a publication of intergraph process, power & marine 2011 … publication of intergraph®...

A publication of Intergraph® Process, Power & Marine

SmartPlant®

3D

SiemensSNC-LavalinSuncorURSGrenland Group

A Special Focus of

2011

Featuring Customer Case Studies for SmartPlant 3D and SmartMarine® 3D

Focus on: SmartPlant® 3D From the Top 3 Building and Operating Facilities More Safely

Safety Management 4 Smart 3D Solutions Increase Safety in the

Engineering Enterprise

Case Studies 6 Siemens Energy Sector Implements SmartPlant® 3D

8 SmartPlant 3D Accelerates SNC-Lavalin Minerconsult Mining Project Implementation

10 Suncor Meets Tight Schedule with Intergraph SmartPlant 3D

12 URS Washington Division’s Project Approach Delivers Results

15 Genpro Engenharia Uses SmartPlant Enterprise to Promote the Complete Design Workflow

20 IBERDROLA Ingeniería y Construcción Realizes the Power of Integration

22 Chematur Engineering Achieves TIC in the Box

24 Grenland Group Advances Productivity with SmartPlant 3D Automation

26 C&I Engineering Shortens the Learning Curve

28 With Growing Demand for Alternative Fuels, De Smet Engineers & Contractors Look to Intergraph Solutions

Industry Perspective: ARC Advisory Group 16 Intergraph No. 1 Process Engineering Tool Provider

17 Process Engineering Tools Drive Efficiency Improvements

Did You Know? 30 Market-leading Smart 3D Offers New Productivity and

Performance Enhancements 34 Gain the Most Value from Laser Scanning with

SmartPlant Enterprise

36 Industry Newsbytes

Table of Contents Focus on: SmartMarine® 3D From the Top 40 The Industry Gold Standard – Smart 3D

Case Studies 42 Smooth Sailing for Samsung Heavy Industries

44 COSCO Shipyard Group: Speeding Offshore Design

48 Keppel Offshore & Marine Chooses SmartMarine® 3D for Design Efficiency

50 Grenland Group Chooses SmartPlant Enterprise to Maximize Offshore Production

52 Vietsovpetro Stays on Top of Offshore Design

Did You Know? 54 Intergraph Expands SmartMarine 3D Design Software

Capabilities for Offshore Market 56 Intergraph SmartMarine Enterprise Boosts Productivity

6

30

Industry Leaders Depend on Intergraph Smart 3D Technology for Competitive Productivity ImprovementsEngineering, procurement and construction firms and owner operators in more than 60 countries around the world rely on Intergraph software to increase productivity and provide for safe and clean operations. Recognized as the industry’s market leader by all independent analysts, Intergraph’s commitment to customer success is known around the world.

Building on its industry leadership and closely collaborating with its customers, Intergraph invested more than US$170 million and hundreds of thousands of man hours to develop Smart 3D, the

only next-generation design technology on the market.

This data-centric, rules-based 3D technology enables better user productivity, improved collaboration and higher quality engineering deliverables than previously available.

Smart 3D’s innovative plant modeling also provides consistent 2D and 3D integration between process engineering and

detailed engineering disciplines, and workflow-managed integration across the project enterprise and workshare teams globally.

The result? Power and industrial plants, ships and offshore platforms can be designed, built, operated and maintained with greater efficiency, speed and safety. EPCs and owners alike benefit from more than 30 percent productivity gains during the design phase and reap potential one percent reductions off large CAPEX budgets during procure-ment and construction as a result of faster, higher quality engineering deliverables.

2 Insight

SECTION TITLE GOES HERE

2 Insight Issue 28

fROm THE TOp

3Insight

There is a growing interest in safety due to recent events involving a variety of industries which Intergraph Process, Power & Marine (PP&M) serves. Insight discussed the heightened focus on safety and the ways that Intergraph can help with Gerhard Sallinger, president of Intergraph PP&M.

Insight: How can Intergraph improve safety for facilities?

Gerhard Sallinger: Safety by design has always been central to our philosophy. Our solutions support the life cycle of facilities and can address process safety, personal safety and facility safety.

SmartPlant and SmartMarine solutions can help to increase safety in the engineering enterprise by enabling our customers to design, build and operate safer, more reliable and more efficient plants, offshore structures and ships.

Insight: What can rules-based technology provide your customers?

GS: Smart 3D technology (encompassing both SmartPlant 3D and SmartMarine 3D) is our state-of-the-art 3D plant and ship design system. It is unique because it is the only system which is able to incorporate engineering rules of all types directly into the engineering tool. This rules-based, data-centric technology empowers engineering companies and plant operators to transfer engineering and operational knowledge as well as relevant safety and regulatory require-ments and procedures into the system. By doing this, the system can automatically optimize the design process and facilitate the automation of engineering, leading to better, more effective and more error-free design.

More error-free design, combined with the inte-gration of relevant process safety data, materials handling and construction, can reduce the need for last-minute modifications at the construction site or fabrication yard to correct undetected design errors.

Besides the high costs of last-minute modifica-tions, late modifications also bear risks, such as area classification errors, improper documenta-tion and tracking. By nature, late modifications convert an “as-designed” plant into an “as-built” plant, bringing in all sorts of new risks.

Insight: Can rules work as “safety watch dogs” to increase safety?

GS: Rules-based design can save engineer-ing time and increase design accuracy. For example, it can ensure that safety-related design rules are properly applied and can only be modified with proper authorization.

The rules-based design capability that Smart 3D offers is the top differentiator to traditional design systems.

Intergraph engineering and information manage-ment tools can also assist in identifying, preventing or managing safety issues by automating hazard and risk identification and conducting efficient explosion impacts studies – to name a few.

Insight: How can better management of facility data increase safety?

GS: SmartPlant Foundation and SmartPlant Enterprise for Owner Operators are highly efficient solutions for plant data management, specifically developed to address the demands of the plant design industry. Engineering companies and plant operators can use these solutions to effectively manage and document all relevant information, e.g. work procedures, about the plant operations during its life cycle, such as maintenance procedures, change man-agement data and safety documents.

Insight: What other Intergraph capabilities are available for a comprehensive safety approach?

GS: A major strength of Intergraph is that we offer a deep breadth of integrated applica-tions for the complete life cycle. For example,

SmartPlant Enterprise for Owner Operators enables you to document non-conformities and waivers. In case of an incident, you have a traceable, auditable record for regulators and investigators.

We work closely with leading O/Os, EPCs and other technology providers to deliver new functionalities, such as:

n We now offer highly expedited explosion and gas dispersion analysis through an optimized interface between Smart 3D and GexCon’s FLACS solution, which enables you to quickly load Smart 3D models into FLACS to gener-ate an impact report and apply the explosion analysis findings to improve the plant design, if necessary for your workflows

n Fireproofing rules are available in Smart 3D

n Leak detection and repair (LDAR) analysis can be performed by operations and main-tenance teams using SmartPlant P&ID and SmartPlant Foundation to find and document leaks in the plant.

And there is much more to come. We are com-mitted to helping increase facility safety for the industry with innovative solutions!

Jana Miller is editorial director of Insight and is based in Huntsville, Alabama, U.S.

www.intergraph.com/go/smartsafety

Building and Operating Facilities More SafelyIntergraph technology can help build better and safer facilities and operate them more effectively

n By Jana Miller

InsightSmart 3D

4 Insight


4 Insight

As recent events have indelibly illustrated, lapses

in plant safety can result in the loss of life and

property, unimaginable environmental damage

as well as corporate financial and reputation

ruin, and intense governmental scrutiny.

SmartPlant Enterprise and its ship and offshore

counterpart, SmartMarine Enterprise, inherently

promote safer plant design and construction

with their rules-based Smart 3D engineering

design solution. The software helps users to build

safety into plants early in the design process and

enforce regulation and engineering standards to

reduce rework, increase productivity and quality

and lower costs. The rules can be nominally

configured to ensure compliance with many

industry and safety standards organizations from

around the world.

For example, with Smart 3D, the design and

modeling of cans, tubular structures added to

nodal connections on the jackets of offshore

platforms to provide reinforcement, is compliant

with American Petroleum Institute (API) stan-

dards. Users can also create their own methods/

rules of flagging or containing questionable or

hazardous construction designs that could result

in compromising the safety of the plant, equip-

ment or employees.

Rules-based design impacts safety early in the

area classification of the 3D model. The software

identifies the locations of equipment that could

be unsafe if located near each other and will flag

or disallow the placement of that equipment in

the 3D model design. This helps to better man-

age the hazardous locations of equipment and

activities in those areas to ensure safe operations.

GexCon fLACSNow, to meet the growing safety demands of today’s design engineers and plant owners, Intergraph has interfaced its Smart 3D and design software with GexCon’s FLACS explosion analysis software to enable users to visualize impacts and ensure that equipment is placed cor-rectly and that structures are able to withstand an incident such as an explosion. FLACS has been the leading tool for explosion consequence prediction on offshore oil and gas installations for more than a decade.

Ideal for chemical, metals, oil and gas, pulp, power and other plants involved in the handling or manufacturing of explosive or flammable materials or pressurized liquids and gases, the safety management software configuration reduces design and component placement errors that later must be corrected during construction.

Smart 3D Solutions Increase Safety in the Engineering EnterpriseIntergraph automated rules-based design offers better solutions for safer assets

SAfETY mANAGEmENT: SMART 3D SOLUTIONS

Insight: Special Focus

5Insight 5Insight

With the interface between Intergraph design

software and FLACS, Smart 3D models can be

imported for analysis and validation in as little

as an hour or a couple of days. This capability

favorably compares to the typical workflow of

creating the model within FLACS or revising the

project models which can take from one week to

three months to complete.

The interfaced 3D design and explosion analysis

software enables users to more easily produce

reports showing gas dispersion and explosion

impacts and then incorporate changes while

still in the design process to minimize costly

late changes.

Using the rules, FLACS validates design and

rework is cut to a minimum due to the fact that

rules have enforced the right engineering deci-

sions from the beginning.

more Smart 3D featuresSmart 3D can also model intelligent fireproof-

ing for both structural steel and concrete. The

process is specification-driven. Reference data

are preconfigured to enable automatic determi-

nation of key design aspects such as material,

grade, rating, segmentation and setback lengths.

Additional safety management capabilities of

the SmartPlant Enterprise and SmartMarine

Enterprise suites include leak detection and

repair (LDAR). By integrating SmartPlant P&ID

together with SmartPlant Foundation, users are

able to find all critical process connection points

inside a plant that are susceptible to leaks and

need regular inspection. Inspections can be

better managed by using SmartPlant P&ID as

the plant roadmap to identify all critical connec-

tions. SmartPlant P&ID then links to inspection

documentation and reporting, which can be

managed in SmartPlant Foundation. Smart 3D

locates connections to help plan inspections. For

example, the user can click on the connection in

SmartPlant P&ID, open the 3D model and zoom

in on the connection point.

www.intergraph.com/go/smartsafety

www.gexcon.com

Intergraph SmartPlant Process Safety software streamlines process safety review and builds the corporate safety knowledge base, leading to considerable benefits for capital projects and operating plants in lowering operational risks. By automatically identifying hazards (causes and consequences with the associated risk fac-tors) from the plant’s schematic drawings using SmartPlant P&ID, SmartPlant Process Safety enables companies to:

n Produce consistent, high-quality HAZOP study reports for much less time and cost across the complete design

n Identify and eliminate hazards early in the design process, before change becomes limited and expensive

n Quickly and easily assess the effect of change on the safety of the entire plant by comparing several HAZOP studies

n Take advantage of action management to execute risk reductions

n Pre-verify the P&ID before the HAZOP to ensure safety devices are in place.

For capital projects, SmartPlant Process Safety leads to lower risk, improved design quality and reduced schedules. For the operating plant, it means that through better Management of Change (MOC) processes, users can achieve improved and much faster re-HAZOPs and also increase plant safety. Powered by HAZID, SmartPlant Process Safety is an integral part of SmartPlant Enterprise. Benefits include:

Substantially reduce HAZOp study time and cost – By largely automating hazard and risk identification, SmartPlant Process Safety can easily cut the time and cost of HAZOP studies in half. SmartPlant Process Safety inte-grates with SmartPlant P&ID and automati-cally traces hazard and operability issues and potential safeguards across multiple P&IDs.

Gain a powerful visual aid to under-standing – Information such as nodes, fault-consequence paths, and potential safeguards may be highlighted at any time to help the

HAZOP study team evaluate risks and brain-storm for any other fault-consequence pairs.

Enhance action management with com-prehensive change validation – Changes resulting from the action management process can be validated before acceptance, even though the HAZOP team may have dispersed.

See thorough, consistent, auditable results – Unlike conventional HAZOPs in which two teams may produce different results, hazard identification with SmartPlant Process Safety will always be thorough and consistent from HAZOP to HAZOP.

Enable better quality designs and reduced cost of change – Process engineers can check for safety at any stage of the design, even to verify the P&ID on safety practices before physical design. This improves design quality and eliminates hazards and operability issues before change becomes limited and costly.

Build and retain corporate safety know-ledge base – Companies can capture the safety knowledge of their most experienced engineers, operations staff and safety people into a corporate safety knowledge base for consistent reuse throughout the organization.

Improve mOC processes – SmartPlant Pro-cess Safety may be incorporated into MOC processes to ensure that safety of any plant modification is assessed across the whole plant before work permits are issued.

Check the safety of your plants against recently reported incidents – All of a com-pany’s plants can be quickly audited to ensure they are not susceptible to recently reported incidents in similar plants.

Support mergers and acquisitions – New acquisitions can be quickly checked against the corporate safety knowledge base as soon as the P&IDs are available.

www.intergraph.com/products/ppm/

smartplant/process_safety

SmartPlant Process Safety Improves Safety in Capital Projects and Plant Operations

Smart 3D

6 Insight

By any measure, Siemens AG is a global pow-erhouse. For 163 years, the company has been synonymous with technological innovation and operational strength. In 2009, Siemens reported revenues exceeding US$114 billion, with more than 400,000 employees in some 190 countries.

Today, Siemens’ business activities are bun-dled into three main sectors: Industry, Energy and Healthcare. It is into the Energy Sector that Siemens recently introduced SmartPlant 3D, with very beneficial results.

Serving the entire energy conversion chainSiemens’ Energy Sector offers products, services and solutions for power generation, transmission and distribution, and for oil and gas production, conversion and transport. Within the sector, there is also a growing focus on the dynamic renewable energy market, with emphasis on wind turbines, photovoltaic pro-jects and solar-thermal power plants.

According to Energy Sector CEO Wolfgang Dehen, 2009 was a “year of major orders and trail-blazing innovations ... We set new records for profit and revenue.” In fiscal 2009, with some 85,000 employees in 90 countries, Siemens Energy generated revenue of $37.6 billion and profit of $4.8 billion.

Smartplant implementation in Siemens EnergySiemens’ far-sighted willingness to embrace innovative technologies has been a source of the company’s strength since its founding in 1847 by the inventor of the pointer tele-graph. Siemens continually examines every business unit to make certain it is using the best technologies available to stay competi-tive, profitable and nimble, a challenge for such a large corporation.

Siemens’ vision for its plant engineering frame-work required a change in the engineering

execution process. In the old environment, most

tools were not integrated, data storage was

decentralized, much of the transfer of data was

on paper and the environment was “organi-

zation-oriented.” The company wanted a new

environment to modernize its engineering and

communication processes by introducing inte-

grated tools, centralized data storage, automated

data transfer and a “process-oriented” environ-

ment. The strategy for realizing this vision of

an integrated engineering environment was to

implement SmartPlant Enterprise engineering

software at Siemens Energy Solutions.

The Smartplant Enterprise business case In making the business case for implement-

ing SmartPlant Enterprise throughout the

engineering enterprise, Siemens believed it

would derive benefits not only in engineer-

ing and data management, but also in time

and cost savings and quality improvements.

Siemens Energy Sector Implements SmartPlant 3DReduction in time reported by approximately 150 users in multiple disciplines

n By Guenter Mauss

CASE STuDY: SIEMENS AG ENERGy SECTOR


7Insight

As part of the business case for SmartPlant implementation, Siemens also looked forward to savings in per-project hours among the dis-ciplines – process, civil, electrical, mechanical and 3D modeling. This, of course, would lead to greater ROI.

Expected benefits of integrated toolsOne anticipated benefit of migrating to a sys-tem based on a central data pool was that it would provide a way to streamline data ex-change among all the disciplines involved in a project. This easier exchange of data could then enable integrated workflows across dis-ciplines and processes, including business pro-cesses beyond design.

