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SmartPlant3D

Materials Handling

Taylor D. ColeTaylor D. ColeVice President, IntergraphVice President, Intergraph

Global Metals & Mining IndustryGlobal Metals & Mining Industry


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676

872

2007 2015

35

44

5466

2007 2012 2017 2022

19

26

33 38

2007 2012 2017 2022

844

1136

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


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Materials Handling Problem

Time to Market Solution: Work-sharing Skilled Resources

Higher Productivity and Qualityfor Same Hours

Re-use of Design

Reduce Interfaces and Re-work

Supply Chain Efficiency

Vendor Integrated

Problem

2008 2015

Produ

ction

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 Cost

Optimise: Layout, Pre-assembly, Design Stds Safety: Reviews: Hazop, Constructability, O&M

Knowledge: Asset Lifecycle and Re-use

Benefits:


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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 times design time

Profit

Time

FasterStartup

TraditionalStartup

CapitalCostSavings

Faster

Profitability

Increased

Profit

TraditionalProjectCost/BreakevenCurve

DigitalPlantProjectCost/BreakevenCurve

Co

st

Reduced

CapitalSpend

CapitalCostSavings

ConceptualDesign

DetailedDesign

Fabrication &Construction

Commission& Test

Plant Operations & Maintenance

According to a Construction Industry Institute studyof 53 major projects, projects which included the most efforton conceptual plant studies averaged:

20% Lower Engineering costs39% Schedule reduction15% 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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Intelligent DesignReduce Time on Task

Comparison

Microstation

Old technology [1980s]

Fantastic change for the time

PDS

Newer technology Faster design time improvement over Microstation

SmartPlant3D

Latest technological advance

Data base engineering

Significant improvement over PDS in design time

Improved integration between disciplines
http://../MicroStation-PDS-SP3D.avi


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Proof of Concept ProjectBackground / Purpose / Status

Problem industry demand andresource supply needs a stepchange solution

Document centric (2D) projectdelivery compared to ProcessIndustries

Proof of Concept initiates thestep change

Industry requirements specified

Solution concepts established and tested

Initiated solution configuration anddevelopment

Concept proved - confidence to continue Pilot project for project readiness

objective


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SmartPlant 3D Materials HandlingBenefits 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


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SmartPlant 3D Materials HandlingConveyor Design Workflow

Curre

ntScenari

oPro

file&Dat

aShee

tDrawing

Solu

tion

Conveyor

&Pa

rtsCatalo

gueS

pecificatio

n


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SmartPlant 3D Materials HandlingChute Catalogue Workflow

Curre

ntScenari

oCh

uteArran

gement

Drawing

Solut

ion3D

iDesi

gntoCat

alogu

eandRe-u

se


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SmartPlant 3D Materials HandlingBenefits 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
http://../Final%201024%20x%20768%2030fps%20Take%20IV.m2v


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SmartPlant 3D Materials HandlingKnowledge Management & Re-use

Critical Information Transfer

Design

Operate

Commission

Build

Critical Feedback Loop

Critical Feedback Loop




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SmartPlant 3D Materials HandlingKnowledge Management & Re-use

Design

Operate

Commission

Build

SmartPlant Foundation

Application Integration

Engineering Data Handover

Engineering InformationManagement


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SmartPlant 3D Materials HandlingHandover & Asset Lifecycle

By establishing a holisticstrategy for plant assetlifecycle management,Owner Operators can

manage their assets forshort and long termprofitability rather than

the traditional sweat theassets strategies

Measurable Value

Expedited Commissioning & Startup (2-3% of TIC) - through expedited commissioning & start-upresulting from as-built data validation, transformation & loading into operating systems

Minimized Plant As-Built Verification (1-2% of TIC annually) - through auditable plant assetinformation management of change

Reduced Production Loss (0.2-0.5% of revenue annually) through elimination of unplannedoutages as a result of decisions based upon inadequate / incomplete plant data

Increased Turnaround Intervals (20% annually) Through application of reliability in design andasset performance management principals


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SmartPlant EnterpriseFinancial Benefits

Base W/ SPE ChangeSales (Revenue) 1,000 1,020 +2.0%

Less:

Operating Cost

Depreciation

- 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% earlierproject completion (approximately +20% revenue increase in Y1

on a three year CAPEX project life).


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SmartPlant 3D Materials HandlingNext Steps

Pilot Project Australia

Q4 2008

BETA Version

Q1 / Q2 2009

Commercial Version SmartPlant3D v9 Release


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Materials Handling Solution

Questions?

Taylor D. Cole

Vice President, Intergraph Global Metals and Mining

[email protected]
mailto:[email protected]:[email protected]

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