SmartPlant Engineering & Schematic in Production - Intergraph

SmartPlant Engineering & Schematic in Production

Frank JoopGlobal Business DevelopmentIntergraph

November, 2011

June 2011 SmartPlant Engineering & Schematics

Proof of Value is with the Customers

Use cases of SmartPlant Engineering & Schematic– Bayer Antwerp

– OMV Petrom Petrobrazi Refinery Romania

– ORLEN Projekt SA Poland

– ECM Mining Brazil

Different industriesDifferent driverOne common goal:

Improve business and lower operational risk


SmartPlant Enterprise


Engineering & Schematics Seat count (SP P&ID, SP Instrumentation, SP Electrical)

0

5 000

10 000

15 000

20 000

25 000

30 000

35 000

40 000

2005 2006 2007 2008 2009 2010 2011

16,000

21,000

28,00031,000

29,000

36,000

* Estimated

36,000

41,000*


Solving the Business Problems

Overall Solution Focus– Cost of ownership– Value proposition– Integration– Automation (API)– Task focused– Complete and reliable


Putting the Solution in Perspective

Designing the Process– SP P&ID

Safety and Risk Mitigation– SP Process Safety

Controlling the Process– SP Instrumentation

Powering the Process– SP Electrical B&D

Value add Engineering– SmartSketch– SP Explorer

Validating the Design– ETAP– SmartPlant P&ID Engineering Integrity

Power

Process

Controls

Safety

Motor Operated Control valve


From Requirement to Implementation

PFD

RelationshipsRules

The SmartPlant Difference

June 2011 SmartPlant Engineering & SchematicsSmartPlant Engineering & Schematics

Bayer Antwerp BelgiumPlant owner


Full year sales: EUR 35.1 billion112,500 employees

291 subsidiariesR&D expenditures: EUR 3.1 billion

As of December 31, 2010 / Employees: March 31, 2011


Key Locations / Regions

Europe

Africa / Middle East

North America

Asia / Pacific

LatinAmerica

The Bayer Group is a global enterprise with companies in almost every country


SPPID / SPI @ Bayer in facts & figures

Licenses covered by “Global Alliance Agreement” (BTS)Other used SmartPlant products:– SmartSketch– SmartPlant Electrical– SmartPlant Explorer

SPPID SPI2 Data / Application Servers(Leverkusen, Caojing)

3 Data / Application Servers(Pittsburgh, Leverkusen, Caojing)

All use Version SPID 2009 SP1 All use Version SPI 2009, SP2

Local installations at small sites

+- 25 User +- 200 User

3.500 P&ID’s 80.000 Loops


Engineering documents

PDS

®


The Engineering & Design Basis


Integration concept

Basic idea– Multidisciplinary sharing of plant information– One point of entry to ensure consistent as built documentation– One stop shop principle to gather information– Documentum folders structured according the plant naming convention– Automated interfaces with engineering tools and SAP

Benefits– Guaranteed consistent as built data Safety!– Reduce the search time for accurate information by maintenance

personnel (“An engineer spends 40 % of his time just by searching the right document”)

– Low cost solution, no investment needed– Super fast maintenance workflow, initiated in the SAP notification


OMV PetromPetrobrazi RefineryPlant Owner


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ORLEN Projekt SAEPC


Almost 40 years on the market

180 employees

Cooperation with biggest European companies

Entering into EPC market

25

Who is ORLEN Projekt SA ?

June 2011 SmartPlant Engineering & Schematics 26


… Since 1998 we have delivered over 2500 projectsfor oil & gas, refinery, chemical, power generation and environment protection industries.




1998 2006 2007 2008 2010 2011

Engineering, Procurement & ConstructionEngineering

General Agreement with Intergraph for software and

services

Co-operation with Intergraph

SPPID & PDS integration

First testswith SPF


SmartPlant 2D main features:

Data centric tools

Rules-driven software

Basic source of technicalinformation for 3D model

Working with P&ID is a realdesigningnot only sketching

Life cycle control system solution from specification to ordering, installation, construction, and operations

29

Why SP Engineering & Schematics


SPP&ID in use:

produce drawings and reports faster and with high quality

holds all process data we need in one place

propagate data to other tools without retyping them

propagate topology of pipelines to 3D

30

SP E&S applications integrated environment


SPP&ID customization:

new attributes for valves, instruments

ItemTag.dll configuration

Templates for dwgs, reports

31



SPI in use:

produces loop drawings,

generates specifications of instruments and cables

stores data for junction boxes

propagates list of instruments and their dimensions to 3D

32




Enhanced

Smart Loop

SPI Instrument Index

JB Layout Cable Schedules

Calculations

Spec Sheet

Process Data



34

Piping spec remote access

SPE publish/retrieve

SPI – DDP

Calculation of wall thickness, corrosion allowance, etc.Data import also for small none integrated projects


Integrated SPE environment is more effective

One input data – then only reuse

It is faster to publish/retrieve versus exchange of paper documents between departments

