Implementation_of_an_integrated_3-D_information_system_for_EPC_projects.PDF

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Automation and Robotics in Construction XVI 1999 by UC3h1

IMPLEMENTATION OF AN INTEGRATED 3-DINFORMATION SYSTEM FOR EPC PROJECTS

Shannon HolyBen Song

Rob WubbenhorstFluor Daniel, Inc.

Construction TechnologyOne Fluor Daniel Drive

Sugar Land, Texas 77478 USArob. wubbenhorst(a fluordaniel.com

Copyright 1999 Fluor Dan iel, Inc.All Rights Reserved

Abstract : The process of engineering , procurement , and construction (EPC) project execution usesa great amount of diversified information . A means to integrate the various sources of data andconcisely display this information is needed . An advanced object-oriented system developed byJacobus Technology , Inc. and customized by Fluor Daniel , Inc., allows data integration between3D-design model . information and engineering , material management and construction databases.By focusing on construction as the end -user of the EPC process , this system streamlines theintegration of data, and provides a user-friendly and flexible interface to the construction fieldstaff.Keywords : Construction Visualization , Integrated Project Information , InVisionSM

1 INTRODUCTIONThe engineering and construction of an EPC

(Engineering , Procurement , and Construction)project creates and consumes large quantities ofinformation [3]. The potential of informationoverload in attempting to understand and correlatedata is high . A means to integrate diverse collectionsof engineering and construction related informationinto a centralized project information system wouldassist engineering and field construction tounderstand the complex problems and priorities ofthe project.

Fluor Daniel , Inc. began to investigate and develop asystem that improves integration of projectinformation sources based on the 3D-design model in1996. The key user of such a system would be theconstruction field leadership . Issues to consider inselecting and developing a design model viewersuitable for construction field sites were: trainingrequirements, user interface , and flexibility of thesystem to configure to unique project requirements.After surveying the market for available plant designviewer software , the P lantSpace' EnterpriseNavigator'pplication by Jacobus Technology, Inc.

(Jacobus ) was selected as the core technology of theFluor Daniel system, which would come to be knownas the InVisionSM system.

2. SYSTEM FEATURESThe PlantSpace Enterprise Navigator provides anexcellent user interface for field staff to navigate themodel . The PlantSpace core provides the basicviewing functions of annotating , dimensioning, andother common model review features . The InVisionsystem is composed of pull-down menu-basedqueries and connections to specific construction andengineering databases used throughout the Comp anyor specific function databases created on individualprojects.Fluor Daniel has been using the InVision system onconstruction field sites since March , 1998. Trainingrequirements for field users are minimal. Fieldforemen and first level leadership are proficient innavigating and querying the model for information inunder an hour of instruction . Standard interfaceshave been developed to link the InVision system tothe Fluor Daniel field progress system, material

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management and warehousing system, and weldingquality system. Customized field databaseintegration has also been implemented on severalprojects for their locally created turnover systems andsupplier shipping databases . This flexibility of theInVision system to adapt to local projectrequirements is an additional strength to theimplementation strategy.As of mid-1999, there are twelve projects using theInVision system . Fluor Daniel ' s execution strategyfor projects has embraced the InVision system as aviable tool for use in the preliminary engineeringphase, through detailed engineering, intoconstruction , and concluding with turnover of theproject to the plant owner.

Figure 1. InVision System D ata M odel

Use of the InVision system model by the client fordesign review and operator training has occurred onat least three projects . A current project owner isusing the InVision system for plant start - up trainingof operations personnel during the field constructionexecution phase, well in advance of the scheduledoperator training.

