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9/17/2009
1
Process, Power and Marine Division
Early Decision Engineering with SmartPlant Schematics
Intergraph
September 16, 2009
Agenda
Introduction of the team
Objective of the session Objective of the session
The Scope
Success Criteria
Process Design
Control System Design
© 2009. Intergraph Corporation. All Rights Reserved.
Control System Design
Electrical Design
Conclusions
9/17/2009
2
Team & Objectives
Show the additional value of rule drive integrate engineering solution
Enabling to make earlier design decision and create quality and consistent data for down stream use
Improve productivity
Open and flexibility to comply with project/customers demands
The Team Rene van Strien, CBI Process Design
John Dressel, Fluor Control System Design
Scott Hendrickson, Burns & McDonnell Electrical Design
© 2009. Intergraph Corporation. All Rights Reserved.
Challenges & Opportunities
Competitive environment
Shorter project cycles
Joint ventures
Complex projects (process technical)
Risk management
Engineering data for Operations
Innovation is the Single Most Important Condition to Transform the Crisis into an Opportunity
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
3
Opportunities
Innovative solutions
R l d i Rule driven
Open to add complementary solutions
Automate design
Drive consistency in the design and deliverables
Break down silo’s
Be a winner, offer added value
Ability to use the data in operations Ability to use the data in operations
© 2009. Intergraph Corporation. All Rights Reserved.
PipingInstrumentation
Equipment
Electrical
P&ID
Scope Workflow setting (for this session limited to process, instr. and electr.)
The scope
Create the P&ID in a work shared environment
Add the controls
Add the pump/ electrical distribution
Pump Motor
© 2009. Intergraph Corporation. All Rights Reserved.
Unit
Controls
Pump Motor
9/17/2009
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Success Criteria
The bottom line– Faster plant productivity improvement
Minimized downtime– Minimized downtime
– Reduced engineering efforts & costs
– Up to-date plant documentation
Enabled through– Better collaboration (intra- and inter-company)
– Faster access to all relevant engineering information
– Management of change– Management of change
– Re-use of designs
– Design automation
– Accurate material quantification, purchasing and delivery
– Optimized construction
– Automated update of plant documentation© 2009. Intergraph Corporation. All Rights Reserved.
Process Design
First Step in the work processp p– Create the P&ID using best practices
– Leveraging the engineering capabilities
– Validate the design
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
5
Introduction
• SmartPlant P&ID experience list:– Over 10 years
– BDEP, Feed and EPC projects
– Small (about 30 dwg) to large (over 500 dwg) projects
• Basis for this presentation:– Current Feed project
– Client: Staatsolie, Suriname
© CB&I - 9
C e t Staatso e, Su a e
– Refinery Complex incl. Licensor packages
– About 300 dwgs
Global Execution Capabilities
Ft. Saskatchewan
C l
The Hague
MoscowCalgary
Everett
San FranciscoSan Luis Obispo
Los AngelesThe Woodlands
HoustonBeaumontTyler
Dallas
Plainfield
AtlantaNew Castle
BloomfieldPittsburgh
Niagara-on-the-Lake
Caracas
Puerto Ordaz
LondonMoscow
Brno
Cairo
Al KhobarDoha
AjmanDubai
New Delhi
Bangkok
Beijing
Tokyo
Shanghai
Manila
Singapore
© CB&I - 10
Perth Brisbane
Sydney
Secunda
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SmartPlant P&ID Engineering
• Drawings are developed by Process Engineers – Typical hookups / Assemblies
– Rule configuration
– System editing
• MOPEX projects using Connected Workshare– Consistent basis for symbols, rules
– Database synchronization
© CB&I - 11
atabase sy c o at o
– Consistency on interfaces
– Access to drawings not in own office
Reports
• Deliverable reports– Drawing list
– Line list
• Check / Consistency reports– Inconsistency report
– Valve list
© CB&I - 12
• Interface reports– Instrument export
– MTO export
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AVI
Performing the Task
© CB&I - 13
g
Conclusions
• SmartPlant P&ID Benefits– Consistency of data
• On the drawings
• Between offices
• Between drawings and related reports
• Between SmartPlant P&ID and other applications(e.g. SmartPlant Instrumentation)
– Efficiency
© CB&I - 14
• SmartPlant P&ID requirement• Not to be used as CAD application
• Configuration of rules
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Completing the Process Design
Key pointsy p– Use of assemblies (best practice)
– The rules and validation helps to avoid iterations and facilitates faster execution
– The data centric approach allowed to ‘query’ for the changes made and helps MOC
Let me ask you…..
