Digital design workflows to reduce non-conformances …energycentral.fileburst.com/EC/052418_bentley.pdf · Advanced Analysis Features for Varied Piping Environments ... –Read in

1 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated © 2018 Bentley Systems, Incorporated

Digital design workflows to reduce non-conformances in the power industry

Mark Upston – Senior Director

2 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

2017 USA Energy Infrastructure Report Card – What is the Gap?

https://www.infrastructurereportcard.org/wp-content/uploads/2017/01/Energy-Final.pdf


Recommendations to Improve USA Power Infrastructure


Brownfield Plant Projects – Design Challenges

• Determining as-built conditions

• Evaluating engineering integrity of existing facility

• Evaluating and selecting facility expansion alternatives (new design)

• Coordinating new proposed design with on-site conditions

• Coordinating progress across teams, offices, and disciplines


Bentley Solving Multi-Discipline Team Collaboration


AGENDA

With the digital data integration of design and analysis applications across key engineering disciplines like structural and piping, companies are abandoning traditional paper workflows and managing engineering projects more efficiently and with less risk. Engineering content can be easily managed in a central distributed document management system for handover and operational asset management.

– Digital data transfer of structural and piping design engineering information and richly integrated design models for asset management

– Improved 3D Visualization and digital clash detection to avoid costly non-conformances

– See how integrated design analysis applications are being used to manage ageing assets on brownfield projects

Q&A


Brownfield Project: Laser Scan to 3D Modeling to Engineering Analysis for Checking Structural Integrity


Where is Structural Integrity Needed Most?

Source: 2002 Report http://www.nace.org/Publications/Cost-of-Corrosion-Study/

Area $Billions /

Year

Drinking Water / Sewage 36

Petrochemical 3.7

Oil & Gas 1.4

Pulp & Paper 6.0

Electrical Utilities 6.9

Bridges 8.3

Gas & Liquid Pipelines 7.0


• The Structural Integrity is deteriorating due to age and corrosion

▪ Plant has been in operation for over 20 years.

• Pipe racks are failing due to increased loads.

▪ As operations have increased further steel and pipe work has been added.

• There are no 3D models available for the structure.

▪ The only viable solution is ‘As Built’ capture.

Brownfield Projects – Industry Problem

Plant Pipe Racks are failing with increasing downtime

leading to significant production losses

Corrosion is

Everywhere!


Brownfield Projects – Design Solution

• Aging Plants – Integrated Design Models using STAAD for Structural and AutoPIPE for Piping

LaserScan


Brownfield Projects – Design Solution

• Aging Plants – Integrated Design Models using STAAD for Structural and AutoPIPE for Piping

LaserScan

3D CAD

model e.g.

OpenPlant

Engineering

Analysis

(STAAD &

AutoPIPE)

Optioneering

(Scenario

Services)


▪ Descartes

▪ Advanced point cloud data processing

▪ Pipe centrelines modelled with one click from point cloud data

▪ ProStructures

▪ 3D modelling environment for structural steel and metal work

▪ Modelling from 300 databases and International Standards

▪ Open Plant Modeler

▪ 3D Plant design and modelling

▪ Attachment of point cloud data for pipe modelling

▪ STAAD.Pro

▪ Analyze and design virtually any type of structure.

▪ Steel, concrete, timber, and aluminum design codes from all International Standards

▪ AutoPIPE

▪ Advanced Analysis Features for Varied Piping Environments

▪ Interface with AutoPIPE Vessel, STAAD.Pro, Plant Design CAD Systems, and

ProjectWise

Bentley Solution – Model and Analyze Failing Structures


Design Integrity and Asset Management

43

AssetWise Reliability

Server

RBI SIM Assessment

ProjectWiseDocument Management

6

1

2

5

Engineering Analysis


Integrate brownfield project

extensions to existing plant

Reusable 3D intelligent plant

and analysis models for

future Plant sustainability

Accurate modeling of ‘as built’ assets

Use of existing tools and design

resources already in house

Rapid Efficiency savings as

high as 75% compared to

traditional design methods

Assets that are structurally at risk can be

identified quickly and accurately.