Working in an integrated tool environment would also enable controlled data sharing, im-proved data management and enhanced data integrity. Siemens also anticipated one more benefit from selecting SmartPlant specifically – a software partner who was accessible and whose global reach ensured support of Sie-mens’ multinational projects.

Smartplant implementation and resultsSince 1996, Siemens had used Intergraph’s PDS, and continued to use it for all projects until October 2008. Also in 1996, the compa-ny began using SmartPlant Review for design reviews by clients and management. Smart-Plant Review supports the entire plant design

workflow and natively views PDS files, as well as SmartPlant files.

Starting in 2006, the company began to use SmartPlant P&ID and SmartPlant Foundation information management solution for all new combined cycle power plant projects. And in 2007, Siemens began using SmartPlant 3D, In-tergraph’s advanced design software, for three execution and three reference plant projects, followed in November 2008 with full release of the software for all new projects.

Smartplant 3D discipline trainingMost of the 150 Siemens engineers who be-came SmartPlant 3D users were experienced in PDS. The SmartPlant users were trained in the following disciplines, including many who are cross-trained:n Piping and pipe supportsn Structuraln Civiln HVACn Racewayn Equipmentn Drawing and reports.

Did Smartplant 3D save time and money?In a word, yes! In evaluating SmartPlant 3D’s performance of modeling tasks, Siemens found the greatest reduction in project hours in mod-eling piping (39 percent time savings) and piping supports (26 percent savings). The next

most significant work-hour reductions were in HVAC (22 percent savings), structural (16 percent savings) and equipment modeling (8 percent savings). These results were based on a comparison of SmartPlant 3D to PDS, Inter-graph’s highly respected first-generation plant design software, which Siemens used for 12 years before implementing SmartPlant 3D.

Next goal? Comprehensive use of Smart-plant EnterpriseSiemens has exhaustively tested SmartPlant 3D, with very satisfying gains in productivity. Based on these results and the company’s previous ex-perience with other SmartPlant applications and with PDS, Siemens has set a new target – the comprehensive use of SmartPlant Enterprise.

With regard to its engineering tools portfolio, Siemens plans a complete migration to Smart-Plant 3D. So far, it has completed the migra-tion for reference power plants and combined cycle power plants. In mid-2010, it will com-plete the migration for steam power plants and conventional islands.

In work processes, the company anticipates integration of SmartPlant in the entire Plant Engineering operation by mid-2010. And in regard to development and upgrades, Siemens Energy Sector’s plans call for the complete integration of SmartPlant throughout the en-tire engineering process. The use of Global Workshare and Catalog Workshare have been completed, as has the V2009 SP1 upgrade for SmartPlant 3D. Further modularization, con-figuration and automation will follow.

Werner von Siemens, the company founder, re-marked in 1857, “In critical situations, decisive and vigorous action is nearly always the best strategy.” Following that axiom, Siemens has aggressively pursued new markets with inno-vative technologies, now including the Smart-Plant Enterprise family of solutions.

Guenter Mauss serves as vice president, Central & Eastern Europe, Intergraph Process, Power & Ma-rine. He is based in Frankfurt, Germany.

www.energy.siemens.com

Smartplant 3D Introduction in Siemens Energy Solutions

APRIL2006

NOVEMBER2006

APRIL2007

SEPTEMBER2007

NOVEMBER2008

END PILOTPROJECT

FIRSTPROJECT

SECONDPROJECT

THIRDPROJECT

FULL RELEASE OFALL NEW PROJECTS

V7 V7.2 V7.3 V7.4V7.1

CONTINUOUS IMPROVEMENT OF SMARTPLANT 3D ■ Performance, stability, functionality ■ Skills and experience of user

EVALUATION OF SMARTPLANT 3D BENEFITS

Smart 3D

8 Insight

The SNC-Lavalin Mining and Metallurgy (M&M) division is a world leader in its sec-tor, carrying out projects in the fields of alu-mina, aluminum, bauxite, copper, gold, iron ore, nickel, phosphate, potash, steel, zinc and other commodities. SNC-Lavalin’s global ser-vices range from scoping studies to full project implementation for some of the largest proj-ects ever undertaken in the industry.

Most SNC-Lavalin M&M technical staff mem-bers have extensive practical operating back-grounds that complement their design and project management skills and have often worked on the same projects together. SNC-La-

valin’s approach to project execution and de-

livery embodies strong project management,

technological excellence and quality assurance.

SNC-Lavalin has been active in Latin America

since the early 1970s and is one of the leaders

in project execution in the mining and metal-

lurgy sectors in Brazil.

SNC-Lavalin Minerconsult, founded in 1990 as

Minerconsult, became part of SNC-Lavalin in

2007. With approximately 1,000 employees and

revenues last year of approximately US$100 mil-

lion, SNC-Lavalin Minerconsult has developed

and implemented more than 1,000 projects in

the past 20 years. Major EPCM projects executed are the Barro Alto Nickel, Rio Paracatu Gold Ex-pansion III, Juruti Bauxite and Alumar Aluminum refinery projects in Brazil.

The experience won by SNC-Lavalin Miner-consult during this period provides a unique knowledge of mining processes, including a high level of technical service to its custom-ers. This level is recognized in Brazil and other countries in the region. Thanks to the experi-ence, talent and background of its local en-gineers, SNC-Lavalin Minerconsult performs large-scale and complex mining projects in Brazil, Malaysia, Peru and Argentina. The

CASE STuDY: SNC-LAVALIN MINERCONSULT

SmartPlant 3D Accelerates SNC-Lavalin Minerconsult Mining Project ImplementationIndustry leader manages projects more efficiently and increases productivity in record time


9Insight

unique knowledge of its professionals and the global execution mindset require tools to help the company during the design stag-es to improve productivity and deliver the highest engineering quality products and a global integration capability with all of the SNC-Lavalin divisions spread around the world.

SNC-Lavalin Minerconsult realized that there were limitations to its existing CAD systems to achieve its project implementation goals. To manage its projects more efficiently, in-crease productivity and better understand the needs of its major clients while remaining at the forefront of the volatile and ever-chang-ing mining industry, SNC-Lavalin Minercon-sult turned to Intergraph. SNC-Lavalin, an existing Intergraph customer, was familiar with Intergraph’s user-friendly interface and easy-to-use tools. In addition, the software’s open architecture, utilizing commercial da-tabases such as Microsoft® SQL and Oracle, was an attractive feature that helped ensure a versatile operating environment.

As part of the evolution process, SNC-Lavalin Minerconsult added Intergraph’s SmartPlant 3D and SmartPlant Review to its product suite. SmartPlant 3D is a next-generation, data-cen-tric design system that provides clients with the most productive, highest quality, multi-dis-cipline 3D modeling environment in the world for global multi-office execution of mining

projects. SmartPlant Review is the complete visualization environment for interactively reviewing and analyzing large, complex 3D models during engineering, construction and operations.

With approximately 100 users, the full training on the new design tool took only four weeks. Because of the high competence level of the professionals and the user-friendly software environment, they were then ready for pro-duction.

With support from Intergraph’s Brazilian dis-tributor, SISGRAPH, as well as SNC-Lavalin’s Canadian and Chilean counterparts, the im-plementation went smoothly in record time. Al-though there was no data migration involved, SNC-Lavalin Minerconsult did require some customization of catalogs, specifications, sym-bols and drawing templates, created by refer-ring to customer documentation.

Now that the SNC-Lavalin Minerconsult team is up and running, it is using SmartPlant 3D as a design tool and SmartPlant Review to vi-sualize the plant sections as well as review, design check and update construction status on its projects.

SNC-Lavalin Minerconsult has received full support from the SNC-Lavalin corporate team as well as many other group offices that have implemented the entire SmartPlant En-

terprise suite of tools, including SmartPlant

Foundation, presently on an Oracle/SQL plat-

form. In addition, the inclusion of SmartPlant

Reference Data will help build and standard-

ize a global approach.

Taking advantage of local talents that exist

globally in SNC-Lavalin, the company’s work-

share environment has proven a great success

thanks to the group’s global commitment in

choosing SmartPlant Enterprise.

Although it is still too early to quantitatively

measure results and benefits from the new

applications in terms of reduced work time or

rework, SNC-Lavalin and its customers have

realized benefits in terms of discipline inte-

gration and engineering development. One

of the main reasons for choosing Intergraph

and the SmartPlant Enterprise engineering

solutions was the fact that there is an in-

tegrated common database that eliminates

duplication of data. Using this integrated

database with concurrent engineering saves

significant time since multiple designers

working on a project can easily know which

data have changed in their environment.

Additionally, with rules-driven design, interfer-

ence checking is continuous and a special pro-

cess is not needed to synchronize the design.

This automation of design reduces not only

the design time, but also provides SNC-Lavalin

Minerconsult professionals with an online en-

gineering coordination tool.

Looking to the future, SNC-Lavalin Miner-

consult hopes to integrate more Intergraph

SmartPlant tools into its product portfolio, in-

cluding SmartPlant P&ID, SmartPlant Instru-

mentation, SmartPlant Electrical and Smart-

Plant Foundation, to enable it to become a

premier full-service engineering, procure-

ment and construction provider.

David Joffrion is a contributing editor for Insight

based in Huntsville, Alabama, U.S.

www.minerconsult.com

Smart 3D

10 Insight Insight: Special Focus

Suncor Meets Tight Schedule with Intergraph SmartPlant 3DWorksharing and data handover boost Firebag project

n By Paul Crowley

One of our latest developments is our Firebag In-Situ operation, located 40 km northeast of our original oil sands plant. In-situ technology opens up the potential to recover large reserves that can’t be reached economically by traditional mining methods. An independent evaluation of our in-situ leases estimates recoverable resources with a potential to produce about nine billion barrels of crude oil.

Our in-situ operations use recycled water in a closed system for steam generation. No additional surface or groundwater is required and no tailings ponds are created. In-situ development disturbs only about 10 percent of the surface land in the development area.

For more than 40 years, Suncor has been known as both an innovator and a leader – from our pioneering work in developing the oil sands of northern Alberta, to our introduction of more environmentally responsible fuel.

Suncor pioneered the world’s first commercially successful oil sands operation in 1967 and reached a new milestone in 2006 with the production of our billionth barrel of oil. In 2008, production at the Athabasca Oil Sands facility averaged 228,000 barrels per day.Construction is now underway for the next phase of oil sands growth, which is expected to increase production capacity in stages to a goal of up to 550,000 barrels per day in 2010 to 2012.

WorksharingWith our current Firebag expansion work, we need to mobilize very large engineering forces to be able to complete the project on time and within the expected first oil recovery dates.

There’s a huge amount of ongoing engineering work – not only in Calgary, but worldwide. Our engineering providers, such as Jacobs Engineering and Colt WorleyParsons, have severe constraints in regard to the skilled work force that they can draw upon.

To access a skilled resource base, we needed to expand the market beyond a single engineering provider into a multiple engineering environment across the world. In this manner, we’re able to

CASE STuDY: SUNCOR ENERGy

11InsightSmart 3D

benefit from the best expertise from around the world rather than having to live with the constraints of a very small marketplace. That’s why we chose Intergraph SmartPlant 3D.

Worksharing was one of the primary drivers for our selection of SmartPlant 3D. During our first year of using SmartPlant 3D, the top benefit has definitely been workshare. We enjoy a real-time worksharing environment with our engineering providers in Mumbai, Charleston, Edmonton and Calgary, each working eight-hour shifts.

Data are a valuable assetOur secondary driving force in choosing SmartPlant 3D was the ability to own the asset data at the end of the project. We believe that the data represent an important asset to our actual operations. We need to control how those data are deployed and managed within our organization, so that when we’re operating this plant, we can create an effective information workflow. We are looking forward to the expected project completion in 2011 when the database turnover will certainly be a major milestone.

The other major benefit will be to our procurement system. We are looking at how we manipulate model attributes to our procurement management. The attributes describe the actual billing materials, takeoffs and implementation across to the various fabricators and manufacturing equipment. Also in the future, we plan to provide our operators with the data so that they can manage their plant in the most effective way possible.

Productivity toolsSmartPlant 3D has promoted our engineering, procurement and construction contractors’ (EPCs’) visualization. SmartPlant 3D represents a significant advancement toward achieving increased productivity. Any piping designer would rather work in a fully rendered visualization than a stick- model type design.

We have also implemented real-time piping clash mechanisms. When an individual places a component within the model, any clashing is immediately evident, rather than waiting to run a report later in the project. Sometimes our EPC will turn off the automatic clashing systems to speed processing because the models can get quite large. But the functionality does enable them

to perform one-time placement of objects without a lot of rework.

Dedication to successIntergraph has implemented many of our recom- mendations in the latest version of SmartPlant 3D. Intergraph has been very proactive in working with us to make the tool more effective through customization. One of the key things about SmartPlant 3D, as with any 3D model, is that the large amount of data and moving data around the world with limited Internet highway pipelines can become a significant issue. Intergraph has been very supportive in streamlining the design of SmartPlant 3D to eliminate data move- ments that we didn’t need.

Intergraph has also helped us with customizing Work Breakdown Structure (WBS) diagrams to pull spools or isometrics out of the model. For example, we need to be able to identify a series of pipe rack modules from, in our case, a heavily modular plant. We needed to break up those pipe rack modules into specific groups of piping isometrics. Intergraph has been very helpful in building the macros that created the dicing of the models to be able to produce that WBS so that we could actually create the isometrics we desire.

Suncor has a series of standard pipe supports that we use for all of our piping design. In fact, it’s integrated with our procurement strategies and our fabrication strategies. We use many commercially available custom pipe supports, but we commissioned Intergraph to create some specific parameterized pipe supports for us, and these are now incorporated within our database. Now when we place a pipe support, we get a Suncor pipe support with our engineering rules and intelligence built-in automatically.

Intergraph has been very supportive in helping us work through the issues that we’ve had. This has been the biggest advantage of our relationship with Intergraph.

I give kudos to the Intergraph team for their commitment to making us a success. We had some “teething problems” along the way, and I think Intergraph recognized we’ve taken a pretty big step out with the product by starting the

project in such a big way. Intergraph employees, from the very highest executive levels, have been very supportive in assisting us, in committing to support us and in making sure that we’re a success with this tool.

Building on SmartPlant EnterpriseWhen looking for a solution, we wanted software that would be reasonably familiar to engineer-ing providers, either through their training on other software tools or through actual experience with the product. We were already comfortable with using PDS. Because of the similarity between PDS and SmartPlant 3D, that made it a good fit. Of course, SmartPlant 3D has its own special characteristics.

Our future plan for SmartPlant 3D is to integrate SmartPlant P&ID and SmartPlant Instrumentation through SmartPlant Foundation. SmartPlant Foundation will enable us to manage data back to the operators. This way, not only will we be able to create the project because of workshare, but we will also be able to share those data with our operators to make them more effective in what they do.

Changing the work processI encourage other users to plan their SmartPlant 3D implementation, and plan it well. Recognize that there is a learning curve. Sometimes engineers are excited about getting a new product, but then it turns out that they don’t want to put the work into it. Remember that if you put the work into it, you’re going to get good things out of it.

you must also accept the fact that SmartPlant 3D represents a different work process. Convincing your engineering providers to change their work processes to match the input method of SmartPlant 3D takes a little effort and a little time, but it’s worth it in the end.

While traveling along the learning curve, it’s really all about implementing new processes and new ways to do things. We’re excited to see where this great adventure leads us.

Paul Crowley serves as director of engineering with Suncor Energy’s Major Projects division, and is based in Calgary, Canada.

www.suncor.com

URS’ Washington Division is currently in a process of transformation. The Washington Division, previously Washington Group International, has a rich history and consists of a number of well- known heritage companies that not only have brought extensive industry expertise to the organization, but also a variety of different business models into the fold. As a large division of an even larger company doing business on a global scale, it is critical that the Washington Division transform itself to better provide consistent, reliable services to clients worldwide, while creating efficiencies and avoiding overlap.

To align with the Washington Division’s business strategy of using a global, multi-office execution approach, the Division established a priority of standardizing work and work processes. In doing so, the Division then needed to choose the tools to make this standardization possible and

establish the plan to implement the tools. As the mode, the Division chose SmartPlant Enterprise, an integrated suite of engineering authoring tools developed by Intergraph. As the method, the Division felt the best approach to use would be one it has the most experience with, a classical “project” approach.

Project approach to implementing new technologyFor the Washington Division, implementing the SmartPlant Enterprise technology meant it could achieve its goal of standardizing processes and products, but at the same time, the change in process would impact the work of multiple offices and thousands of employees. It was determined that a well-thought-out approach would be cru-cial to ensure efficient and successful execution, as well as acceptance by those impacted. The Washington Division chose to use a “project”

approach, modeled after how it approaches proj-

ects for external clients. The approach included

detailed steps to test, configure, pilot, document

and deploy the new technology platform. In

addition, the approach would ensure executive-

level support, alignment with business drivers,

a focused scope and a schedule with adequate

time for completion, plus it would provide an

estimated cost.