© 2009. Intergraph Corporation. All Rights Reserved.
Audience Poll...
The creation of the intelligent PID takes more time than creating PID with traditional CADtime than creating PID with traditional CAD like AutoCAD.
A) Yes, much more time
B) Yes, a little more time
C) They are about the sameC) ey a e about t e sa e
D) No, it takes less time
E) I don't know
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Control System Design
Next step in the work processp p– Adding the controls
– Creating the specifications and wiring
– Creating the deliverables to buy, install, test and later maintain
© 2009. Intergraph Corporation. All Rights Reserved.
Control System Design
Next step in the Project Work Process
– Interfacing SPI with SmartPlant Foundation Applications
– Indexing Control Systems and Instrumentation Systems
– Specifying and Sizing of Control Valves and Instruments
– Defining the Control System Wiring and Signals
C ti d li bl t h i t ll t t d l t– Creating deliverables to purchase, install, test and later maintain the Instrument Control Systems
© 2009. Intergraph Corporation. All Rights Reserved.
John DresselPrincipal Control Systems Application Specialist
9/17/2009
10
SPI - SP-P&ID Interface The SPI – SP_PID interface is a correlation process that transfers
Instrument Tag related data and data modifications from the P&ID to SPI
Tags that are in both SPI and SP_PID will correlate to each other without having to import new Instrument Tag numbers into SPIhaving to import new Instrument Tag numbers into SPI
This will allow SPI users to create the Instrument index in SPI before the P&ID is published and maintain the SPI automation capabilities without having SPI data overwritten
This interface allows MOC between tags on the P&ID and SPI with the P&ID being the master source of change throughout the project
PUBLISH PUBLISH
RETREVEDO NOT
RETREVE
SmartPlant User Interface SPI Explorer Interfaces with Module Work Area Window
Allows navigation to all Tag, Loop, &to all Tag, Loop, & Wiring Properties
Allows access to all SPI Documents
Allows access to all primary support tables
Powerful MenuPowerful Menu Functions for Editing, Duplication and Generation of Documents and Data
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Instrument Index Module
Index Add, Edit or Duplicate Tag Number or Loop Properties
Displays Loop association for Tagsassociation for Tags
Access to primary support tables with pick lists for data consistency
Additional data for SPEL power requirementsrequirements
Access to User Defined Custom Tables
Instrument Index Module
The Instrument Type Table contains entries for every type of instrument that is expected to be used on a project.
Instruments areInstruments are grouped by Process Function
Each different technology is given a separate Description
The Profile definesThe Profile defines the SPI Automation
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Instrument Index Module
Instrument Type Profile defines the Tag Automation Functions
Automation Functions Instrument SpecificationsInstrument Specifications
– Define Spec Form
– Populate Spec from Template
Automatic Loop Creation
Process Data Workflow
Populate Support Tables
Initialize Device Wiring
– Define I/O TypeDefine I/O Type
– Define Signal Cable
– Define Connection Type
Define Material Requirements
Define Dimensional Data for Piping – for SP3D interface
Instrument Index Module Query Wizard for User Defined Index Browse and Browser Views
Full Index Command Menu for data editing
Drop down Data Windows for pick lists
Create User Browser views of Spec Sheets and Process Data
Automatic Report and Export of query data from Browser
Linked access to external and internal documents for full document management
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Instrument Spec Module
Instrument Specification
– Form for each Spec Type
– Edit Forms in SPI
– Drop Down Data Windows
– External Form Editor
– Multi-Item forms
– Multi-Sheet forms
– Revision control
– Show data from Index table
– Link directly to Process Data
– Export Specs to Excel or Intergraph External Editor
Interfaces with Vendor Sizing and Selection Software