3. WORK PROCESS CHANGEThe implementation of the InVision system on

Fluor Daniel projects has provoked positive workprocess change . Introduction of an integrated systemhas encouraged traditional design and constructiongroups to collaborate and plan the format of projectinformation as a deliverable product. In past projectsusing 3D CAD, construction received paper copies ofisometric and plan view drawings , and did notreceive the benefit of the encoded intelligentinformation in the design model. Introduction of aconstruction model viewer enables this valuabledesign information to be accessed an d integrated withnon-graphical databases . Field database programsare using the design information formatting tomaintain consistent queries of data. For the inVisionsystem to function, the coding structures ofisometrics, work packages , uniquely taggedequipment, etc. must follow design conventions.This process is not difficult to implement, butrequires effective communication among projectparties in the planning phases of the 3D design andconstruction databases. Potential for automaticdownloading of design information into theconstruction databases is available , but has onlyrecently been utilized as required for the use of theInVision system.Projects using the InVision system have greateraccuracy in their construction databases due to theirrequirement to use design based informationstructures and early involvement in the informationplanning process.Constructability is also enhanced through the use ofthe InVision system in the detailed engineeringphase. The project teams mobilize constructionplanners early in the design process to achievesavings from design suggestions regarding the abilityto construct the in-progress design efficiently. TheConstruction Industry Institute (CII) has publishedreports attesting to the high impact and low cost ofdesign changes early in the project [1] [4] [5]. FluorDaniel is capitalizing on the knowledge andexperience of construction planners and managers toassist the design team produce a cost efficient design.This constructability effort is enhanced through theuse of the 3D model in the InVision system. Theability to see the in-progress model assists theseplanners and m anagers in analyzing vessel placementand space-constraints, construction vehicle placementand space- constraints , pre-assembly studies ofstructures , lay-down and staging yard planning,rigging and heavy lifting operations, and simulationof the erection schedule.Implementation of the InVision system has enacted achange in the traditional engineering -constructionwork process. With the consideration that

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construction is the end-user of all EPC information,project teams are now designing for construction inan inter-disciplinary environment. Effectiveconstructability is possible through the integratedvisualization of diverse design and constructioninformation . Projects using the InVision system areable to interject greater value in the delivery processof client facilities.

4. PROJECT IMPLEMENTATIONIn the period of March 1998 to April 1999,

twelve projects have implemented the InVisionsystem. The first project to use the InVision systemhas completed and won numerous Fluor Daniel,client, and industry awards for successful execution.The client named the InVision system as a significantcontributor to the project success. Currently, sixprojects are active in the field, and five are in thedetailed engineering phase.An active InVision system field project will bereferred to as Gulf Coast Client at project request.This project began to use the InVision system in thedetailed engineering phase for model review andconstructability in the Spring of 1998 . The project isusing two InVision system stations in the field withdatabase connections to: Isometric approval database (engineering

database) Pipe Spool Mark Piece received status

(construction warehouse database) Pipe Spool Mark Piece shipping status (pipesupplier web -based report database) Progress database (construction database) Welding Quality database (constructiondatabase) Future integration to the project specific Turn-Over System database is planned.

The Gulf Coast project has foremen with priorexperience using the InVision system from an earliercompleted project , and is maximizing the system forpurposes of field planning of pipe and equipmentplacement and erection.4.1 Visualize Complex Field ErectionForemen who assist their craftsmen with fieldconstruction planning frequently use InVision systemgenerated screen prints . These printouts allowjourneymen and helpers to understand thecomplexities of the design in a 3D modeledperspective.A difficult field construction situation involves theuse of rolling off-sets. When a section of pipe travelsdown a vessel or large piece of equipment, it may

need to roll in two directions to make a connection toanother section of pipe. This rolling off-set isdisplayed on an isometric drawing as a rectangularframed box containing the pipe off-set. The imagecontains dimension lilies along with the pipe linesegments , and can often be misleading or requirelengthy analysis by the construction personnelerecting this section of pipe.

The InVision system has been used in theconstruction of piping off- sets to show foremenexactly how the finished section of pipe should look.This is especially useful on international projectswhere craft workers may not read or understandEnglish drawings. The old cliche, `A picture is wortha thousand words' truly applies in this situation.

Figure 2. Rolling off- set Isometric and InVisionsystem model view4.2 Pipe Material StatusPiping material status is available to the field userthrough a pull-down menu of query options. Fieldleadership is able to quickly display relevantinformation regarding pipe spool mark piecesreceived in the field warehouse , and inquire on thestatus of pieces not yet received . Planning andexpediting for other material availability and laborresources is enhanced by this visual access to criticalinformation.The Piping Material Status pull-down menu consistsof three queries: ISO Issued, Spool Received, andSpool ETA.The ISO Issued query displays sections of pipe thathave been released to the pipe man ufacturer for shopfabrication . This status is known by examining thedesign software database for approval status, and

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then displaying corresponding isometrics in theInVision system model.