In this sense, implementation of SmartPlant

Enterprise was treated as any other full-service

project the Washington Division undertakes,

complete with a project team established

to ensure each step of the project plan was

adhered to and to guarantee successful results.

We’ve all heard the adage, “Plan your work,

and then work your plan.” This is nothing new

in project execution, and it is also how the

URS Washington Division’s Project Approach Delivers ResultsImplementing successful system and cultural changes by using the right tools and the right plan

n By David Collett

CASE STuDY: URS WASHINGTON DIVISION


Washington Division undertook the implemen-tation of SmartPlant Enterprise.

As part of good project management practice, a project vision was determined to maintain undeviating focus and direction. The vision was to transform the Washington Division into a one-way global engineering organization and help its business units succeed with a more efficient, cost-effective business model. Using the project approach helped smooth the way for change with the Division’s project community, giving them con-fidence implementation would be handled with rigorous diligence and attention to detail. A project approach is seen to be one that delivers results.

The project team was initially located in Huntsville, which allowed the team to fully focus on its efforts and have direct access to Intergraph staff at its corporate headquarters. This meant the project team could resolve issues immediately and more thoroughly assess, validate and test the new

technology platform, ensuring it would deliver

the benefits as promised. To further establish the

project team culture, a team logo was created and

to kick off the project, a team-building and align-

ment workshop was held.

In the beginning, the Washington Division also set

project baselines for performance management,

including scope, schedule and cost (budgeted cost

of work scheduled). During the project, detailed

monthly project reviews were conducted, as well

as monthly estimate at completion forecast-

ing based on trends, and quarterly forecasting

based on detailed estimating. Formal change

control was applied to help prevent scope creep

and to add bona fide new scope.

Finally, reporting was conducted at

both the project and executive levels to

ensure executive support.

Using SmartPlant Enterprise for standardizationOne of the key business drivers for the Washington Division’s implementation of SmartPlant Enterprise was standardization. Efficient, multi-office execution can only be successful where standard work processes are applied. Secondly, the integration and enabling of discipline and multi-discipline processes were major priorities that would help the Washington Division more effectively utilize global resources. This was accomplished by closely coupling the SmartPlant team with the global engineering leadership team that was simultaneously tasked with standardizing discipline and multi-discipline work processes. In essence, the configuration of SmartPlant Enterprise was a catalyst for the parallel standardization efforts. Consequentially and finally, standardization and the reduction of overlap would help keep the Washington Division competitive in an industry experienc-ing shortages of people trained in certain technical fields.

SmartPlant Enterprise supports management initiatives for quality and standardization. The technology can integrate and enable various disciplines in a single platform and give the Washington Division a data-centric approach with enhanced quality and efficiency through integration. The SmartPlant architecture is specifi-cally designed to enable multi-office execution. This enables the leveraging of our global resource base through standard processes and tools.

Focus first on outputs, functionality and work processTo configure the effort and set the required bar for success, the Washington Division’s project approach focused on outputs, required function-ality and supporting work processes.

The core focus for defining the scope of the proj-ect was on outputs. The goal was to make sure the Washington Division could continue its business, and its business is focused on generating outputs. For this reason, it was essential to create outputs in an efficient, consistent and standardized way.

SmartPlant Enterprise comes with basic function-ality that requires users to configure to coding, naming and numbering conventions in addition

13Insight

to symbols, drawing and document formats. By incorporating this technology, the Washington Division was able to meld its various methods into the SmartPlant configuration and create standard outputs that still allow for flexibility to accommodate client-specific requirements. A functional requirements specification became the checklist against which a readiness analysis was conducted. This specification was essentially comprised of existing tool functionality as a minimum to help assure that vital business functions were not disrupted.

As standards were coalesced into a single stan-dard with business unit and client flexibility, work processes were also assessed for consistency with SmartPlant. Initially the tools were config-ured to meet our existing work processes. When piloting was completed, work processes were adjusted with prime focus on the integration of P&ID and instrument design. As the Washington Division is now moving through the early stages of deployment on live projects, even more adjustment is being made to the work process to attempt to extract more efficiency based upon tool and integration functionality.

Communication key to culture changeThe Washington Division felt communication was one of the most important aspects of making the technology implementation a success. By creating an open and regular discussion, with input to and from a diverse and varied audience, the Division was better able to achieve employee buy-in and

ownership. Because a large number of people would be affected and employees would have to change the way they work, it was important to be sensitive to the issues and communicate effectively to help avoid resistance to the changes, which could have caused delay and/or failure. Instead, it was the Washington Division’s goal to make employees feel empowered and part of the new initiative.

The perception of what change brings with a one-of-a-kind project can be difficult to address. So the Washington Division employed a two-way communication strategy using a variety of communication tools, including:n Meetingsn Monthly reportsn Articles in company magazinesn Presentationsn Business unit project manager focus groups.

Now as deployment is in progress, communication with the projects is taking the prime focus, both in terms of training, as well as familiarization presentations with the project management teams to establish and reinforce expectations for what changes may be required from previous methods to fully take advantage of the SmartPlant platform.

Deployment statusThe Washington Division chose to start with a single project to ensure the platform was ready for production, as well as to ensure the appropri-ate support was in place and to build confidence

in the tools and processes. After positive results

and feedback, the Division moved on to addi-

tional projects. It has started implementation of

five projects under the new configuration, begin-

ning with the first project now underway.

The SmartPlant Enterprise tools currently in use

are SmartPlant 3D, SmartPlant P&ID, SmartPlant

Instrumentation and SmartPlant Foundation. Other

tools, such as SmartPlant Electrical, are still being

configured and are in a pilot stage. In order to main-

tain a successful implementation, the Washington

Division has been cautious and tries not to deploy

more broadly or quickly than it can support.

Feedback

Feedback from Washington Division project

teams has predominantly focused on the consis-

tency, multiple-use, and time-saving aspects of

the new technology platform. The technology has

helped enforce consistency in work processes and

output, while exposing any disconnects in

existing work processes. Integration of tools

allows for the users to enter data once and have

it available for multiple uses and users, saving

valuable time. Interfaces are consistent and

productivity tools reduce design time. In addition,

data is generated during the design, making

outputs a byproduct of the design process.

Conclusion

The Washington Division is still early in the

process of implementation of its new technology

platform, but the indications are positive. Through

meticulous planning and a focus on creating an

environment that embraces change, the Division

is looking forward to seeing great results from

its transformation, while continuing to be a

leader in global, multi-office capabilities for its

clients worldwide.

David Collett is a senior project director at

URS’ Washington Division. He is based in

Boise, Idaho, U.S.

www.urscorp.com

photos in this article are from stock sources.

CASE STuDY: URS WASHINGTON DIVISION


Genpro Engenharia SA is a Brazilian company

offering consulting and engineering services for

the oil and gas, petrochemical, chemical, mining,

steel, pulp and paper, manufacturing, pharma-

ceutical, cosmetics and food industries. With

more than 500 employees, Genpro operates

throughout Brazil and boasts many clients who

are leaders in their respective industries.

To meet its customers’ expectations, Genpro must deliver complex process plant and engineering projects on time and within budget. Previously with PDS, training, correcting generated draw-ings and creating reports and customization were consuming too much time. Conversion to SmartPlant Enterprise was accomplished quickly due to the easy-to-learn and use solutions.

Once Genpro implemented SmartPlant Enterprise, its engineers were able to more quickly customize and extract information and produce reports which accelerated their project. As a result, Genpro was able to complete its pilot industrial plant project in just one year while gaining important new efficiencies for future projects.

Choosing SmartPlant 3DWhen Genpro had an opportunity to deliver and complete a project from initial design to commis-sioning and start-up for a polypropylene plant, the company reviewed its options for the solu-tion to use. There were several major factors that influenced its course of action:

n The software should come from a qualified, worldwide company

n The software should have a good interface

n The software should provide time savings over current methods.

Genpro evaluated its alternatives and ulti-mately chose Intergraph SmartPlant Enterprise for this project. As an existing Intergraph PDS customer, Genpro implemented SmartPlant 3D, SmartPlant Instrumentation and SmartPlant P&ID as well as third-party software for archi-tectural and steel modeling.

Fast implementationThe integration of the third-party software for steel and architectural models worked smoothly and issue-free. Because of the time and work involved in implementing, customizing and

training users on Intergraph’s new software,

Genpro decided to use its existing systems for

steel and architectural model design.

Intergraph and SISGRAPH, its Brazilian distribu-

tor, assembled a task force to work with Genpro

to tackle any issues that arose, find the solutions,

and solve them in a timely manner without sac-

rificing quality of work. The training process for

SmartPlant 3D took three months. Within just

a week, SmartPlant Instrumentation users and

administrators became operational. And training

for SmartPlant P&ID was completed in three weeks.

No data migration was involved, but product

customization was easily completed for the

SmartPlant Enterprise products in three weeks.

Customization included catalogs and symbols

for SmartPlant Instrumentation. SmartPlant 3D

customization involved piping and electrical/

instrumentation catalogs and the imported third-

party models for architecture and steel modeling.

Time and cost savings

All in all, there were more than 150 people involved

in the project who directly or indirectly contributed

to its success. Genpro estimates that in compari-

son to previous projects, SmartPlant P&ID saved

80 percent and SmartPlant Instrumentation saved

20 percent in time and cost. Genpro received an

Icon Award at Intergraph 2008 in recognition of

these significant accomplishments.

Waldir Pimentel Junior is a systems engineer

at Genpro Engenharia SA and is based in São

Paulo, Brazil.

www.genpro.com.br

CASE STuDY: GENPRO ENGENHARIA

15InsightSmart 3D

SmartPlant Enterprise Promotes Complete Design WorkflowSmartPlant 3D delivers significant time and cost savings

n By Waldir Pimentel Junior

16 Insight

Intergraph Ranked No. 1 Worldwide 3D Design and Process Engineering Tools ProviderARC Advisory Group research reveals value customers derive from SmartPlant Enterprise

Ph.D., senior analyst with ARC Advisory Group and the author of the PET study. “In addition, Intergraph’s integrated life cycle solutions pre-serve and leverage knowledge reuse through all stages of the asset.”

Gerhard Sallinger, Intergraph Process, Power & Marine president, said, “The results of ARC’s PET global market study validates why our custom-ers have rapidly adopted SmartPlant Enterprise across 3D design and the other engineering disciplines. They experience a quick return on their investments, increased productivity and streamlined operations resulting in shortened project timelines, all of which gives them a com-petitive edge that is so important particularly in challenging economic times.”

Intergraph’s SmartPlant Enterprise offers a pow-erful portfolio of next-generation, best-in-class plant automation solutions that leverage critical project information and knowledge to improve and automate work processes, from the very early project phases through plant operations

Intergraph has been ranked the No. 1 overall worldwide leader in the engineering design 3D software and Process Engineering Tools (PET) market according to the 2009 PET Worldwide Outlook Market Analysis and Forecast through 2013 by the ARC Advisory Group.

The report provides an in-depth analysis of the worldwide PET market for engineering software used in workflow practices and data manage-ment for designing, building, operating and maintaining process plants. The tools and appli-cations covered in the PET study include a large portion of those necessary to manage engineer-ing activities that create or use engineering data throughout the life cycle of a plant.

As the overall PET leader, Intergraph was ranked first in key global regions and process industries as well as functionalities such as 3D engineering design.

“Intergraph offers a large and comprehensive portfolio of products that provide users with a compelling value proposition,” said Tom Fiske,

and maintenance up to decommissioning. For most projects, SmartPlant Enterprise improves plant engineering efficiency by up to 30 percent.

Over the past two decades, ARC Advisory Group has become the leader in providing in-depth and accurate market intelligence for the industrial automation marketplace. ARC consultants fol-low technology and industry events on a daily basis and use a five-step approach to conduct market research, providing a solid framework to formulate meaningful strategies for their clients. This approach is proven and is designed specifi-cally to conduct global market research for the industrial automation marketplace.

www.arcweb.com

INDuSTRY ANALYST pERSpECTIvE: ARC ADVISORy GROUP


17Insight

The process engineering tools (PET) market consists of two major segments of products that play a critical role in the design, creation, commissioning and operations of plants and assets. The engineering design applications are used for the physical plant layout. The process simulation and optimization software includes tools used for conceptual and process design, as well as tools used for process mod-eling and off-line optimization.

During the past several years, the use of PET expanded rapidly as favorable economic conditions and high demand drove capacity expansion projects around the world. The onset of the financial crisis in the latter part

of 2008 slowed down new capital projects. However, not all industry sectors or regions are affected to the same degree. Many capital projects are still ongoing, so the investments in PET continue. In addition, as the recession reaches global proportions, the market dy-namics present new challenges and additional PET requirements for O/Os and EPCs.

Collaboration, efficiency and cost savingsWhile some areas such as the Middle East and China continue to build new plants and assets, other parts of the world, such as North America and Western Europe, have different priorities. Manufacturers in these regions are dealing with:

n Tight credit marketsn Few growth opportunitiesn Intensifying global competitionn Stricter governmental regulationsn Volatile raw material and energy costsn Fewer technical resources.

Companies in these regions are going back to

basics and trying to improve their cost structure.

Getting the most out of human and physical

assets is a major challenge for O/Os and EPCs

as they try to improve engineering and opera-

tional performance. To improve engineering

efficiency, companies want to shorten the en-

tire design cycle through concurrent and

Process Engineering Tools Drive Efficiency ImprovementsTechnology investment can shorten the design cycle and improve engineering collaboration

n By Tom Fiske, Ph.D.


Smart 3D

18 Insight

collaborative methods. To improve operational performance, companies need more efficient, environmentally friendly and agile assets along with the necessary design information to operate and maintain them.

During the past several years, there has been a trend to use every available resource to com-plete projects on time and budget. This means more partnering projects, both internally and externally. There is a growing need for smaller companies to assist larger ones and take on some of the engineering design work. Con-sequently, the project work is getting more fragmented and distributed – and more chal-lenging to manage.

To better deal with the growing complexity of project work, many companies are investing in highly sophisticated design, engineering and collaborative tools to obtain greater efficiency of their valuable resources. Companies use dif-ferent tool sets on projects, but they still need to work together. Additionally, many owners require data handover in a format that is use-ful for operational and maintenance purposes. This is driving the growth of collaboration and data management tools.

As-built informationThere are many risks associated with plant design and construction. The risks are even greater for brownfield engineering projects where existing structures often clash with proposed changes. Many existing plants do not have accurate as-built information about their facilities to ensure error-free project execution. With the advent of affordable la-

ser scanning, the process plant engineering industry has quickly embraced the technology as a means to obtain detailed as-built status of existing facilities.

Laser scan data can generate a photorealistic 3D model of a plant with accurate dimen-sional information. The focus on capturing as-built engineering data and CAD modeling for existing facilities reduces risks and enables the completion of more projects on time and within budget. Laser scanning and 3D plant models have the potential to become standard

procedures in brownfield engineering during the next several years.

Laser scanning models are useful for brownfield retrofits and revamps, as well as for operations. As-built models from laser scanning are finding use as asset manage-ment programs. The models are integrated with other applications for plant maintenance, operations, training, etc., and extend the value of asset data to everyone within the plant.

Design for sustainabilityWith growing concerns about climate change and other environmental damage, companies are adopting sustainability programs. To many, sustainability has come to mean “green” or environmentally friendly. However, sustain-ability has a much broader and far-reaching meaning. The sustainability business model encompasses the ability to operate indefinite-ly, while delivering economic benefits and be-ing socially and environmentally responsible.

To address the challenge of sustainability, companies are investing in new production assets along with new production manage-ment and asset management applications.

The primary Asset Life Cycle management Business processes

To better deal with the growing complexity of

project work, many companies are investing in

highly sophisticated design, engineering and

collaborative tools to obtain greater efficiency of

their valuable resources.



19Insight

For most companies, sustainability makes sense for a number of reasons that go beyond the obvious environmental benefits. Sustain-ability helps companies to better deal with volatile raw material and energy costs. It also helps them to reduce waste and comply with increasingly more stringent environmental regulations. In addition, companies want to improve design efficiency and overall opera-tions to achieve a greater return on assets. They expect improved designs to also extend the operational phase of their assets.

Improving asset life cycle managementThe cost of poor interoperability across the complete design, build and operate value chain has been estimated to be US$15.8 billion per year in increased capital and oper-ating expenditures. Of these costs, two-thirds are borne by owners and operators, which incur most of these costs during ongoing facil-ity operation and maintenance. This represents a loss of 1.3 percent of CAPEX in the project life cycle stages and 2.8 percent in terms of return on assets during the life cycle stages related to asset operation.