Benefits


Power Plants Using Integrated Design Technology

200MW - Coal-Fired Power Plant – PhilippinesDoosan Heavy Industries

600MW Gas Power Plant – CairoProjenia S.r.l

“50% Reduction in interference checking

80% Reduction in Site Non-conformances

95% on-time delivery”

“15% Design time savings, Faster Erection

Schedule just 14.5 months and Clash Free”



STAAD Pro and AutoPIPE saved ESI a

combined 700 resource hours on the project

The integrated software facilitated exchange of information

among disciplines, reducing mistakes and automating processes

such as collision detection and generation of specifications and

estimates. The time savings reduced costs by about 15%.

Biomass - ESI Inc of Tennessee 42MW Gas-Turbine Power - Giprotyumenneftegaz



AutoPlant was configured for each engineering discipline and all models were

managed through a controlled workflow in ProjectWise. eB Data Quality Manager

enabled efficient asset location and transfer of approx. 75,000 vendor assets and

design information vital to construction, operation and maintenance

As a result, the startup and commissioning group will save nearly 6000 man-hours.

The team used Microstation, Bentley Navigator, Structural Modeler and

STAAD.Pro for integrated analysis ad modeling which enabled

engineers to identify hindrances and optimize the layout in the turbine

building. These efficiencies reduced engineering cycle time by 8%.

582MW Clean Coal Plant – Mississippi Southern Company

375MW Combined Cycle Plant in India –L&T & Sargent Lundy



Design Teams shared information using i-models which improved

multi-disciplined collaboration. Bentley Navigators view and

review capabilities provided self service in the clash detection and

model review processes by putting the software in every project

professionals hands.

Designs were changed in the model before procurement errors and

installation conflicts, which helped minimize interferences and

eliminate redesign and construction rework. Additionally, the project

team conducted weekly model reviews with the client using an up to

date and accurate design model via the internet

540MW Sewaren 7 Combined Cycle Plant New Jersey, Black & Veatch

Flue Gas Desulfurization Plant in North Carolina Utility Engineering


A Brownfield Plant Retrofit Project – Design Integrity Check


The As-Built System

AutoPIPE– Stress analysis of piping system

– Piping in isolation (no structure)

– Acceptable stresses in piping

– Export to STAAD.Pro using pipelinkformat

STAAD.Pro– Read in pipe support locations and

applied reactions from pipelink

– Analyze structure and run design code checks on steel members

– All members pass checks

AutoPIPE

STAAD.Pro


Revise Piping System and Investigate

AutoPIPE

– Upsize main lines from ø350 to

ø450

– Rerun stress analysis

– Verify piping design passes

• Pipe stresses

• Equipment e.g. pump loads

• Support design

– Update Pipelink data exchange file for use in structural analysis design in STAAD.Pro

350 mm Dia. 450 mm Dia.


Revise Piping System and Investigate

STAAD.Pro– Read in updated pipelink file

– Rerun analysis and code checks

– The revised piping imparts higher forces on portions of the structure

– Some members now fail code checks

– Add bracing to add stiffness and strength

– Rerun the analysis and design

– All members now pass code checks

BeforeAfter

(Braces Added)


Revised System - Combined Piping-Structure

AutoPIPE– Read updated pipelink structure into

AutoPIPE

– Includes revised structure designed in STAAD.Pro

– Re-run stress analysis as final check

– Check possible increase in pipe support loads and pump loads


3D Clash Detection


Evaluating Model for Clashes

AutoPIPE– Publish AutoPIPE model to i-model

– Optionally consider deformedgeometry

– Upload to Bentley Cloud Services project

Bentley Navigator– Create a clash detection job

– Identify specific clashes

– Leave markups so other team members can easily review and update

AutoPIPE

Bentley Navigator


Case Study – Hot Operation Clashes

KEPCO Engineering & Construction Company

2x1,000MW Ultra Supercritical Thermal Power Plant

Samcheok, South Korea

Image Courtesy of KEPCO E&C

Samcheok Green Power Unit 1

and 2 Project, Be Inspired 2014

Samcheok Green Power Unit 1 and 2, South Korea


Case Study – Hot Operation Clashes

The Solution – Run Full 3D Clash Detection of AutoPIPE 3D ‘Hot’ deflected DGN

model in Bentley Navigator, or MicroStation or OpenPlant

KEPCO Engineering & Construction Company

2x1,000MW Ultra Supercritical Thermal Power Plant

Samcheok, South Korea

LP Bypass Line

Warm Up Line

Image Courtesy of KEPCO E&C Samcheok Green Power

Unit 1 and 2 Project, Be Inspired 2014

3 Critical Hot Clashes Identified

during Design Phase


Summary Highlights

These Case Studies highlights the speed and accuracy of a solution to evaluate structural integrity of aging plants

