects of weld production and testing. It produces detailed welding documentation for the shop and field.

    Figure 20: PICODA-WELDING supports weld management.

    The form shown in Figure 20 is initially populated with weld data received from SmartPlant Spoolgen. Configurable, automated, rule-based selection methods are driven by code lists. This helps the user to quickly specify a variety of items, such as:

    Weld properties

    Heat numbers

    Material and welder certificates

    WPS

    NDT data (not shown here) is also set on this form.

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    When everything is set, welding documentation is automatically produced. This documentation then accompanies the piping isometric drawings produced by SmartPlant Spoolgen into the shop. The welding input form is shown in Figure 21.

    Figure 21: This welding input form is provided by Spoolgen-Welding.

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    6.3.3. Automatic Production of Final QA Documentation

    QA and final handover documentation can be generated automatically using Spoolgen-Piping.

    Figure 22: Spoolgen-Piping enables automatic production of final QA documentation. In this example, it is in accordance with PED.

    Template documents provided with Spoolgen-Piping can be configured to meet the needs of the user.

    See Section 7 for samples of some of the reports shown in Figure 22.

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    6.4. Business Benefits

    Established, proven solution based on industry practices

    Is configurable to any piping contractors work practices and deliverables needs

    Systematic CAE procedure with an electronic data workflow

    Enables shop, field, and QA work processes to be streamlined

    Delivers efficiency and productivity gains

    Reduces operating costs and schedule

    Electronic data exchange

    Reduces manual data entry and paper handling

    User-configurable, flexible reporting options

    Provides status and progress information on demand for management and other stakeholders

    Consistent results due to capture and automation of work process decisions and rules

    Significant man-hour savings due to data-driven, automatic production of documents and reports

    Classifies lines according to ASME/PED (or other standards)

    Produces welding & QA handover documentation in accordance with ASME/PED (or other standards)

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    7. Sample QA and Final Handover Documentation This section presents sample QA and final handover documentation produced by SmartPlant Spoolgen Plus:

    Welding documentation

    Confirmation of pressure test of pipes according to PED

    Confirmation of final test of pipes according to PED

    Confirmation of handover test of pipes according to PED

    Manufacturers declaration for pre-fabrication and erection of pipe

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    Figure 23: SmartPlant Spoolgen Plus produces welding documentation.

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    Figure 24: This form shows the confirmation of pressure test of pipes according to PED.

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    Figure 25: This confirmation of final test of pipes according to PED was created with SmartPlant Spoolgen Plus.

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    Figure 26: The confirmation of handover test of pipes according to PED is generated with SmartPlant Spoolgen Plus.

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    Figure 27: This shows the manufacturers declaration for pre-fabrication and erection of pipe.

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    8. Conclusion

    For the owner operator or the primary engineering contractor, using SmartPlant Spoolgen Plus for all piping operations downstream of 3D design means that data can be accurately and reliably passed through the digital chain. Loss of integrity and errors due to transferring data between different systems and recreating drawings can be eliminated. Any piping subcontractor, whatever its size and the scope of its work, can be relied on to produce a consistent output and to be able to accurately describe its progress at any point.

    Any general piping contractor using SmartPlant Spoolgen Plus can support electronic data transfer from almost any client and use the same workflow for all of them.

    For the project as a whole, the productivity gains delivered by SmartPlant Spoolgen Plus offer faster, higher quality deliverables of all kinds generated from a single source. Drawings and documents are automatically generated to a consistent standard to form part of handover packages to plant construction, commissioning, and operating teams.

  • For more information about Intergraph, visit our website at www.intergraph.com.

    Intergraph and the Intergraph logo are registered trademarks of Intergraph Corporation or its subsidiaries in the United States and in other countries. Other brands and product names are trademarks of their respective owners. Intergraph believes that the information in this publication is accurate as of its publication date. Such information is subject to change without notice. Intergraph is not responsible for inadvertent errors. 2012 Intergraph Corporation. All Rights Reserved. 3/12 PPM-US-0142B-ENG

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