Operating companies recognize these losses and are beginning to adopt asset life cycle management strategies to improve their interoperability among systems and users. Asset life cycle management (ALM) applies to all the life cycle stages, from design and build to operate, maintain and retire. It not only

applies to the physical asset, but also to humans and virtual assets as well.

ALM is becoming a priority for manufacturing, utilities and every other enterprise where suc-cess depends upon complex equipment. Capital budget overruns and startup delays can turn excellent market opportunities into major ca-lamities. Other concerns include revenue, safety, compliance, quality and operating cost problems that arise when asset performance is less than expected.

Asset information management (AIM) is the foundation for and key enabler of excellence in every asset life cycle stage. Studies show that asset-intensive organizations suffer staggering losses each year as a result of poor AIM across plant design, build and handover. AIM issues likewise plague groups involved with facility operation and maintenance. Neglect in this area has also been linked to major safety and compliance violations that blemished corporate reputations and jeopardized their very survival.

Asset information exists in many forms and is created and used by many groups across the enterprise and plant asset supply chain. Each group feels some pain from poor AIM and most contribute to the problem. Asset O/Os suffer the most as they incur the impact this has on asset performance.

ARC’s research shows that collaboration and teamwork across all asset stakeholders are vi-

tal to ensuring good AIM. Each group needs to appreciate the impact their practices have on asset performance. In addition, all groups need to align their practices and goals to achieve optimal asset performance. Leading companies recognize this need and have im-plemented technology and programs to enable collaborative teams of stakeholders within and external to their organization.

Last wordAs the recession spreads globally, both O/Os and EPCs need to get more out of their en-gineering resources and production assets. To meet these challenges, companies now place greater emphasis on PET solutions that short-en the design cycle and improve engineering efficiency and collaboration. Additionally, many owners are requiring engineering and design data handover in a format that is useful for operational and maintenance purposes. Better ALM is the foundation for improving engineer-ing efficiency at every asset life cycle stage, as well as overall asset performance.

Reprinted with permission from ARC Insight, April 2009

issue, www.arcweb.com.

Tom Fiske, Ph.D., serves as a senior analyst with ARC Advisory Group. He is based in Ded-ham, Mass., U.S.

Smart 3D

20 Insight

Realizing the Power of IntegrationSmartPlant Enterprise helps IBERDROLA grow operations around the globe

CASE STuDY: IBERDROLA INGENIERÍA y CONSTRUCCIÓN

IBERDROLA Ingeniería y Construcción (Engineer-ing and Construction), established in 1995, has become one of the world’s leading energy engi-neering companies. With active projects in more than 25 countries and a project portfolio valued at more than US$3.3 billion, IBERDROLA is re-alizing increased activity from a strategy shift to target the creation of engineering and con-struction of power generation, distribution and control facilities.

Heavily involved in large nuclear and renewable energy projects, IBERDROLA’s services also include project management, engineering, sup-ply, construction and commissioning, turnkey projects and operational support. IBERDROLA has approximately 2,500 employees. Headquar-tered in Spain, the company has subsidiaries and branches in another 22 countries.

We specifically chose SmartPlant 3D because of its powerful global workshare and automation capabilities. fernando Torres System Manager, IBERDROLA Ingeniería y Construcción

Integration is the keyIBERDROLA began implementing Intergraph solutions in 2003, when the landscape was ripe for expanding its business into new mar-kets. The company wanted to execute interna-tional EPC projects much like the ones it had in Spain, and the challenge was to do this while saving time and money in execution in spite of the distance and geographical distribution of its international customers.

To access international markets, IBERDROLA knew it must be more competitive. And, to be more competitive, it focused on one goal – integration. IBERDROLA understood the success of an EPC project depended in large part on the integration of all the components in the project. In effect, this meant coordina-tion between all the disciplines involved in the life cycle of a power plant, from engineering to commissioning.


21Insight

Within each of its EPC projects, many groups are involved – subcontractors, engineering, procure-ment, logistics, construction and commissioning. Managing the data flow and information is criti-cal in this environment. All the groups have ac-cess to view and edit data, and with the Smart-Plant Enterprise solutions, the workflow operates smoothly and seamlessly.

The firm has also been able to avoid conflicts of information between disciplines, preventing duplication of data and guaranteeing modifica-tions are done in real-time and received across the entire workshare.

“We chose the Intergraph solutions because, as a company, it has provided us a secure imple-mentation with excellent technical support,” said Fernando Torres, system manager at IBERDROLA.

“Intergraph has helped us evolve our func-tionality toward a more user-friendly environ-ment, and we have experienced great per-formance in our engineering and 3D design efforts. We specifically chose SmartPlant 3D because of its powerful global workshare and automation capabilities.”

Standardizing on Smartplant 3DFor its initial implementation, IBERDROLA chose Intergraph’s PDS, SupportModeler, SmartPlant P&ID and SmartPlant Instrumentation for its design and engineering functions. SmartPlant Review and SmartPlant Explorer were used to access information for visualization purposes. However, for its goal of system integration, IBERDROLA decided it made no sense to start that process while it was still using PDS and SupportModeler, so it began the migration from these solutions to SmartPlant 3D, Intergraph’s next-generation, data-centric design solution.

IBERDROLA completed implementation of SmartPlant 3D in early 2008, and continued its use of PDS and SupportModeler only on proj-ects that began before then. SmartPlant 3D provided increased functionality, design speed, and better performance on power plant design projects. In the latter half of 2008, IBERDROLA began the implementation of SmartPlant Foun-dation, and in 2010, it will begin the integration with the SmartPlant Foundation project docu-ment management tool.

Products usedn SmartPlant 3Dn PDSn SupportModeler™n SmartPlant P&IDn SmartPlant Instrumentationn SmartPlant Reviewn SmartPlant Foundation

Key benefitsn Short product learning curve; reduced

design times and reuse of designs

n System integration helps to prevent con-flicts of information between disciplines

n “Environment of engineering” enables all subcontractors and partner engineering companies to work within IBERDROLA’s templates, procedures and specifications

Dual project environmentsIBERDROLA breaks down its EPC projects into two scenarios – Environment of Engineering and Project Management.

The Environment of Engineering contains almost the entire Intergraph SmartPlant En-terprise suite of solutions and its integration with SmartPlant Foundation. For IBERDROLA, the key is to keep the “know-how” within the company. This means all of the subcontractors and engineering companies work with their templates, procedures and specifications, and all the designs are made by remote access us-ing Citrix. Using the same systems, architecture and working models, everyone involved in the project will work with a common model. It is within this environment that SmartPlant Instru-mentation, SmartPlant P&ID and SmartPlant 3D are used for designing process diagrams, con-struction drawings, purchasing counts, design reviews and checking assemblies.

The Project Management environment is where IBERDROLA accesses and integrates all of the value-added products within the EPC projects. Connections to the enterprise and resource planning (ERP) system running SAP, the bill of materials system running BDU, the document

management system running SmarTeam, the planning system running Primavera, and the visualization system running SmartPlant Re-view all reside here. All are strategic disciplines in IBERDROLA’s EPC projects. For example, the integration between SmartPlant Review and Primavera empowers IBERDROLA to revise the main sequences of project construction sched-ules, correct mistakes and make improvements in the early stages of a project.

Internal group aids implementationTo help with the implementation of the Inter-graph solutions, IBERDROLA has an Architecture and Technology (ARTE) department responsible for, among other things, testing new software and configuring new products. When the prod-ucts are “developed and proven,” ARTE trains the respective business area within IBERDROLA on the new application and provides technical support, if necessary.

This methodology was quite helpful for IBERDROLA. As IBERDROLA added new prod-ucts during the software implementation pro-cess, the ARTE team received the training and then, in turn, provided it to the IBERDROLA application teams. One exception to this was for SmartPlant 3D, where the whole design application team received training together with ARTE.

To maximize software performance for the company’s implementation, some customiza-tion was required, such as adding properties to objects, creating libraries, configuring out-puts (reports, drawings, isometrics, etc.) and establishing a methodology to work with these tools for its projects. Once the custom-ization was complete, IBERDROLA quickly ex-perienced such benefits as reduced learning curves, expedited design times and the ability to reuse designs. These benefits, in turn, have resulted in increased productivity throughout the enterprise.

www.iberdrolaingenieria.es

Smart 3D

Setting the standardAlways an innovator, Chematur’s fermentation process is an industry-standard and the company is now involved with its customers in the development of bioethanol as an alternative source of fuel.

Chematur is also a long-term user of Intergraph’s plant technology solutions. According to Chematur, during the design and execution phases of a project, Intergraph technology “provides the right information to the right people at the right time.”

Chematur says that the benefits include reduced time for project completion, with no reduction in quality or safety. The level of input data is reduced by storing all design and project information in a single project database – any project and plant data and documents can then be generated from the same database.

As an organization that consistently exceeds set expectations, Chematur is eager to streamline its engineering workflow to maximize efficiency,

Chematur is a group of engineering companies operating in Sweden, Finland, Germany, the United States and India. Headquartered in Sweden, Chematur Engineering AB (CEAB) has a long and successful history of handling the complete design, delivery, construction and commissioning of specialty chemical production plants. Since 1930, more than 1,000 plants have been supplied to customers worldwide.

Chematur’s wide range of project and contracting services includes feasibility studies, project management, process development, staff training, modernization of existing plants, startup and commissioning.

The company is not only a qualified engineering contractor, but also the proprietor and holder of a number of top-ranked chemical technologies, which it licenses to customers. As a result, it usually has a detailed involvement in plant startup and operations planning.

TIC in the BoxChematur reduces total installed costs by at least 10 percent

making best use of its high-value engineering facilities while maintaining full project control.

SmartPlant EnterpriseThe company is taking on the latest generation of Intergraph plant design and information management technology with the implemen-tation of Intergraph’s SmartPlant Enterprise solution, beginning with SmartPlant 3D and SmartPlant Foundation.

SmartPlant 3D is currently in use on six Chematur projects worldwide, with full worksharing between engineers in Sweden, Poland and India. SmartPlant P&ID is also in place, with SmartPlant Instrumentation scheduled for implementation soon.

Working smarter“The technology provides us with valuable functionality,” says Hakan Andersson, an engineering manager at Chematur. “It is database-centric and rule-based, both of which have a big impact on engineering, flexibility and productivity, and

CASE STuDY: CHEMATUR ENGINEERING AB


it enables full worksharing. It also allows us to continue to make use of our investment in our legacy data.”

According to Andersson, better design quality is another benefit, with less engineering rework and on-site changes needed, and the ability to produce better plant design drawings faster.

Construction and installation data can be gen-erated more quickly, too. “An earlier construction kickoff means we can start the plant up earlier for the customer,” Andersson says.

Plant paybackIn all of its chosen markets, Chematur expects that having faster, more reliable access to project data and the ability to perform concurrent engineering and reuse data will reduce engineering labor hours by 20 percent.

Having more accurate and consistent data should cut on-site rework by 10 to 15 percent, according to Chematur calculations.

Innovative Technologies CEAB has developed and acquired rights to many world-leading technologies in its target markets, including:

n Isocyanates

n Nitroaromatics

n Evaporation and crystallization

n Bioethanol, BIOSTIL®

n Hydrogen peroxide

n Explosives and propellants

n Nitric acid

n Supercritical fluids

n Fertilizers

n Acid Concentration and Recovery System

And the bottom line?

“We expect to reduce the total installed cost of the plant by 10 percent plus,” says Andersson.

Asian outlookChematur’s business in Asia – particularly China – is increasing rapidly. For a company that is used to deploying and controlling key technologies that add value for the industries it serves, the world’s fastest growing market offers unique opportunities.

“We do feel that plant life cycle standards are there to be set,” Andersson observes. “China wishes to embrace the best, but it is also a highly competitive market.

“We will succeed by working smarter – using plant information technology to deliver projects more quickly, at lower cost.”

www.chematur.se

What is SmartPlant Enterprise?ScalabilityIntergraph’s SmartPlant Enterprise solution offers a powerful portfolio of best-in-class applications, which may be deployed individually or as a flexible, integrated enterprise solution – allowing an organization to successfully unleash the untapped value that is often restricted by silo-centric communication and execution. This modular architecture provides scalability, enabling clients to start small and later grow in harmony with their specific business needs to create substantial return on investment while reducing risk.

Integration across the workflowSmartPlant Enterprise leverages success-critical project information and knowledge to improve and automate work processes, from the very early project phases through operations and maintenance up to decommissioning, significantly and measurably improving engineering efficiency throughout the project life cycle.

The technology provides us with valuable functionality. It is database-centric

and rule-based, both of which have a big impact on engineering, flexibility

and productivity, and it enables full worksharing.

23InsightSmart 3D

24 Insight


24 Insight

Here at Grenland Group, we have developed an

in-house BIG utility. BIG is the common plat-

form on which we perform almost all of our 3D

automation. The name BIG was chosen because

it provides a big picture of what we do.

After attending an Intergraph SmartPlant 3D

Automation course in 2008, we wrote sev-

eral automation applications, all based on

BIG, covering diverse areas such as drawing

view styles, reports and piping progress.

These applications have given us tremendous

productivity benefits. By displaying data from

the 3D model in a spreadsheet-like browser,

we can sort, filter and select objects quickly

based on the data presented in the list.

For example, all objects that have been modi-fied by a certain user can be selected by simply double-clicking on the user’s name. Achieving the same results without BIG would take much longer and involve creating a special filter – something many users would find difficult.

foundation for building applicationsWe now have control over an interface where groups of objects’ properties are listed. This gave us the ability to create new applications.

We also have full control within these new applications. This enables users to perform previously out-of-bounds tasks, such as special view-style creation.

Filter and XML file creation are managed automatically. Users don’t have to worry about

making mistakes. Administrators don’t have to

worry about their standard viewstyles getting

messed up.

Dramatic time savingsOur most advanced application came about

when our “money guys” started asking ques-

tions about how things were going in our proj-

ects. Apart from making a pretty good guess,

we were pretty certain that it would be possible

to create an application to measure design

progress in piping using reports and some sort

of macro to format the data.

But we already had a platform that could pro-

vide the answers – and quickly. Using BIG and

some custom commands from the SmartPlant

3D tool kit, we were able to provide a graphical

Grenland Group Advances Productivity with SmartPlant 3D AutomationEPC provides customization training course for Scandinavian 3D Technical User Forum members

n By Darren Litherland

CASE STuDY: GRENLAND GROUP

From left to right: Terje Ørbeck (Grenland Group), Darren Litherland (Grenland Group), Knut Meland (Intergraph), Ivan Randbye (Grenland Group), Pierre Fransson (ÅFConsult), Katarina Gustavsson (Chematur Engineering AB) and Jonas Wedin (Chematur Engineering AB).


25Insight 25InsightSmart 3D

representation of the progress of piping layout and design in only a few days. This was much quicker than if we had used reporting.

Encouragement to go furtherTo share our success story, we performed dem-onstrations of our BIG system at two Intergraph Scandinavian 3D Technical User Forum (TUF) meetings in 2009. In gathering feedback from my fellow TUF members, I learned that many of them were interested in this technology and applying it in their own businesses.

We knew this was a valuable opportunity, but were not sure how to proceed. At first, we thought we had three options:

n Offer the software as a commercial productn Give it away for freen Make it available as open-software.

After weighing the pros and cons, we came up with a fourth option: to provide the know-how behind the BIG technology so others could develop their own versions. We decided to conduct a course in SmartPlant 3D auto-mation with Microsoft Visual Basic® for the Scandinavian Technical User Forum. We think this offers several benefits, because the class:

n Provides a base on which Scandinavian com-panies can easily build their own applications

n Increases Scandinavian companies’ knowl-edge of SmartPlant 3D automation

n Promotes activity in the Scandinavian 3D TUF.

Trial runWe first put together a three-day training course for our own staff, made up of admin-istrators and super-users. The administrators had previously attended Intergraph’s own automation course a year earlier, but had not had the opportunity to practice afterward. The super-users had experience with Visual Basic, varying from minor spreadsheet customization to advanced programming.

The class reviewed the primary elements of Visual Basic 6.0 in the SmartPlant 3D framework and how to extract data from the 3D model using ready-written, modular code. All five students were soon able to create their own browser, search for particular objects and find them in the model.

Rounding off their class with an exam, the students had to successfully complete their choice of two tasks from the following options:

n Add double-clicking functionality that auto-matically selects objects with the same name

n Create a command that writes Microsoft Excel® data into the browser

n Add three or four new object attributes to the browser using at least one new interface

n Create a command that hides selected objectsn Create a command that adds the different

values of a particular attribute to a func-tional ComboBox

n Make their existing command buttons that depend on selected objects be displayed as “grayed-out” command buttons when there are no selected objects

n Create a command that makes the highlighted objects flash.