Figure 3. Piping Material Status Pull-Down Menu

Choosing the Spool Received query option displaysall pipe spool mark pieces that have been received inthe warehouse database system. Pipe spool markpieces are sub-assembly units of a complete isometricof pipe. This function is useful to foremen andconstruction planners when they examine the modelto identify areas ready for pipe installation.The pipe fabrication contractor on the Gulf Coastproject maintains a spreadsheet of estimated time ofarrival (ETA) shipping information on an internetweb site. Fluor Daniel downloads this shippinginformation, and accesses the ETA data through theInVision system interface. When planners andforemen are examining the model and discover pipespools that have not been received, the shippingstatus and ETA can be quickly and easily referenced.

rwirr t utirbrit t fi. ''." ...::1 [recl ^ l .< r r

discipline various levels of the work break-downsystem (WBS), and milestone percentages.

4.4 Weld Status

Fluor Daniel utilizes a weld tracking and qualitycontrol database program as a standard referencesystem. The Non-Destructive Examination andWelding System (NEWS) tracks all weldproduction, welder qualification, and administersselection and tracking of non-destructiveexamination (NDE) requirements. The InVisionsystem is integrated to the NEWS program and candisplay a project's welding status at the isometriclevel of detail. Field uses of this interface have beento identify locations of randomly selected welds forNDE testing, and monitor the weld production oferected isometrics of pipe.4.5 Client UsesThe Gulf Coast client is currently using an InVisionsystem station to conduct operator start - up trainingduring the construction execution phase of thisproject. This advance training and planning willaccelerate the duration of commissioning the newunit. Clients have consistently been impressed withthe InVision system and its capabilities and supportits use as a constructability tool.Expanded future use of the InVision system modelby owner-operator clients is possible. Suggestedintegration applications would be to the owner'smaintenance and operations legacy database systems.Many Fluor Daniel clients are using the SAPTM R/3TMapplication by SAP Aktiengesellschaft, Systems,Applications and Products in Data Processing (SAP)for plant maintenance and production planning.Development between SAP and Jacobus is underwayto offer an off-the-shelf linkage to the SAP brandEnterprise Resource Planning suite of products.

5. BENEFITS OF THE INVISIONSYSTEMFigure 4. Progress Query Menu

4.3 Construction ProgressTracking field progress on Fluor Daniel constructionprojects is the responsibility of the project controlsteam. A database program and standard referencesystem used for field progress tracking is calledMileMarker. The InVision system has an interface tothe MileMarker system which allows field personnelto check progress of the project in the visual modelenvironment. The queries in the ConstructionProgress menu allow field leaders to select by

Prior research in the field of quantifying thebenefits of effective use of 3D CAD models inconstruction have been conducted by the CII [2].This research produced benchmarks of effectiveconstruction use of the 3D model in the areas of. Reduction of rework Improved communication Visualization of related information

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The following benefits were found to be the result ofeffective use of 3D CAD models: 5% reduction in cost growth 4% reduction in schedule slip 65% reduction in reworkFluor Daniel is in the process of benchmarking itsuse of the InVision system's performance againstthese metrics. Project teams have already recognizedthe InVision system's benefits in the areas of. Reduction of direct labor hours in Piping,

Structural Steel, and Electrical trades Field visualization of related database

information Comprehension of difficult design structures Improved constructability planning Productive field material and execution planningThree Fluor Daniel projects, which currently have theInVision software system in the field, were surveyedto document InVision savings. An InVision log sheetwas used to track daily InVision system use.

Description of work performed on InVision Discipline Estimated manhours saved using the InVision

System Prints made (Y/N?) Date

From this data, several assumptions were made toquantify actual dollar values from the manhourssaved. The manhours were averaged over a specific

time period, depending on the survey dates, andprojected over the duration of the project.

As of April 1999, the German Project is 55%complete, the Gulf Coast Project is 50%complete, and the Canadian Project is 26%complete. Duration of InVision system use in the field:German Project 18 months, Gulf Coast Project12 months, Canadian Project 24 months.