Process & Calculation Module Handles multiple Process Cases
Fluid properties lookup
Data entered by Tag or Line
Unit of Measure conversion
Copy data from other Tags
Additional Properties
Base Conditions
Alarm / Trip Settings
User Defined Fields
Workflow control
Process datasheets with RevisionsProcess datasheets with Revisions
Process Calculation Module– Control Valve Sizing
– Relief Valve Sizing
– Flow Meter Sizing
– Thermowell Parameters
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SmartPlant Wiring Module Handles Conventional and Foundation Fieldbus wiring matrix
Drag and drop cables to terminals for connection with automatic signal propagation
Allows simultaneous Field and DCS side wiring
Automated Junction box wiring with pre-loading
DCS I/O loading and built in DCS manufacturer interfaces
Automatic or manual cross wiring and continuity checking
Generates Wiring and Loop Diagrams with Revisions
SmartPlant Loop Module Automatic Loop Generation
Enhanced SmartLoop
– True CAD documents
f– User configurable
– Interactive with database
– Save in CAD file formats
AutoCAD & Microstation Automatic Loop Generation
– Completely configurable
– Can use existing or client Blocks or CellsBlocks or Cells
– Saved in native formats
SPI Loop Wiring and DCS I/O data is handed over to the Owner Operator for Plant Maintenance and Asset Management
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SmartPlant Loop Module Automatic Loop Generation
Enhanced SmartLoop
– True CAD documents
f– User configurable
– Interactive with database
– Save in CAD file formats
AutoCAD & Microstation Automatic Loop Generation
– Completely configurable
– Can use existing or client Blocks or CellsBlocks or Cells
– Saved in native formats
SPI Loop Wiring and DCS I/O data is handed over to the Owner Operator for Plant Maintenance and Asset Management
SmartPlant Loop Module
Fieldbus Segment Diagrams and Fieldbus Loops
– True CAD document
– User configurable
– Interactive with database
– Save in CAD file formats
– May be annotated
– Uses SmartSketch RAD graphic enginegraphic engine
9/17/2009
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SmartPlant Instrumentation Interfaces
SmartPlant Foundation Interface allows Data Sh i t S tPl tSharing to SmartPlant Applications
Work Sharing via Citrix allows real time global access to the SPI database over the Web
Vendor Interfaces for D t Sh i tData Sharing to instrument sizing, selection and DCS programs
Controls in place
Key pointsy p– Getting the instruments from P&ID
– Browser are central data and task management to make sure all is completed
– Deliverables ‘view’ from that data
– Consistency thru the complete document set
– Cover all CS tasks
– Data is available for operations (calibration, maintenance, revamps, etc
Let me ask you…..
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
17
Audience Poll...
Capabilities to create user defined rules and pautomate data entry based on external data collection will increase productivity.
A) Yes, by at least 30%
B) Yes, by less than 30%
C) No, it does not make a difference
D) I don't know
Electrical Design
Last step in this workflowp– Powering the system with best practices
– Electrical distribution design
– Making sure it is a safe and reliable design addition thru validation (ETAP)
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
18
Electrical Design Experience with SmartPlant Electrical
– Standard electrical design tool in Energy Global Practice
Executed 10 projects over last 3 years– Executed 10 projects over last 3 years
– Used by Electrical Engineers
Changes experienced using SmartPlant Electrical– Reduction in CAD personnel required for One-Lines, Schematics and Wiring
Diagrams
– Reduction in Engineering time required to cross check deliverables
– More consistent deliverables with use of reference data and design rules
Cl i i i h h di i li– Closer integration with other disciplines
– Singular workflow that will work with small and large projects
Show the new workflow– Workflow used on large coal plant with 1500 loads
– Managed 1000 schematics in SmartPlant Electrical
© 2009. Intergraph Corporation. All Rights Reserved.