Good responseWith the experience gained from the in-house training course, we were confident enough to

offer it to the user community in Scandinavia. We were pleased with the response. Five peo-ple from four companies, including Intergraph, accepted our invitation.

Based on user suggestions and simplification, we were able to condense the course into a two-day schedule with theory and labs on the first day, fol-lowed by a full day dedicated to the exam tasks.

It was clear from the start that the students were very enthusiastic. They all knew what they wanted to do with the knowledge they hoped to gain and the code that they would be able to take home with them. With this kind of attitude, it made my teaching role quite enjoyable. The positive learning atmosphere was also evident during the networking time, which included a special dinner held by the Sandefjord harbor.

positive resultsWith the required exam tasks completed success-fully on day two, all of the students seemed happy with their results and our efforts. Jonas Wedin from Chematur AB in Sweden said, “I thought the course content was very good and liked not having a constant flow of information and that we were given challenges to solve ourselves.”

Considering the fact that the students had no prior experience with automation in SmartPlant 3D and that they could now create their own applications, everyone agreed the course had been a great success. “On my next Intergraph project, I’ll use what I learned during the training,” said Pierre Fransson, programmer at ÅFConsult in Sweden.

If there is sufficient interest, we hope to offer the course again soon. We are also looking into the possibility of offering a second-level course with more emphasis on application develop-ment based on BIG.

Wedin said, “I tried my program when I got back to the office and was, naturally, very pleased when it worked!”

Darren Litherland serves as SmartPlant 3D ad-ministrator at Grenland Group. He is based in Sandefjord, Norway.

www.grenlandgroup.com

SmartPlant 3D automation training tipsn Keep it simple

n you don’t always need to knowhow all things work

n Focus on what to use, when to useit and where to find it

n Extensively use cut-and-paste functionality to save time and reduce syntax errors

n Be open to new ideas and improvements

n Emphasize labs and tasks thatstimulate creativity

26 Insight

At C&I Engineering, we feel that adopting new technology gives us a competitive edge. For this and several other reasons, we recently chose to implement SmartPlant 3D and SmartPlant Review.

Projects designed using SmartPlant 3D have resulted in a very low percentage of rework and a higher degree of accuracy. Over time, we expect our efficiencies to increase drastically.

Plus, global workshare enables us to replicate our database to other sites or field offices and leverage our staff in field offices. This helps us accomplish more work with the same amount of resources.

Doing more with lessC&I Engineering has worked with Intergraph for more than 20 years. Until recently, we used PDS for design tasks. We had to rely on outside contractors to help staff up large PDS projects. Contractors’ rates have increased over the years. This made it very difficult to recruit qualified designers based on market demands. We wanted

to find ways to accomplish more work without the level of additional expense.

To streamline our work processes, we knew we needed to automate as much of the design as possible. We evaluated the products avail-able on the market and the technology behind them, and felt Intergraph had better products based on our previous experience with the solutions, not to mention the company’s excellent customer service.

We believed that with SmartPlant 3D, we could train our designers much more quickly and they would become more productive than they had been with PDS. SmartPlant 3D would help us remain competitive while striving to be the leader in technology usage.

We decided to implement SmartPlant 3D and SmartPlant Review. This decision was based on the ability to train many project teams from various disciplines and have them up and running with a small learning curve as compared to PDS.

SmartPlant Enterprise also gives us a modular path for growth. We felt SmartPlant 3D would allow us to expand our company’s capabilities with other solutions as our business case warranted. In the future, we plan to introduce SmartPlant P&ID and become fully integrated with the entire suite of SmartPlant Enterprise products.

Creating a smooth workflowWe currently have several trained teams of piping and civil designers who work and coordinate their 3D designs using SmartPlant 3D and SmartPlant Review. Coordinating the 3D environment between civil, piping and other disciplines results in a more efficient and streamlined workflow. On subsequent projects, we anticipate noticeable results in the benefits between SmartPlant 3D

and PDS.

Smartplant Review productivityAll of our workgroups have been trained to coordinate and review the designs using SmartPlant Review. We use SmartPlant Review

Shortening the Learning CurveTransitioning from PDS to SmartPlant 3D and SmartPlant Review speeds time to productivity

n By Rich Vance

CASE STuDY: C&I ENGINEERING


27Insight

About C&I Engineering

C&I Engineering, established in 1983, is a full-service, employee-owned fi rm provid-ing engineering, procurement and total project management services. Nationally recognized for its refi ning capabilities, C&I has more than 25 years of experience in the refi ning, chemical, industrial, and food and beverage industries. With 345 employees, it is Kentucky’s largest engineering, procure-ment and construction management fi rm. C&I recently ranked 18th in ENR Magazine’s list of the leading engineering providers for refi neries and petrochemical plants.

to perform 3D walkthroughs, design reviews and client presentations.

The ability to view the completed project in a 3D environment has proven very benefi cial for engineering, construction and our clients.

Smartplant 3D interfacesOne of the benefi ts we have experienced is the ability to interface with third-party software for stress analysis and clash detection. We currently integrate SmartPlant 3D with CAESAR and LFM

point cloud software:

n CAESAR integration – The piping discipline has developed a solid workfl ow that will allow our designers to export pipelines to PCF fi les which can then be imported into pipe stress analysis programs. This enables us to reduce the time and effort required to export the stress requirements from the 3D design to the stress analysis application.

n fm integration – We can merge our 3D designs with the point cloud data, visually manage clash detection of the existing conditions with the new design and establish tie-ins to existing systems and processes.

Implementation and customizationWe have used Intergraph’s implementation services during our initial setup and confi guration and when we have upgraded to major releases.

We used SmartPlant 3D out-of-the-box, as delivered, for approximately six months. As we have gained experience, we have started to customize the software as needed. With the help of Intergraph, we have already created many customized:n Reportsn Labelsn Rulesn Drawing styles and formatsn Parts.

When we bring on new projects, we benefi t from our previous experiences and are able to implement more customization to those projects. Adding the ability to customize to the already powerful software provides us an endless array of options.

piping specifi cationsWe contracted our piping specifi cations out to

Intergraph developers, although those services will be handled in-house on future projects. Production projects are generally started using out-of-the-box delivered piping specifi cations. We then convert the pipeline over to the project specifi cations once delivered and loaded and the placement check is completed.

Having the expertise to create your own piping specifi cations will save lots of time and effort on the projects and allow more control of the specifi cations’ output and consistency.

However, not having piping specifi cations should not delay the start of a project. We were able to use the delivered specifi cations to get started and convert them to the SmartPlant 3D production specifi cations in a timely and organized manner.

TrainingFor our initial implementation, a team of civil designers and engineers as well as a team of piping designers underwent SmartPlant 3D training. We also trained engineers and designers from other disciplines on how to effectively use SmartPlant Review. This would allow team members not trained in 3D to monitor and coordinate the design using the 3D environment.

The project teams were trained in-house using the SmartPlant 3D Virtual Training services and by attending classes at Intergraph’s headquarters in Huntsville, Alabama. Each class consisted of approximately 40 hours of hands-on training.

Our administrators began training approximately two years ago and were able to use the SmartPlant 3D Virtual Training Web site to maintain their skills until they were awarded their fi rst SmartPlant 3D project. Having other trained personnel available in-house proved very benefi cial if there were questions about the software or specifi c commands.

Approximately two weeks after training, the users were expected to be productive. We made sure that the newly trained teams had immediate access to other, more experienced users for questions and met on a weekly basis with all users to discuss tips and tricks with the team.

For other companies that want to implement SmartPlant 3D, we believe it is worth the time and effort to get the system up and running as soon as schedules allow. Because the training and use of the software is somewhat easier than

with PDS, it might surprise companies how soon designers can be up-to-speed and productive.

ImplementationThe initial drawing and reports setup took patience. Once we got those confi gurations in place, we found that the experience and the setup we have put into place will benefi t future projects tremendously.

We were a PDS fi rm for more than 17 years before making the switch to SmartPlant 3D. Now, a little more than two years later, we feel we are more advanced with our SmartPlant 3D setup than with the PDS system.

Of course, we had moments when we struggled, but kept going until each issue was resolved. When we encountered problems we could not resolve internally, we would fi le a service request with Intergraph’s help desk. Fortunately, response times from Intergraph have been outstanding and along the way we have developed many relationships with those analysts who have helped us become successful.

Rich Vance serves as manager of marketing and sales at C&I Engineering. He is based in Louisville, Kentucky, U.S.

www.cieng.com

Smart 3D

De Smet S.A. Engineers & Contractors (DSEC) works with turnkey projects throughout the world involving the alternative fuel industry. With 150 employees, Belgium-based DSEC holds a project portfolio of about US$600 million.

The engineering company serves two primary markets: the sugar and bioethanol industry and the edible oil and biodiesel industry. For the sugar and bioethanol industry, DSEC performs its own process detail engineering.

With the growing demand for alternative fuels, DSEC faces the challenge of completing turnkey projects in a limited amount of time and with a pre-defined budget. That requires flexibility and precise planning.

To reduce erection costs and construction time, piping work is pre-assembled. The assembly work is sometimes completed at great distance from the actual plant site.

To meet these challenges, DSEC selected the SmartPlant Enterprise portfolio of solutions.

“We felt that with Intergraph, we could benefit from efficient and responsive technical support for software implementation,” said Bernard Nokerman, project manager for DSEC. “We were also very interested in the integration of SmartPlant 3D with SmartPlant P&ID.”

Boosting productivityDSEC selected several products from the SmartPlant Enterprise suite for their project needs, including:n SmartPlant 3D n SmartPlant P&IDn SmartPlant Basic Integratorn SmartPlant Reviewn SmartPlant Explorer.

The company’s primary objective was to im-prove productivity using software that was easy to use and that could easily import data from

subcontractors. DSEC wanted reliable software that would be supported in the future. The ability to share the software outside DSEC’s main office was also important.

DSEC implemented SmartPlant P&ID four years ago to use for schematics. That was followed by the implementation of SmartPlant 3D to improve productivity and offer the ability to integrate with third-party products.

SmartPlant P&ID is knowledge-driven engineering software for creating intelligent piping and instrumentation diagrams (P&IDs). SmartPlant 3D is a complementary, full-suite solution that provides all of the capabilities needed to design a plant, and then keep it as-built throughout its life cycle.

Why Intergraph?Using SmartPlant Enterprise, DSEC manages several projects currently in production, includ-ing about 650 pieces of equipment and 3,500

With Growing Demand for Alternative Fuels, De Smet Engineers & Contractors Looks to Intergraph SolutionsSmartPlant Enterprise improves EPC’s productivity, worksharing and dependability

n By Wayne Smith

CASE STuDY: DE SMET ENGINEERS & CONTRACTORS


pipelines distributed among 15 main process buildings. All implemented licenses are used on a daily basis and distributed concurrently.

Nokerman said the main reasons for choosingIntergraph solutions were:n The ability to seamlessly integrate data between

SmartPlant P&ID and SmartPlant 3Dn Importing and exporting documents in common

formats (SAT, DWG, XLS)n Quality of technical supportn Ease of training.

Intergraph solutions are commonly used for DSEC tasks related to structure, equipment, piping and drawings for these integrations. SmartPlant P&ID is mainly used in the produc-tion process for schematics and the output of equipment lists. SmartPlant 3D is used in DSEC’s production, as well as for new project evaluation and quotations.

Nokerman said it is too early to have measur-able results of how the Intergraph solutions have benefited the company because they are still in the learning curve process. But he is con-fident the company will meet its objectives in terms of productivity improvements.

“In the future, we expect faster startup on proj-ects based on currently developed backgrounds, including equipment models, specifications and working procedures,” Nokerman said.

ImplementationOnce DSEC was ready to begin the implemen-tation process, it looked to Intergraph services. Intergraph France was closely involved in the startup process, including training and piping specification creation.

No data migration was required since DSEC started on a clean slate. Internal knowledge was used for data development, with only a few subcontractors’ models directly imported.

The time it took to begin initial production with Intergraph software was very brief. DSEC wanted to get started with projects quickly, so the software was used out-of-the-box without any customization.

“Employee training was completed in a matter of days instead of weeks,” said Nokerman.

Nokerman also said that the company had strong assistance from Intergraph personnel who per-formed training and setup. “The Intergraph team showed superior knowledge and their quick re-sponse time always surpassed our expectations.”

For the futureDSEC plans to evaluate SmartPlant Instrumen-tation for future usage. Depending on its work-load, the company may also expand the number of users.

“We expect to use SmartPlant Enterprise’s worksharing capabilities where needed,” said Nokerman. “The next step for us will be to improve and set up the collaboration process between our civil works and structural depart-ments and related external engineering subcon-tractors with a relay to the workshops.”

With DSEC expecting to meet its objectives using Intergraph solutions, Nokerman said companies in similar situations should consider working with Intergraph to solve their own production problems.

“Independent of software implementation and user training,” said Nokerman, “it is very valuable to invest in a well thought-out setup of working procedures in collaboration with Intergraph experts.”

Wayne Smith is a contributing editor for Insight and is based in Huntsville, Alabama, U.S.

Employee training was completed in a matter of

days instead of weeks.

Bernard Nokerman Project Manager, DSEC

About De Smet Engineers & Contractors

DSEC is a general contracting company focused in the agro-industrial field. Its activity is concentrated on in-house know-how, such as expertise for the sug-ar industry, and on technologies owned by its affiliated companies or available through cooperation agreements.

This is particularly effective in the edible oil and biodiesel sectors in which Desmet Ballestra and its worldwide network are DSEC’s key partners for the implementa-tion of complete crushing, refining and biodiesel production facilities.

DSEC is now making its general-contract-ing know-how available in other fields, including bio-energy, environment and agro-chemical sectors. It has recently be-gun diversification into technically driven niche markets in the chemical industry.

DSEC’s business activity is oriented to-ward auxiliary sections for processing plants. Raw material and finished product storage, handling, packaging and utilities are usually included in its contracts.

Site construction operations, such as civil engineering works and installations, rep-resent the most important non-process discipline that DSEC is capable of con-tributing to a complete project. DSEC’s management skills can also be used in operations outside its core business by acquiring the required technologies from expert companies through carefully es-tablished agreements, ensuring complete security for the end user.

From initial studies to post-commis-sioning training, DSEC can successfully complete large greenfield projects up to turnkey, all within the contract’s budget and time schedule.

www.dsengineers.com

29InsightSmart 3D

30 Insight


30 Insight

The latest releases of SmartPlant 3D and SmartMarine 3D (collectively known as Smart 3D) continue the products’ positions as the first and only next-generation 3D design solutions for the process, power and marine industries. Smart 3D technology delivers approximately 30 percent more productivity than any other system available today.

More than 300 plant, ship and offshore providers worldwide use Intergraph’s Smart 3D technology in production. Key components of the Smart 3D technology architecture include rules, relation-ships and automation.

Knowledge management and design reuseThe latest release of Smart 3D leverages its data-centric architecture to deliver the next generation in knowledge management solu-tions. One of the most powerful of these is the Model Data Reuse (MDR) command which enables intelligent replication of extensive

portions of model data into another location in the same model or into a different model entirely. MDR is not merely a sophisticated copy and paste command. The newly generated data reflects the result of Smart 3D’s rules. Launched and controlled via a wizard, the MDR command is easily configured and simple to use.

Unique, properly formatted names are assigned to all first-class business objects. Likewise, refer-ence data rules ensure that the newly gener-ated data reflect any updates or improvements that have been made to those rules helping to ensure data accuracy, consistency and safety through design integrity.

Data interchangeabilityInterchanging data between 3D systems is an ongoing requirement for capital projects. The Reference 3D (R3D) command brings “externally generated” 3D data into an active model as a reference. Although it may have

originated in another application entirely, R3D

data brings both intelligence and graphics

when attached to a Smart 3D project. The R3D

command supports:

n Multiple 3D formats, including PDS®,

PDMS, AutoCAD®- and MicroStation-

based systems, mechanical CAD

applications and point cloud datan Intelligent piping and nozzle connectionsn Full clash capabilitiesn The use of tool tips for locating

key reference objectsn The creation of general arrangement drawings.

The 3D data that can be brought into a project

are independent of the source database plat-

form, project catalog or version. This makes

the R3D command very useful for evaluating

warehoused project data for applicability in an

active project or bidding situation.