No problem with version of dwgs, data –the latest have been just published

Rule-based designing with real influence for 3D model

Easy upgrade to the newest product version of 2D applications

35

Benefits


ECM BrazilEPC Mining

ABOUT ECM

• ECM is a Brazilian engineering company, founded in 1984

• ECM’s core business is Mineral Industry

• 600 professionals

ECM’s CORE BUSINESS

Mineral processing plants

Pellet plants

Ore handling, stockyards and on shore port facilities

Pipelines & pumping stations

Hydro-metallurgical plants

ITABIRITOS CONCEIÇÃO – VALE, 2008-2012

Itabira / MG – Brazil

12 million t/year of pellet feed from low grade compact ore

Greenfield

U$ 1 billion investment

Under construction

MAJOR PROJECTS

ADEQUAÇÃO DE CONCEIÇÃO AO ROM de 2014 – VALE, 2010-2014

Itabira / MG - Brazil

19.4 million t/year of sinter e pellet feed

Brownfield

U$ 550 million investment

Under detailed engineering

MAJOR PROJECTS

About ECM

The benefits of Engineering & Schematics Solutions

SmartPlant Enterprise at ECM

CLIENT’S NEEDS AT PROJECT’S IMPLEMENTATION

• Performance assurance.

• Safety during construction and operation.

• Compliance to CAPEX and schedule.

• Constructability and maintainability assurance.

• Effective bulk materials control.

• Effective physical and financial progress control.

THE BENEFIT OF ENGINEERING & SCHEMATICS

Better inter and multi-disciplinary information

management and control during all stages of the design –

CONSISTENCY

• Less re-work

• Shorter engineering schedule

• Lower engineering cost due to productivity increase

THE USE OF SPPID TO IMPROVE ENGINEERING RESULTS

CONCEPT DEFINITION OF ALL THE OPERATIONS

AND SYSTEMS

GENERATION OF INFORMATION TO BE DIRECTLY USED BY

OTHER DISCIPLINES –

ELECTRICAL & INSTRUMENTATION

MECHANICAL & PIPING

MINERAL PROCESS & UTILITIES

SPPID

• PFD´s

• LEM (Mechanical Equipment List)

• P & ID´s

• List of lines

THE USE OF SPEL TO IMPROVE ENGINEERING RESULTS

GENERATION OF INFORMATION TO

BE USED BY OTHER

DISCIPLINES / PHASES

INSTRUMENTATION

ELECTRICAL

(SP3D – detailed engineering)

ELECTRICAL

SPEL

• single line diagrams

• power demand calculation

• data sheets

• equipment list

• cables list

Input from SPPIDLEM (MOTORS RATING)

Input from ELECTRICALDESIGN CRITERIA

THE USE OF SPI TO IMPROVE ENGINEERING RESULTS

GENERATION OF INFORMATION TO

BE USED BY OTHER DISCIPLINES /

PHASES

INSTRUMENTATION

(SP3D – detailed engineering)

INSTRUMENTATION

SPI

• basic engineering:

instrument list &

instruments data sheets

• detailed engineering:

instrument lists,

cables lists,

I/O list,

interconnection diagrams

Input from SPPID

THE USE OF SPI TO IMPROVE ENGINEERING RESULTS

MORE RELIABLE INFORMATION TRANSMISSION BETWEEN DISCIPLINES “ON LINE” UPDATE

ELIMINATION OF REPETITIVE TASKS AT THE DEVELOPMENT OF INSTRUMENT LISTS (GENERAL AND SPECIFIC PROPERTIES) ERRORS

MINIMIZATION

EXPRESSIVE TIME REDUCTION FOR DELIVERABLES EXECUTION

CHALLENGES

TO IMPROVE SOLUTION TO DELIVER INTERCONNECTION DIAGRAMS AS PER LOCAL ENGINEERING AND CONSTRUCTION PRACTICES

TO DEVELOP SOLUTION TO ALLOW “COPY & PASTE” OFTYPICAL INTERCONNECTING DIAGRAM

About ECM

The benefits of Engineering & Schematics Solutions

SmartPlant Enterprise at ECM

AUTOMATION PROJECTS

FOURTH PELLET PLANT PROJECT – SAMARCO, BASIC & DETAILED ENGINEERING

610 mechanical equipment

600 lines

50 MW

4,900 instruments

ITMS – MINA DO PICO –VALE, BASIC ENGINEERING

1,178 mechanical equipment

1,900 lines

140 MW

6,600 instruments

AUTOMATION PROJECTS

ENGINEERING & SCHEMATICS EXCELLENCE AWARD 2010


Conclusion

Benefits for EPC and OwnersProven on Projects and in OperationsFit different business modelsSP Engineering & Schematic used and driven by the users

2011 SmartPlant Engineering & Schematic 2011September 2011

Integrating the Engineering Enterprise…

Documents

SmartPlant Engineering & Schematic in Production - Intergraph