Preliminary data shows the following percentagesavings of Total Installed Cost (TIC).P r o j e c t P r o j e c t e d T o t a l PercentageTotal Savings Installed Cost Savcd

from Inv,sion *April 1999German $661,000 $215,000,000 0.31%P r o j e c tGulf Coast $1,011,000 $111,000,000 0.91%P r o j e c tCanadian $278,000 $640,000,000 0.04%P r o j e c t

Figure 5. Percentage of TIC Saved by Using theInVision System

A consideration to be taken into account whenreading the above percentages , is that the Gulf CoastProject and the Canadian Project are self-performprojects while the German Project is a constructionmanagement (CM ) project . The Gulf Coast Projectand the Canadian Project are therefore expected tohave greater savings because of the craft ' s increasedutilization and access to the InVision system. Anadditional factor to be taken into co nsideration is thatthe Canadian Project is only 26% complete. In thefirst quarter of the execution plan, the majority ofpiping and conduit routing has not begun . These areboth areas where significant manhour reductions areexpected.

Misc.1%

Engineering Structural9%1%Eectrca18%

Piping71%MStructural Electrical jPiping gEngineering Misc. ,

Figure 6. Percentage Manhours Saved Per Discipline

As seen in Figure 6, the majority (71%) of themanhours saved were in the Piping discipline. Theuse of the InVision system by the Electricaldiscipline (18%) is very interesting. Electricalconduit is typically not modeled in PDS, but theElectrical foremen and supervisors are second only toPiping in their use of InVision. It is significant that atrade whose design information is not contained inthe model is a major user of the system.Project Benefit/Cost RatioGerman Project 8.26Gulf Coast Project 12.63Canadian Project 2.78

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Figure 7. InVision Benefit /Cost RatioThe benefit/cost ratio is a measure of the benefits, orsavings, created by the InVision system divided bythe total cost of the system. The total cost of theInVision system includes the software, hardware,training, licensing fees, and installation charges. Todate in April 1999, use of the InVision system hasproduced a minimum benefit/cost ratio of 2.78 on the


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Canadian Project and a maximum benefit/cost ratioof 12.63 on the Gulf Coast Project. The benefit/costratio for the Canadian Project is expected to increaseas more substantial progress is made. The InVisionsystem savings are expected to result in an averagebenefit/cost ratio of 8.0.The InVision system's first year of use in the fieldhas been an unqualified success. Actual projectsavings allow a prediction of an average reduction inTIC of 1.0% for a Fluor Daniel self-perform projectand an average reduction in TIC of 0.5% for a FluorDaniel construction management project. Anaverage reduction of 0.5% of total field manhours isalso an accepted benefit of using the InVisionsystem.The future of the InVision system at Fluor Daniel issolid . In the first year of use, twelve projectsinitiated the system. Many foremen have transferredfrom the completed InVision system project to theGulf Coast client field site, and avidly requested useof the InVision system. As project teams dissolveand re-form on new task forces, experiencedInVision system users will assist the propagation ofthe new work processes and use of the system.Fluor Daniel expects to remain an industry leaderthrough the use of effective automation to deliver thehighest quality facilities to our clients for the bestvalue. The InVision system supports the FluorDaniel culture of Better, Faster, Cheaper, and Safer.

AcknowledgmentsThe InVision system team at Fluor Daniel is

multi-national and exists in many offices. Keymembers include : Shannon Holy , Karen Inman,Issam Karkoutli , Mike Ogle, Mark Pingol, RobertPoirier , Ben Song, Martin Stook, John Thomas, TomVaughn, and Rob Wubbenhorst.

REFERENCES

P] Fluor Daniel Construction Practices -Constructability Manual, 1998.[2] Griffis, F., Hogan, Daniel B ., & Li, W. "AnAnalysis of the Impacts of Using Three DimensionalComputer Models in the Management ofConstruction ." CII Report RR-106 , pp. 1-164. 1995.[3] Newton, P., Wilson, B., Crawford, J., & Tucker,S., Networking C A D , CSIRO Division of Building,Construction , and Engineering. 1993.

[4] OConnor, J., Rusch, S., & Schutz, M.,"Constructability Improvement During Engineeringand Procurement ." Construction Industry Institute -Source Document 5. 1986.[5] Tatum, C., Vanegas, J., & Wlliams, J.,"Constructability Improvement During ConceptualPlanning." Construction Industry Institute - SourceDocument 4 , 1986.InVision is a service mark o f Fluor Daniel, Inc.NEWS is a trademark of Fluor D aniel, Inc.PlantSpace and Enterprise Navigator are trademarksof Jacobus Technology, Inc.SAP and R/3 are trademarks of SAP AG

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Implementation_of_an_integrated_3-D_information_system_for_EPC_projects.PDF