Market-leading Smart 3D Offers New Productivity and Performance EnhancementsSmartPlant 3D and SmartMarine 3D improve the entire life cycle and give companies a competitive edgen By Luther Walke

SmART 3D upDATE: NEW ENHANCEMENTS


31Insight 31Insight

Using Intergraph’s product-proven SmartPlant Review technology for data conversion, R3D supports a variety of data interchange workflows that were not previously possible. Intelligent 3D data from external sources is eas-ily attached to the Smart 3D project for spatial referencing of sections of project data gener-ated externally.

These datasets can also be checked against one another – and against native Smart 3D data – for interferences. This is handled by Smart 3D’s sophisticated clash-prevention engine which continuously checks the entire project.

In addition to preventing clashes with externally generated data, Reference 3D enables the review of property information through SmartPlant 3D’s standard user interfaces designed for this purpose: the Object Property Page; Intelligent Tool Tips and Custom Labels. This same attribute information can drive project deliverables such as annotation of the related 3D graphics on orthographic drawings.

With its ability to display externally gener-ated graphics and attributes alongside native Smart 3D data, Reference 3D supports work-flows required by large joint-venture projects. Whether originating from PDMS, PDS or another installation of Smart 3D, Reference 3D normalizes information so that all R3D data behaves identically for optimal interoperability.

Reference 3D can also be used to bring in graphical-only data from a variety of sources, including MicroStation, AutoCAD or standard formats such as SAT. Users can efficiently execute highly complex projects without risk to project cost or schedule.

product performance and user efficiencyTime is one of the most closely managed assets on any capital project. Intergraph constantly develops improvements that enable the Smart 3D model to be developed as rapidly and error-free as possible. The latest product release improves the software’s performance and pro-vides new tools for improving user efficiency.

The first of two performance enhancements result in a reduction in the amount of time required to initialize the 3D workspace. Because it impacts every user on a project, even a

modest improvement in this area can yield tan-gible reductions in direct labor costs. Given the high potential for delivering savings to all users, Intergraph made significant investments in this initiative. Projects deploying Smart 3D will reap the benefit of these investments.

The graphics performance of Smart 3D has also been enhanced. This improvement also promises direct impact to a project’s bottom line, potentially impacting a broad set of users. These performance improvements are achieved by fully leveraging the processing power of the graphics adapter installed in the workstation running the software.

If project management determines that maxi-mum graphics performance is highly desired on all or a portion of the 3D design workstations, higher-end graphics cards can be installed in those machines. Simply put, an investment by the project in higher-end hardware will result in a direct payback in the form of improved user experience and design efficiency.

The improvements to Smart 3D’s graphic per-formance are impressive. Users of prior versions will immediately notice improved responsive-ness during refresh-intensive operations such as pan and rotate. Users running high-end graphics cards will be particularly pleased.

For example, Smart 3D’s View Navigation Control is a new command panel which enables traversal of the model graphics in much the same way as a typical “walk-through” or “shooter-type” video game. A variety of commands can be invoked graphically, including pan, zoom, fit and fly.

An attractive user control overlays the upper corner of the modeling environment. Alternatively, the commands can be controlled with the keyboard.

The View Navigation Control improves user efficiency through an elegant mechanism for quickly moving around the model. While its similarity to the gaming experience is particu-larly attractive to younger designers, even the most seasoned veterans will benefit from the rich functionality and quick learning curve.

In addition to assisting with routine navigation during 3D design, this tool promises to be particu-larly useful for conducting ad-hoc design reviews between designers and other project participants.

Not all mission-critical operations occur on the design floor, so the latest release also delivers increased efficiency for downstream and project-wide activities. Intergraph Batch Services, the long-proven industry leader in the management of schedule-deferred processing, has been seamlessly integrated into Smart 3D. Several back-office operations, including project archival, can now be automated and managed via this powerful infrastructure.

Intergraph Batch Services supports queue pip-ing, assignment of jobs at the processor core level, and the ability to automatically re-map user logins. Given the lack of these and other key capabilities in Windows Task Scheduler, all Smart 3D batch operations will be migrated from the Microsoft® solution to the mechanism now native to Smart 3D.

Smart 3D

32 Insight


32 Insight

Electrical solution

Although its 3D electrical solution already leads the market, Intergraph continues to recognize and deliver additional value in this area. The lat-est release of Smart 3D delivers new capabilities that promise to help capital projects better man-age the electrical discipline by saving time and reducing cost, both in terms of labor required for designing the electrical cableway network as well as capital to purchase materials for construction.

Smart 3D now delivers a comprehensive, specification-driven solution for modeling an intelligent duct bank. Encasement concrete and the conduit array are routed simultaneously following commands virtually identical to those used for routing cableway. The user can specify any combination of conduit types and sizes to be modeled within the duct bank.

In addition to ensuring the proper catalog parts are placed within the model, the selected conduit

specification ensures proper bend radii are mod-eled for each run of conduit within the duct bank. Likewise, the software automatically models the appropriate chamfered turns in the ditch to allow for the longer radius bends.

Once the duct bank has been modeled, the con-duits created within it are ready to accept Smart 3D cables. Most importantly, the entire cable-way network – encasement (or naked trench), conduits and contained cables – are all fully intelligent and are easily modified in response to subsequent changes on the project while main-taining key relationships to one another.

As a result, the data driving MTO reports for the cable and conduit, civil drawings for the duct bank, and cable route information sent to other applications like SmartPlant Electrical through the SmartPlant Enterprise are instantly updated along with the move or other modifications.

Another feature included in the latest release is accounting for divided trays when auto-routing cable and making tray-fill calculations. When a tray divider is inserted into a tray, the software will recognize the position and allocate space accordingly. Separate channels are subse-quently used by the cable routing algorithm in determining available space as well as the allowable signal type (which can be set differ-ently across the divider).

In addition to being modified to account for tray dividers, the automated cable routing and fill calculation algorithms now also account for available bend radius at change-of-direction components, ensuring the minimum bend radius for the cable can be maintained. Otherwise, the path will be rejected as a suitable route for that cable. Other enhancements to Smart 3D’s electrical solution include:n Integration with SmartPlant Electricaln Enhanced support for multi-routing of stacked

cable traysn More robust conduit specs delivered

out-of-the-box.

fireproofingSmart 3D’s latest release offers several fire-proofing capabilities for designers. The process is specification-driven. Reference data are pre-configured to enable automatic determination

SmART 3D upDATE: NEW ENHANCEMENTS

SmART 3D DISpLAY pERfORmANCE ImpROvEmENTS

Independent testing in separate projects performed by four large companies proves the significant time savings available in the latest version of Smart 3D technology.

Calculation and display of enhanced edges in the 3D modelAverage 88 percent time savings (8.7 times faster)

Screen refresh operationAverage 77 percent time savings (5 times faster)

2

1.8

1.6

1.4

1.2

1

0.8

0.6

0.4

0.2

0PROJECT 1 PROJECT 2 PROJECT 3 PROJECT 4

TIM

E IN

SEC

ON

DS

7

6

5

4

3

2

1

0PROJECT 1 PROJECT 2 PROJECT 3 PROJECT 4

LEGEND Previous version of SmartPlant 3D Current version of SmartPlant 3D

TIM

E IN

SEC

ON

DS


33Insight 33Insight

of key design aspects such as material, grade, rating, segmentation and setback lengths. Smart 3D’s new fireproofing can be applied to both concrete and steel.

Concrete designThe ability to model concrete structures has been dramatically enhanced in the latest release with a new set of commands for supporting the mod-eling of highly complex civil structures which are constructed of concrete. From the containment structure for a nuclear reactor or an intricate system of drainage sumps, a wide variety of concrete structures can be modeled using these commands with no special training required.

marine and offshore solutionSome of the most impressive enhancements are in SmartMarine 3D. For example, one key enhancement specifically developed for use on offshore oil and gas development projects is the ability to model cans, which are tubular struc-tures added to nodal connections on the jackets of offshore platforms to provide reinforcement. The design and modeling of cans in Smart 3D

is driven by placement rules, nominally config-uredto ensure compliance with the applicable American Petroleum Institute (API) standard.

Smart 3D’s latest release addresses another critical requirement in the design of offshore jackets, trusses and derricks. Users gain the abil-ity to place steel members with relative spacing to other members coming into a common joint using the new Rule-based Joint (RBJ) capability.

The RBJ command provides required behavior for several key conditions: surface gap spacing; required centerline distances and minimum member overlap. As with rule-based cans, the structural designer can ensure that require-ments specified by the API standard are being met. This eliminates the complex hand-calcu-lations normally associated with this offshore requirement.

Another rule-based capability further strength-ening Smart 3D’s ability to support offshore design is the Advanced Plate Systems (APS) creation command. This highly automated mechanism defines the shape and positioning/

trimming rules for plate systems that ultimately

make up nodal connections.

Users simply design the required plate system

via a graphical interface, after which the defini-

tion – including the code required for calculating

the proper sizing and placement – is permanently

stored in the catalog. The plate system can then be

placed as needed in the future.

The most important benefit of cans, RBJs and

APS is that the rules behind these features auto-

matically fire when any changes are made to the

model. This provides tremendous productivity

improvements during changes to the design in

comparison to other competitive systems.

flex hose and duct spoolsOther functionalities in the latest release of

Smart 3D benefitting offshore industry capital

projects include specification-driven flex hose

and automated spooling of duct systems.

Flex hosing is used widely on oil and gas proj-

ects with each hose and termination assembly.

This requires individual specification and

manufacture. Smart 3D will automatically place

the proper assembly in the model, at the same

time checking minimum bend angle and radius

requirements to ensure the hose will not kink as

designed.

Duct spooling builds on the proven pipe

spooling capability, allowing duct runs to be

automatically broken into uniquely-marked

sections that can be individually manufactured,

transported and installed in a modular fashion.

SummaryIn conclusion, the latest release of Intergraph’s

industry-leading Smart 3D design solution brings

important new enhancements that will help pro-

cess and power plant, ship and offshore design-

ers further increase productivity and accelerate

completion while increasing project safety.

Luther Walke serves as product manager for Smart-Plant 3D and is based in Huntsville, Alabama, U.S.

www.intergraph.com/smartplant3d

www.intergraph.com/smartmarine3d

Smart 3D

34 Insight

How can you best document the existing con-dition of a plant? Laser scanning can identify the elements in your facility to show 3D points in space that reveal what exists. Several terms are used to describe this data:n Laser datan Point cloud datan Existing condition data capture.

The value of laser scanning is that the infor-mation is exact and shows what is already on site. The facility has already been designed and constructed. Now you’re dealing with the real-ity of brownfield projects.

Laser scanning delivers a realistic view of what was built, which is never identical to what was designed. As a result, pipes are not always exactly horizontal with 90 degree turns, es-pecially after insulation has been added. So when it comes to adding, replacing or modi-fying pipelines based on these existing plant

conditions, engineers have a huge challenge on their hands to avoid clashes. Referencing the as-built laser data in the 3D design model is certainly far superior to the old tape mea-sure approach.

vendor-neutral strategyIntergraph maintains SmartPlant Alliance agreements with all of the leading laser scan-ning vendors. These vendors offer hardware

and software configurations to collect the la-

ser data and reference the points in 3D:n Leica Geosystems n Z+F UK/Hi-Cadn Quantapointn CSAn Trimble.

Intergraph is vendor-neutral. We work with

laser scanning vendors to enable seamless

Gain the Most Value from Laser Scanning with SmartPlant EnterpriseIntergraph offers superior, unique technology for a complete life cycle solution

n By Robert Christian

Intergraph provides a better, long-term

usage of your point cloud data investment.

DID YOu KNOW?: LASER SCANNING WITH SMARTPLANT ENTERPRISE


35Insight

integration to our products. This is important because each vendor has unique solutions and service providers available in different parts of the world.

Life cycle solutionLaser scanning is about more than just one application – it’s about all of the applications working together over the complete life cycle:

Smart 3DWith Intergraph Smart 3D technology (which includes SmartPlant 3D and SmartMarine 3D), you can either replace existing elements or avoid existing elements.

you can determine clashes and interference detections of the elements that cannot move, such as the structures, columns and beams that cannot be modified. A new pipe can’t go through these items.

Or you might have an existing line that’s going to be completely replaced. It must be put back in place as it was originally. you can use the laser points to overlay that line.

Smart 3D provides a reference. Points are used to aid modeling. As you perform design work, you reference a group of points. The laser soft-ware isn’t smart enough to turn it into a pipe. The engineer has to consult a catalog and determine the desired pipe specification and place it. So, the goal is to minimize the num-ber of activities an engineer must perform to replace a pipe or position a new pipe.

Smart 3D helps you confirm that the pipe is at the right angle, the right size – all the right characteristics – so that it can be properly fab-ricated and installed in the facility.

The embedded bubble (360-degree) view is a new technology that all of the main laser scanning vendors have adopted. A bubble view is basically a digital raster picture that enables you to move your mouse to turn in the view. you can control the resolution to make it as clear as any photograph.

A year ago, we asked our customers what they would like in Smart 3D, and the bubble view was one of the items they requested. This functionality is now included in our latest re-lease of Smart 3D and SmartPlant Review.

Smartplant ReviewSmartPlant Review can be used as a reference solution with your laser scanning data. It en-ables you to perform complete design reviews outside of the design environment.

The solution promotes communication among everyone involved in the project, whether they have experience working with advanced 3D design tools or have actually been on-site. SmartPlant Review is easy for anyone to use, enabling users to see the new design with the existing condition of the plant as a reference.

Smartplant foundationSmartPlant Foundation helps you take advan-tage of your laser data by performing queries of the new design to find the pipe that needs to be maintained, for example. you can see ev-erything in context and what the existing plant looks like to know if you can perform needed maintenance with the new design.

Dynamic displayIntergraph offers a superior and unique solution for laser scanning. The first reason is thanks to our technology.

A typical laser scanning project involves liter-ally billions of points. Some applications simply read one point at a time. Each point takes up a certain amount of memory. Eventually you fill up all the memory on your machine and there are a lot of objects in your 3D model.

We don’t take that technology approach. Our technology is better because we have devised a way to allow an unlimited number of points to be displayed and used on the screen with-out having to import one point at a time.

Our approach is to dynamically import and display only what the user wants to see. We can do this at such a high speed that you can virtually “walk through” your model in real time. you can basically accomplish everything you need to do, such as display 3D views of the laser data or identify any clashes while you’re modeling. But we don’t ever fill up the memory by sticking all those millions of points into the model.

preserve data investmentAt Intergraph, we don’t convert the laser data into something else. Some vendors convert

the data into triangular surfaces that are ap-

proximations of the original data. They do this

because their 3D rendering software requires

triangles to be processed in advance. This re-

sults in limited accuracy. Accuracy is sacrificed

for performance. Intergraph’s approach sacri-

fices neither accuracy or performance.

Our approach ensures data integrity and pres-

ervation for long-term viewing because we

continue to use the original data. We see your

laser data as an investment, not something

to be disposed of once it’s referenced for the

current project. There is no conversion into a

special Intergraph proprietary format. We’re

not dumbing it down and combining a lot of

information to make it smaller.

Accuracy is maintained and original data

are preserved for later display. We provide a

better, long-term usage of your point cloud

data investment.

Second-generation laser scanning

Another reason we are superior to the com-

petition is that this is our second generation

laser scanning solution connected to plant de-

sign engineering. PDS has worked with laser

scanning for 30 years.

Smart 3D represents our second generation

of laser scanning integration. The software

empowers you to perform all of your work in

Smart 3D. All of the commands are built right

in, taking advantage of the powerful Smart 3D

modeling and clash engines.

Laser scanning is well integrated into the Inter-

graph design environment. you never have to

leave the Smart 3D environment to make the

best use of your laser data.

Now you’re in an intelligent plant design

environment, and Smart 3D treats the points

as more intelligent plant objects. This gives you

much more control.

Robert Christian is executive manager for

business development for 3D Modeling & Visu-

alization at Intergraph Process, Power & Ma-

rine. He is based in Huntsville, Alabama, U.S.

www.intergraph.com

Smart 3D

36 Insight



ENI Saipem Standardizes on SmartPlant EnterpriseENI Saipem S.p.A., one of the world’s larg-est oil and gas EPCs, will standardize on the SmartPlant Enterprise engineering solutions suite, including Smart 3D, Intergraph’s next-generation 3D design software, to further increase productivity and cost savings and to accelerate project schedules.

An Intergraph customer for 20 years, Saipem experienced significant benefits and productiv-ity gains using Intergraph’s plant design and information management software solutions. Saipem will now expand its use of these solu-tions, using Smart 3D as its new standard on a worldwide basis to enable complete integration in production within its onshore, offshore and drilling divisions and help the company maintain a competitive advantage in the global market.

www.saipem.it

BBA Chooses SmartPlant 3D for Metals and Mining ProjectsBBA, an independent Canadian consulting engi-neering firm active in the international energy and mining and metals sectors, has completed the design of its first project for Consolidated Thompson, the Bloom Lake project in Northern Quebec, with SmartPlant 3D.