Benefits:

➢ Coupled analysis provides more accurate, cost effective seismic designs

➢ Explore alternative design options quickly with efficiency savings

➢ A structural integrity solution can verify remaining life and easy to adjust for design modifications

➢ 3D-Models help coordinate on and off-site assembly and fabrication of brownfield projects and reducing site non-conformances


Engineering Document Management Using ProjectWise and Asset Reliability


Engineering Document Management using ProjectWise

"With ProjectWise we can easily manage over 9,000 transmittals and 20,000 technical

documents in a single repository. Also, it’s easy for the EPC subcontractor to collect the related

documents/drawings for closed-out reports. ProjectWise has shortened the preparing time of

closed-out reports."– Bao Jia Chen, Project Manager, CPC Corporation

• ProjectWise – industry leading global engineering content and collaboration server

• Optimized for engineering software integration, model management, drawing management, large file management, review and markup

• Link from Asset Reliability providing access to models, drawings, specifications, inspections, etc

ProjectWise


Structural Integrity Dashboard in Asset Management System

• Asset Summary & Health

• SIM KPI’s: RSR, Inspection Compliance, CP Readings, Anomalies, Trends

• Role specific


Assets – Navigate by Hierarchy, Map, Listing

• GIS Interface

• Select and report on assets and equipment

• Surface Alarms and KPIs


How does Immersive Asset Reliability help?


Asset Performance

IPL used Bentley's AssetWise Asset Reliability to track specific indicators and indicator states for manholes, vaults.

network transformers. and network protectors The team used the application to calculate an overall health score for

each asset based on weighted values To date, monitoring 300,000 indicators for 20,000 assets and associated work

order priorities has decreased equipment failures the network from 49 in 2011 to 15 2016 Substation transformer

failures followed a similar downward trend.

T&D Implementation of Asset Risk at Indianapolis Power & Light


Digital Surveys of Existing Assets


Reality Modelling – Capture

Point Clouds➢ Traditional Laser Scanning Technology.

Photogrammetry➢ 3D meshes created from photos.


Photogrammetry – 3D Reality Mesh Models

Aligning new designs

with existing conditions

Inspecting operational assets

Managing

information

Richer Information Models are available with 4D

(Time), 5D (Cost) and 6D (Operations Management)

Capturing the

context

Better understanding

via 3D is great!


What is the level of 3D Detail with Photogrammetry?

➢ Drone – Falcon 8

➢ Camera – Nikon D810

➢ Capture - 4500 Photos

➢ Processing- 2 Hours

Chemical Plant

https://www.youtube.com/watch?v=o4xgf8

883dU

Not only a dimension but a window into the condition of your asset!

Allow 3D Coordination on Brownfield Projects with Ease

https://www.youtube.com/watch?v=o4xgf8883dU


Reality Modeling

Aerial Photogrammetry and ContextCapture reduced resource hours required for

surveying on site, improving safety and enabling the team to build realistic 3D Mesh at

30% of actual project costs and deliver the final model in just two weeks

Analysis of Transmission Tower, South Korea, GeoINT


Office to Site Coordination


Bentley Cloud Services – ProjectWise Project Share

File Sharing– Share models and files

– Notify teams members automatically when files are added or revised

Issues Resolution

– Review punchlist items created in Navigator

– Coordinate status of each markup


Mobile 3D Visualizations and Interactive Inspections

Visualize 3D i-Models Punchlist of Issues


Thank you for Attending…

Q&A

Product Management: Mark Upston

[email protected]

Marketing: Samantha Langdeau

[email protected]

mailto:[email protected]

mailto:[email protected]

Documents

Digital design workflows to reduce non-conformances …energycentral.fileburst.com/EC/052418_bentley.pdf · Advanced Analysis Features for Varied Piping Environments ... –Read in