Gathering Load Information Loads created automatically using two methods
– Integrated environment using SmartPlant Foundation
• 250 motors and heaters created from SmartPlant P&ID’s
• 250 instruments requiring power from SmartPlant Instrumentation
– Imported vendor loads using SmartPlant Electrical Import Manager
• 1000 loads including motors, heaters and local panels
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
19
Leveraging Reference Data Profiles
– Profiles are the data representation of an electrical schematic
Allow to quickly and consistently create all information needed to manage– Allow to quickly and consistently create all information needed to manage deliverables
– Start from Switchgear and MCC Schematics
– Unique loads are easily handled by using most accurate profile and making the unique change
– Reapply profile options to handle changes in design
Look Up TablesCustomize tables to look up any number of inputs and fill in incomplete data– Customize tables to look up any number of inputs and fill in incomplete data with any number of outputs
Batch Apply Profile– Use tablular editor to apply profiles to all similar loads at one time
© 2009. Intergraph Corporation. All Rights Reserved.
Building Reference Data Example Motor with Space Heater
Voltage Ratings Terminals
Ci i I f i Circuit Information DCS I/O Terminal Strips Control Cables Circuit Internals
Disconnect Circuit Breaker Control Transformer Contactor
© 2009. Intergraph Corporation. All Rights Reserved.
Contactor Solid State Overload Ground Fault Relay
9/17/2009
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Building Electrical Network Build electrical power distribution network quickly using drag
and drop methods
f Duplicate electrical networks from any project using Reference Electrical Engineer
Use batch load association based on preliminary load assignments– Creates circuit based on load profile
– Automatically connects power cable and load to circuit
U El t i l E i i d t hi ll i l t i l Use Electrical Engineer window to graphically view electrical network
Validate bus loading with SmartPlant Electrical and quickly move loads to balance electrical network
© 2009. Intergraph Corporation. All Rights Reserved.
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
21
SmartPlant Instrumentation Interface
Publish information for Control System Engineer– Cable and power source for instruments requiring power
– DCS I/O from Switchgear and MCC schematics
Retrieve partitioned DCS I/O with complete termination information– Connect control cables based on I/O cabinet information
© 2009. Intergraph Corporation. All Rights Reserved.
Generate Preliminary Deliverables
Workflow quickly and consistently creates all deliverables from single data entry.
O Li– One-Lines
– MCC or Switchgear Schematics
– Cable Schedule
– Equipment Schedule
– Material Lists
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
22
SmartPlant 3D Interface
Publish Cable Schedule to SmartPlant 3D for automatic cable routing and validating raceway design
f S Retrieve cable routing path and length from SmartPlant 3D– Perform voltage drop calculations based on routed length
– Automatically resize and replace cables
© 2009. Intergraph Corporation. All Rights Reserved.
Finishing Up…
Publish electrical network to ETAP (bi-directional interface)– Perform Arc Flash Analysis
A i k k t ll j i t Assign work packages to all major equipment– Propagate work packages using rules to equipment internals, cables and I/O
Create and Manage Final Deliverables– Revisions are archived for comparison or viewing if design conditions change
• Automatically cloud changes on graphical reports
• Creates Excel report listing changes from last revision
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
23
Completing the Design
Key Pointsy– Getting the data from the P&ID
– Fast and consistent configuring of the motor load designs using best practice design
– Data entry validations
– Validation of loads and cables
– Deliverables ‘view’ of the design data
Let me ask you…..
© 2009. Intergraph Corporation. All Rights Reserved.
Audience Poll...
How much time can be saved by avoiding the y ginconsistencies across the documents produced in the electrical discipline?
A) More than 30%
B) Less than 30%
C) None
D) I don’t know
9/17/2009
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Conclusion
Integrated rules driven design enables:g g– Fast track project execution
– Work sharing
– Reduce risks
– Management of change
– Reduction of revision iterations due to data validationReduction of revision iterations due to data validation
– Deliverables consistent
– Faster time to production
– Data hand over to Operations
© 2009. Intergraph Corporation. All Rights Reserved.
Q&A
© 2009. Intergraph Corporation. All Rights Reserved.
9/17/2009
25
Test Drive
Try SP P&ID and SP Isometrics at your desk just using the web browser.
Testdrive.Intergraph.com
6 pre-defined workflows 24 hours try if the application would run locally
© 2009. Intergraph Corporation. All Rights Reserved.
The recording of the webinar and additional information can be found at:
http://www.intergraph.com/ppm/engsch.aspx
Process, Power and Marine Division
The Future of
Engineering –
Today