BBA chose SmartPlant 3D because it is well-suited for the specific challenges related to metals and mining projects – large and complex equipment and very mining-oriented specifications for components. The software’s rule-based design and specification-driven capabilities provide true discipline integra-tion into a single 3D modeling environment, minimizing rework for changes and ensuring consistency across designs.

www.bba.ca

PetroVietnam Marine Shipyard Selects SmartMarine 3DPetroVietnam Marine Shipyard Joint Stock Co.

(PV Shipyard) has selected SmartMarine 3D

engineering and design software to increase

productivity and accelerate the completion of

offshore projects.

To enhance its competitiveness in a bid for an

offshore jack-up rig, PV Shipyard needed next-

generation technology to assist in the design,

construction and production of its current and

future complex platforms. PV Shipyard also

wanted engineering software from a stable

and proven vendor that could ensure quality,

accuracy and automated processes in producing

the deliverables required for a number of other

offshore contracts. After an intensive evaluation,

PV Shipyard selected Intergraph for its compre-

hensive solutions suite, advanced technology,

commitment to customers, proven track record

and local distributor support from Intergraph’s

partner in Vietnam, Credent Technology.

www.pvshipyard.com.vn

Fluor Expands Intergraph Global Alliance AgreementFluor Corporation (NySE: FLR), one of the lead-

ing engineering, procurement, construction

and maintenance (EPCM) companies in the

world and longtime Intergraph customer, has

renewed its Global Alliance Agreement (GAA)

with Intergraph for the next five years. This

agreement covers the Intergraph SmartPlant

and SmartMarine Enterprise software suites,

including SmartPlant 3D, PDS, SmartPlant P&ID,

and SmartPlant Instrumentation and numerous

other solutions.

As an Intergraph customer for 35 years, Fluor

uses Intergraph enterprise engineering solutions

on a significant number of its mid- and large-tier

contracts across multiple industry sectors – oil

and gas, power, mining and chemical.

www.fluor.com

Oerlikon Solar Selects SmartPlant 3D and SmartPlant P&ID Design SoftwareOerlikon Solar, the leading supplier of high performance solutions for cost-effective mass production of thin film silicon solar modules, has selected Intergraph SmartPlant 3D and SmartPlant P&ID engineering design software to increase productivity and accelerate plant project completion. With business doubling in just two years, Oerlikon Solar outgrew its previous CAD 2D design software. To meet growth demands, the company chose SmartPlant 3D, Intergraph’s next-generation, data-centric 3D design system, combined with SmartPlant P&ID. Oerlikon Solar will use SmartPlant 3D and SmartPlant P&ID for end-to-end manufacturing lines for the mass production of thin film silicon solar modules.

SmartPlant 3D engineering design software is the most productive, highest quality, multidis-cipline 3D modeling environment in the world for global multi-office execution of process and power projects. Customers using SmartPlant 3D typically realize 25- to 35-percent initial increases in productivity compared to other systems, higher quality deliverables and shorter schedules.

www.oerlikon.com/solar

China National Chemical Engineering Co. Ltd. Expands Use of SmartPlant Enterprise SolutionsChina National Chemical Engineering Co., Ltd. (CNCEC), one of China’s largest engineering, procurement and construction (EPC) concerns, has expanded the use of Intergraph SmartPlant Enterprise design and engineering software to five of its operating companies to further increase productivity and cost savings and to accelerate project schedules.

An existing Intergraph customer, CNCEC had already experienced the benefits and productiv-ity gains using Intergraph’s next-generation 3D modeling and visualization, information management, instrumentation, and piping and instrumentation diagram software solutions. Now, CNCEC will expand use of these solutions, including SmartPlant 3D, further into five more

I N D u S T R YNewsbytes

37Insight 37InsightSmart 3D

companies within the CNCEC group: China

Tianchen Engineering Co. Ltd.; Sedin Engineering

Co. Ltd.; East China Engineering Science and

Technology Co. Ltd.; China Hualu Engineering

Co. Ltd. and China Chengda Engineering Co. Ltd

Shin Kurushima Dockyard Implements SmartMarine 3DShin Kurushima Dockyard (SKDy), recognized as

one of the most productive shipyards worldwide,

has standardized on Intergraph SmartMarine 3D

design and engineering software after an inten-

sive two-year benchmark study.

The SmartMarine 3D implementation will

encompass the entire SKDy enterprise, includ-

ing its yards in Onishi, Hashihama, Ujina, and

Toyohashi, Japan, and offices in Indonesia, with

specific focus on worksharing capabilities across

Southeast Asia. Ship modeling will be managed

in a central location, and SmartMarine 3D work-

sharing capabilities will permit design reviews

and changes to be seamlessly shared from vari-

ous locations throughout the entire ship design

process, from initial design through the manufac-

turing phase. The ability to workshare will save

valuable time and labor costs while increasing

productivity for SKDy.

SABIC Standardizes on SmartPlant EnterpriseSaudi Basic Industries Corp. (SABIC) has stan-

dardized on Intergraph SmartPlant Enterprise,

including SmartPlant 3D and SmartPlant

Foundation, as its engineering design and data

management platform for all of its manufac-

turing affiliates.

SABIC is the largest and most profitable non-

oil company in the Middle East and one of the

world’s 10 largest petrochemicals manufacturers.

Its products include chemicals, plastics, fertilizers

and metals. SABIC will use SmartPlant Enterprise

to facilitate data handover from its EPC contrac-

tors to its affiliates’ plants and assist in every

aspect of the plant life cycle. This includes design,

procurement, construction, commissioning,

operation, maintenance, expansions, retrofits and

decommissioning, if applicable.

www.sabic.com

WorleyParsons to Standardize on SmartPlant EnterpriseGlobal project services provider WorleyParsons

has entered into a Global Alliance Agreement

with Intergraph to facilitate the standardiza-

tion of business solutions across its globally

located operations.

The past year has seen WorleyParsons signifi-

cantly increase its adoption of Intergraph plant

management software, much of it centered on

the SmartPlant Enterprise plant engineering and

design solution. With 118 offices in 38 countries,

the Australian-based company provides techni-

cal, project and operational support services to

customers in the hydrocarbons, minerals and

metals, power and infrastructure sectors, and lists

some of the world’s largest energy companies as

clients.

www.worleyparsons.com

Tsuneishi Shipbuilding Standardizes on SmartMarine™ EnterpriseTsuneishi Holdings Corp. Tsuneishi Shipbuilding

Co. has standardized on the Intergraph

SmartMarine Enterprise suite of 3D engineering

design and data management solutions to opti-

mize design efficiency and increase productivity.

Tsuneishi Holdings Corp. is a maritime affair

enterprise composed of a leading Japan-based

shipbuilding group and shipping business.

Tsuneishi Shipbuilding Company is continuing to

deliver high-quality ships at an economical price

to customers around the world.

In committing to the entire SmartMarine

Enterprise suite, Tsuneishi will now have a com-

prehensive set of integrated solutions to manage

its shipbuilding operations – from early stage

design technologies to next generation 3D design

and manufacturing capabilities in addition to

efficiency-boosting materials management and

production programs.

www.tsuneishi.com

Six Tee Marine and Offshore Engineering Groups Select Intergraph SmartMarine 3DSix Tee Engineering Groups, one of Asia’s leading marine and offshore facilities engineering firms, has adopted Intergraph SmartMarine 3D software.

The Singapore and China-based company spe-cializes in the basic and detail design and project management of marine and offshore structures. Six Tee selected SmartMarine 3D to increase pro-ductivity and quality for its work in the basic and detail design and project management of marine and offshore structures.

Six Tee projects include floating production, storage and offloading (FPSO) vessels; jack-ups; semi-submersibles; drill ships; offshore fixed platforms; pipe-laying/derrick barges; sub-sea pipelines; offshore support vessels and a variety of merchant ships.

www.sixtee.com

COSCO Shipyard Group Significantly Increases Productivity and QualityAfter only 10 months of implementation, the COSCO Shipyard Group, one of China’s major shipbuilding companies, has already realized significant productivity and quality results to warrant a more rapid deployment of Intergraph SmartMarine™ 3D engineering design software solutions to all five of its yards for ship and off-shore projects.

Typical startup times for comprehensive software solutions use on real projects is one to three years, but because of SmartMarine 3D’s ease of use, integration and ability to increase shipbuild-ing productivity and quality, COSCO is accelerat-ing implementation. SmartMarine 3D streamlines marine outfitting and structure design processes and provides all the functionality needed to design and build many different types of marine facilities and equipment, including offshore platforms, naval and commercial ships, and float-ing production, storage and offloading (FPSO) vessels.

www.cosco-shipyard.com

Read our blogs atwww.intergraph.com/blogs

Follow us on Twitter at www.intergraph.com/twitter

Become our fan on Facebook at www.intergraph.com/facebook

Join our LinkedIn groups at www.intergraph.com/linkedin

Subscribe to our RSS feeds at www.intergraph.com/rss

Subscribe to our YouTube channel at www.intergraph.com/youtube

Get Connected!

39Insight

What the World’s Top Marine Industry Leaders and Class Societies Share in CommonTo manage the challenges of producing increasingly complex ships and offshore platforms, the world’s top marine industry

leaders and class societies are continually seeking ways to increase productivity and accelerate project schedules.

Intergraph® solutions have been used in offshore projects around the world for more than 20 years. Twenty of the top 25

petroleum companies in the world and 18 of the top 20 engineering companies in this market are Intergraph customers.

Intergraph has been instrumental in advancing marine design and production effi ciency. Notable vessels built using Intergraph

marine software include the world’s fi rst Arctic icebreaker tanker, the world’s largest container ship and the Cunard liner

Queen Mary 2. Intergraph solutions have also been used for ships of the Australian, Danish, Norwegian, Spanish and U.S.

navies as well as for French, Indian and Spanish submarines.

40 Insight

Intergraph Smart 3D technology is the industry’s only next-generation 3D plant and ship design solution. SmartPlant 3D and SmartMarine® 3D are being adopted by customers at a rapid pace and are in production around the world. Insight recently discussed Smart 3D’s momentum with Gerhard Sallinger, president of Intergraph Process, Power & Marine.

Insight: Can you tell us about Smart 3D technology?Gerhard Sallinger: Smart 3D is based on a very powerful software core architecture which is data-centric and rules-based that is fundamen-tally different to any other, traditional system. Although the software is extremely powerful, it is easy to learn and use – customers love it!

Due to its rules-based architecture, Smart 3D can increase engineering productivity and optimize design accuracy and quality. Smart 3D includes powerful worksharing capabilities

as a standard feature, based on modern data-

base replication technologies from Oracle or

Microsoft® SQL Server®.

Insight: What benefits does Smart 3D offer?GS: Because Smart 3D is object-oriented and

rules-based, it is much easier to create new

designs and make design modifications. All

components such as pipes, ducts, equipment

and structural elements have true intelligence.

They “know” who they are, what they can do

and what they can’t and how they relate to other

elements.

All design changes are summarized in elec-

tronic “to-do” lists. This enables rapid design

and modifications to be made while retaining

model integrity.

Traditional systems do not provide this function-

ality or level of change management, so their

users must delete and redesign elements when making modifications.

Insight: How does design automation improve productivity?GS: In addition to the powerful rules Smart 3D delivers out-of-the-box, the software comes with tools to create customer-specific rules to automate the design process. Other products offer a limited potential for automation by using old-style com-mand languages to create macros. Smart 3D goes far beyond this, allowing users to create highly complex rules which can reduce manual engineer-ing work by more than 90 percent.

At our users’ conference in Las Vegas, I show-cased an example from Linde Engineering, one of our most experienced PDS® customers. To test Smart 3D’s technical potential to increase Linde’s engineering performance, team members developed some rules to automate the design of control stations. In many petrochemical plants,

The Industry Gold Standard – Smart 3DCustomers’ results prove strength of technology behind SmartPlant® 3D and SmartMarine® 3D

n By Jana Miller

fROm THE TOp


41Insight

there are hundreds of control stations needed. With the rules, Linde is able to design a complete station in about one minute in comparison to spending more than 10 minutes using PDS!

Insight: Can you describe Smart 3D’s rules-based environment and data import capabilities?GS: Smart 3D offers a true rules-based design environment. A range of engineering rules is provided within Smart 3D to assist design mod-eling. Users can also capture and develop their own engineering rules to ensure that engineer-ing knowledge and experience can be retained within the organization.

Plus, you can import 3D mechanical CAD model data with our native SAT import interface. Competitors rely on a partner for the interface, which introduces a risk.

Insight: How does Smart 3D drafting stack up against competitors?GS: We offer the most modern drafting func-tionality available in the market today. Smart 3D includes a powerful, automated drawing production environment allowing users to cre-ate all drawing deliverables directly from the 3D plant model, with a significant reduction of manual touch-up work that is surprising many new clients. Siemens Energy has claimed a 20 percent overall reduction in time requirements immediately following its implementation, and I think we can double that initial benefit as we gather more feedback from clients. What’s more valuable from a business perspective is the increased quality of deliverables and the higher speed of delivery when deadlines are near.

Insight: We are hearing a lot about integration. How does Smart 3D support integration?GS: We fully support integration and interop-erability to address the way our customers work. We are proud to offer the best-of-class solutions in all key disciplines, including P&ID, instrumentation, electrical schematics, design review, materials management and more.

Some of our competitors employ more of a communication approach than real integration. We are taking a forward-thinking approach with integration.

Smart 3D technologies are making a difference around the world. Insight recently spoke with two customers about their experiences and why they chose Smart 3D. Terje Ørbeck is a CAD manager and 3D coordinator at Grenland Group. Waldir Pimentel Junior is a systems engineer at Genpro Engenharia S.A.

Insight: What is your biggest enterprise engineering challenge? Terje Ørbeck: For Grenland, our biggest engineering challenge is to be able to deliver quality data on time and with limited engineering resources available.

Waldir Pimentel Junior: Meeting project deadlines is our major enterprise engineering challenge, followed by the quality of work delivered and the need for a user-friendly system that enables quick implementation and training.

Insight: Why did you choose Intergraph’s SmartPlant Enterprise?TØ: SmartPlant Enterprise will help us to deliver quality engineering data on time. With SmartPlant Enterprise’s data sharing capabilities, we will improve the quality and speed up the engineering work performed by Grenland.

One of the important reasons we started using SmartPlant Enterprise was the ability to perform worksharing. Grenland is building engineering capacity with Grenland Group offices in different parts of the world. We see the benefit of worksharing on coming projects, especially with our offices in China and Malaysia, to increase our engineering capacity and keep engineering costs down.

WPJ: We made our decision based on our long- term relationship with Intergraph using PDS, SmartPlant Instrumentation and SmartPlant P&ID. We are impressed with the proven quality of Intergraph systems and the total commitment of their professionals in supporting our work.

We see enterprise-wide value in having a comprehensive solution across the phases of the life cycle. The main value is the integration between disciplines (such as process, piping and electrical) and our customers. Improving data quality is another major factor.

Insight: Can you estimate the productivity savings since adopting SmartPlant Enterprise solutions?TØ: We estimate an average increase in productivity by 30 percent in activities directly connected to SmartPlant 3D and SmartPlant Enterprise. For certain activities, the time savings are even greater.

WPJ: In today’s market, we need to reuse data to save time, especially in configuration of the system’s environment. Reusing data positively impacts our major challenge of shortening project schedules.

SmartPlant Instrumentation yields an increase of approximately 20 percent in productivity. SmartPlant 3D gives us a large boost, and SmartPlant P&ID offers an 80 percent increase.

Insight: Have SmartPlant 3D and SmartPlant Enterprise resulted in faster project completion times?TØ: Grenland is now performing its first major project with SmartPlant 3D and SmartPlant Enterprise. It is very important to note that we are using the “learning by doing” method.

Any implementation can be a challenge for the whole project organization when it comes to meeting deadlines and schedules. Despite implementing a new system with many new users, we have still been able to meet the project deadlines and standards with quality engineering documentation.

Staying on schedule gives credit to the SmartPlant Enterprise solution as an easy-to-learn and easy- to-use system. Soon we expect a tremendous increase in productivity as the system is adopted more fully and becomes familiar in our organization.

WPJ: We estimate a huge time savings compared to the previous systems. Key reasons for this sizable savings include a simple and friendly user interface and the evolution of system functionalities. We are looking at SmartPlant Foundation and believe it would further reduce our schedules and promote integration with our customers.

Jana Miller is editorial director of Insight and is based in Huntsville, Alabama, U.S.www.intergraph.com

What Customers Say about Smart 3D

Smart 3D

42 Insight


Smooth Sailing for Samsung Heavy IndustriesSmartMarine 3D cuts design errors and boosts productivity

n By Jana Miller

CASE STuDY: SAMSUNG HEAVy INDUSTRIES

The second largest shipbuilder in the world,

Samsung Heavy Industries Co. Ltd. (SHI) is

strongly focused on the shipbuilding and off-

shore markets. The South Korean company has

almost 11,000 employees and sales totaled

US$8.5 billion in 2008.

SHI designs and constructs high value-added

vessels such as LNG carriers and large pas-

senger ships, as well as drill ships and shuttle

tankers, for which it is globally ranked No. 1.

The company operates eight overseas facilities,

including a ship block factory in China. SHI

holds three international quality standards –

ISO 9001, ISO 14001 and OHSAS 18001 – and

is internationally recognized for its quality,

safety and environmental awareness.

Seeing results

SHI’s Geoje Shipyard began using Intergraph

SmartMarine 3D in production in 2004 and

it has already yielded measurable results that have impacted SHI’s bottom line.

“Since choosing SmartMarine 3D, we’ve made a remarkable reduction in the amount of design errors and material costs. We’ve also improved construction productivity,” said yeong Soo Bae, executive vice president of Shipbuilding Design at SHI.

“With SmartMarine 3D, we have reduced design errors in half. We have also improved productivity by about 10 percent.”

Smartmarine 3DSHI uses SmartMarine 3D for designing and building the structure and outfitting of ships (see table). The solution helps SHI manage a Microsoft® SQL Server™ database with 1.1 terabytes of active data.

SmartMarine 3D supports concurrent engi-neering and a front-loading workflow. The solution provides a large amount of production

information to easily interface with ERP systems, and SHI is working to take advantage of this by developing an interface.

Integrations with third party solution Enest, a structure nesting program, along with several in-house solutions, have proved very beneficial. “These integrations translate into a large reduc-tion in design labor hours at SHI,” said Bae.

Across the enterpriseSHI recently chose SmartPlant Foundation, Intergraph’s information management solution, to improve its productivity. This marks the first implementation of SmartPlant Foundation in the shipbuilding industry. SmartPlant Foundation forms a central data warehouse and engineer-ing and manufacturing data change channel for large and complicated ship design.

As shipbuilding projects grow larger while project schedules become shorter, an integrated product and engineering information management system


43Insight

represents a key success factor. The shipbuilder can exchange quality design information and manufacturing information during the project and deliver as-built information to ship owners at the same time the project is completed.

SmartPlant Foundation will be used as a stan-dardized data warehouse in the shipbuilding division as a first step. SHI has plans to use Intergraph solutions for the entire design process, in both shipbuilding and offshore plant projects.

In addition, SHI will standardize its basic CAD format corporate-wide to Intergraph’s SmartSketch®. This SmartSketch standardiza-tion will extend to SHI’s offshore plant division and its subsidiary shipyard in China.

In-depth servicesSHI’s experience has shown that SmartMarine solutions require far less training than previously used software solutions and its employees can be fully productive in far less time – in a matter of months instead of a year or more. Training includes basic courses such as a seven-week course for structural users, and a three-week course for outfitting users.

“Intergraph supports our management team with valuable services,” said Bae. “The Intergraph staff has also helped us with a number of customization efforts, including catalogs, rules, specifications, drawing labels, plus standards data migration.”

proven experience“We chose Intergraph because they have adopted the most advanced, state-of-the-art architecture,” said Bae. “Intergraph is a steady and promising company, with strong experience in developing both plant and shipbuilding CAD software.”

SHI looks forward to even greater success in the future, and is looking at possibly expand-ing its enterprise solution by adding Intergraph SmartPlant P&ID to its solution mix.

“One thing we plan to achieve in the upcom-ing year is to reduce design cost,” said Bae. “SmartMarine 3D will be used for at least the next 10 years for all of our projects as our main CAD tool.”

Samsung Heavy Industries is using Intergraph technology for a variety of high- value marine structures:

Through the Workflow

SHI takes advantage of SmartMarine 3D for a variety of shipbuilding tasks, including:

Ship structure design

n SmartMarine 3D molded formn �Structure detailingn Structure manufacturingn �Planningn Drawing

Ship outfitting design

n SmartMarine 3D pipe routingn SmartPlant Structuren Equipment placementn �HVAC routingn Cableway routingn Cable routingn Planningn Hole managementn Hanger and supportn Weight and CGn Interference checkn Drawing

Other Intergraph solutions used

n SmartPlant 3D n SmartPlant Foundationn SmartSketchn SmartPlant Markup Plusn PDS

Complementary solutions used

n Enestn EzHULL

Project Implementation Area Delivery Date

97,000 tonnes drill shipAft E/R (excluding forward M/C

room, thruster room)2008

96,000 tonnes drill ship E/R 2009

950,000 bbls FPSO All area 2009

910,000 bbls FPSO All area 2010

Smart 3D

44 Insight


Speeding Offshore DesignSmartMarine 3D boosts efficiency and ensures data accuracy for COSCO Shipyard Group

n By Gu Xiang, Song Zhiwen and Li Jingjing

COSCO Shipyard Group (CSG) started to implement SmartMarine 3D in early 2007. Now, with more than 10 successfully implemented projects, SmartMarine 3D has become an es-sential part of CSG. The technology contributes directly to CSG’s vision to become the preferred partner for the world’s top shipping companies and offshore oil service providers with profes-sional services and modern management.

Expanding businessCSG originally focused on ship conversion and repair which required limited design performed using AutoCAD or only hand-drawn sketches.

In 2006, CSG expanded its business to include new ship and offshore building design and construction. A large number of experienced shipbuilders, as well as new graduates, were hired to staff a new CSG Technical Center (CSG TC).

For new ship and offshore design and construc-tion, the traditional usage of AutoCAD was obviously not enough. New design software, specifically 3D CAD, was required to support these endeavors.

CSG TC initiated research into current market offerings for shipbuilding and offshore design software. A variety of software vendors were invited to the Dalian Technical Center to pres-ent their offerings.

On Sept. 7, 2006, Intergraph was invited to present its next-generation 3D CAD system IntelliShip® (now known as SmartMarine 3D) for shipbuilding and offshore design. The CSG TC evaluation team attended the presentation, along with a reference group of shipyard and university experts invited by CSG TC to support the selection of the next generation 3D CAD. Most of these experts had Tribon shipbuilding design experience and had never heard of SmartMarine 3D before attending the presentation.

During the presentation, all of the attendees were very surprised at SmartMarine 3D’s powerful capabilities. The group was deeply impressed by the software’s vision, ease of use, permission manage-ment, relationship management, rule-driven intelligent design and advanced core architecture. After consultation with the group of experts and

the CSG leadership team, CSG TC decided to imple-ment a pilot project on Sept. 11, 2006 – just four days after the initial presentation.

pilot projectCSG had an FSO offshore project from MODEC International L.L.C. Hull design had already been subcontracted to a design company that was using Tribon. Due to the flexibility and open-ness of SmartMarine 3D, it was possible to use a Tribon interface that could import Tribon hull models into SmartMarine 3D as the background of the outfitting design. The FSO bulk area for outfitting design, specifically piping design, was selected as the pilot project for SmartMarine 3D.

In preparation for the pilot project, three activities were performed:

n Intergraph provided three weeks of on-site training, including equipment, piping, electrical, structure and HVAC.

n Each discipline compiled a list of its requirements, especially for drawing. Intergraph then performed customizations to fulfill these requirements.

CASE STuDY: COSCO SHIPyARD GROUP


45Insight

n With material provided by CSG TC, Intergraph compiled reference data, including not only the catalog, but also the capabilities of advanced design rules that would enable automatic data generation.

CSG engineers and two Intergraph engineers worked together on this three-month pilot project that started at the beginning of October. The pilot project ran smoothly. All of the required key functionalities and customizations were met within the timeframe of the pilot project.

After a detailed evaluation, CSG TC decided that SmartMarine 3D was powerful and well-suited for its design needs. A contract was signed at the end of 2006 in which SmartMarine 3D was chosen as the primary software to design CSG TC offshore projects.

first production implementationThe first production implementation was similar to the pilot project. CSG TC sent 10 engineers to Intergraph’s Shanghai office for SmartMarine 3D reference data and administration training. One of those engineers was then responsible for catalog management and basic administra-tion with Intergraph’s help. The objective was to provide CSG TC with in-house capabilities of an automation engine that is part of the core SmartMarine 3D technology. This would enable CSG TC to continuously capture the knowledge it gained during the project and differentiate itself from its competition by producing better quality and faster designs.

For the first production implementation project encompassing all outfitting disciplines, CSG TC used SmartMarine 3D as its design solution. In parallel, Intergraph delivered additional intelli-gent customization for pipe support.

The FSO project design was finished in July 2007, marking just 10 months from the pilot project to the completion of the first production project. The vessel was delivered one year later to the owner on July 17, 2008.

moving design to a single platformWhen Intergraph released its new version of SmartMarine 3D V7SP4 in April 2008, the company announced major improvements in hull design that would incorporate the earlier identi-fied requirements from CSG. Although the hybrid implementation (hull by Tribon, outfitting by

SmartMarine 3D Benefits

Underscoring the vision of a single data-centric solution, CSG has enjoyed many benefits from using the software, such as:n Easy to use and easy to learn – New graduates or engineers from other industries require a

very short period of training to perform design work. Just one-to-two days of training are needed for a single discipline.

n many powerful functions – The relationship management and rule-driven technology are very powerful and far better than capabilities offered by any other system.

n Efficiency – The product’s efficiency is much better than other systems. For some disciplines such as piping, the efficiency gains can be calculated in several orders of magnitude compared to other systems.

n view and rule-driven drawing – Using view style and rules is powerful. The solution reduces the labor needed to create drawings and ensures a uniform style by various designers throughout the team.

n Robustness of the solution – CSG has never lost any design data. This is unheard of com-pared to other systems.

n Openness – The software is very open. CSG can define additional model attributes according to its practices. If performed with another system, this had to be done manually. It would take longer and introduce a higher chance of errors. Other systems therefore lack the required quality that SmartMarine 3D can ensure.

n Advanced core architecture – CSG can develop additional functionality or write an interface to other systems.

n Data-centric approach – A powerful database server is required, especially for large projects. This is mainly due to very rich data for relationship management.

n System administration – The knowledge and experience requirements for the system admin-istrator are higher than those needed by other systems.

SSP650 – Sevan Driller

COSCO and Intergraph played major roles in a significant new offshore drilling industry milestone with the building of the world’s first circular drilling rig. SSP650, the Sevan Driller, classed by DNV, another strategic partner of Intergraph, was named at COSCO Shipyard Group’s Qidong Shipyard on June 28, 2009.

“The successful construction of the Sevan Driller is a mile-stone for the COSCO Shipyard Group. It is also a milestone for China in the offshore industry. Offshore newbuilding has been clearly recognized as one of the focus areas for the Chinese ship-building industry to develop in the years to come,” said Jorg Beiler, the vice president and regional manager of DNV China.

The Sevan Driller has advanced deep-water drilling capabilities that allow it to drill wells of up to almost 13,500 meters (40,000 feet) in water depths of up to nearly 4,200 meters (12,500 feet) and an internal storage capacity of up to 150,000 barrels of oil.

The owner is Sevan Marine. The construction of this rig started at COSCO Nantong Shipyard in May 2007 and was relocated to COSCO’s Qidong Shipyard in April 2009 for derrick erection and final commissioning. The rig will be deployed by Petrobras in the Santos Basin off Brazil.

Smart 3D

46 Insight

SECTION TITLE GOES HERECASE STuDY: COSCO SHIPyARD GROUP

SmartMarine 3D) was acceptable, the company wanted to perform the entire design on a single platform to gain the additional benefits of such an integrated approach. SmartMarine 3D outfit-ting had been successfully used in many projects and proved to be very powerful in outfitting design. CSG TC decided to implement the SmartMarine 3D hull module at an appropriate time given its ongoing and new projects.

Intergraph was invited to present its new and existing hull capabilities in June 2008. CSG TC decided that with the new version of SmartMarine 3D, it was appropriate to initiate a hull pilot project to be performed from August through October 2008.

Hull pilot projectTo verify the requirements of implementation and to test SmartMarine 3D hull functionality, CSG TC selected a barge project which had been designed on AutoCAD. The engine room, which represented a typical hull structure, was selected as the pilot area.

Intergraph, with CSG being a strategic and valued partner, gave its full attention to the project, preparing a very detailed schedule and assigning its China-based vice president to serve as project manager.

Intergraph provided on-site support engi-neers who worked side-by-side with the CSG TC-assigned engineers for the duration of the pilot project. All of the hull modules were tested to cover the complete design process from early design all the way to production. This included molded form, structure detailing, planning, structure manufacturing, structural drawing and appropriate reports.

Rules that allow automatic structural detail and manufacturing data generation along with supporting reference data were customized by Intergraph in accordance to CSG requirements. Also, specific drawing report customization was performed by Intergraph. During each stage, training was provided to ensure an accurate knowledge handover to CSG.

The pilot project was completed successfully in just 35 workdays, shorter than originally antici-pated. CSG TC found that the SmartMarine 3D hull module was very close to meeting actual production usage within CSG. The pilot

COSCO offshore projects implemented with SmartMarine 3DFollowing the first project, COSCO implemented many offshore projects with SmartMarine 3D outfitting, including the SSP650, GM4000, MPF1000, Super M2, Octabuoy ,92500 (deck house), and Sevan300.


47Insight

project also revealed that effi ciency and produc-tivity could be further increased and risk could be managed by implementing the SmartMarine 3D hull module in a phased approach. For the fi rst live project, CSG TC will use SmartMarine 3D for molded forms and planning. The structure detailing, manufacturing and drawing reports will be tested in a limited area to ensure the CSG-based rules are implemented appropriately. The CSG knowledge-base structural rules will be developed in parallel.

CSG Windmill projectAs its fi rst integrated SmartMarine 3D hull project, the CSG Windmill project was selected to implement molded forms and planning. All outfi tting will be performed using SmartMarine 3D outfi tting modules already embedded within CSG design processes.

For the Windmill project, CSG TC will perform detailed design while CSG Nantong TD will be responsible for production design. CSG TC will deliver the integrated 3D hull and outfi tting model to CSG TD for production design. The Windmill project marks the fi rst time a detailed

About COSCO Shipyard Group

Founded in June 2001, COSCO Shipyard Group Co., Ltd. (CSG), a subsidiary of China Ocean Shipping Co. (COSCO), is a large enterprise group, specializing in large vessel building, marine engineering construc-tion and conversion, and ship repair and building services. With locations including Dalian, Nantong, Zhoushan, Guangdong Province, Shanghai and Lianyungang, COSCO Shipyard Group offers large ship enterprises and ancillary services enterprises which lead the domestic market and enjoy a high inter-national profi le as well. Built on professional services and modern management, COSCO Shipyard has become the preferred partner for the world’s top shipping companies and offshore oil service providers.

design has been created by a 3D CAD system at CSG.

Creating deliverables with SmartMarine 3D was much faster than with the other previ-ously evaluated software. This will help to further reduce production design hours and continuously improve deliverables and engineering quality.

Currently, CSG is preparing further steps to implement SmartMarine 3D’s capabilities for both hull and outfi tting into production on a live project at the appropriate time.

Joe Guxiang serves as principal piping engineer at COSCO Technical Center. He is the 350POB and Windmill project technical manager. Song Zhiwne holds the current position of principal hull engineer at COSCO Technical Center. Li Jingjing is a hull engineer at COSCO Technical Center and is responsible for SmartMarine 3D.

www.cosco-shipyard.com

Smart 3D

SmartMarine 3D, developed by Intergraph, represents one of the latest 3D design soft-ware solutions in the market. The software provides shipbuilders with better decision support capabilities to facilitate global design, production and life cycle optimization.

In 2006, Keppel Offshore & Marine (Keppel O&M) adopted this “next generation” soft-ware as a data-centric solution to streamline its new-build design processes.

“We started talking to Intergraph in late 2003 about using PDS® to deliver the P-51, P-52 and P-56 projects,” said Aziz Merchant, gen-eral manager for engineering at Keppel O&M. “At that time, the SmartMarine 3D software was new to us. Intergraph provided us with training which helped our team understand the tools and their usage.”

Keppel Offshore & Marine Chooses SmartMarine 3D for Design EfficiencySoftware to speed production of offshore designs

n By Jana Miller

48 Insight

CASE STuDY: KEPPEL OFFSHORE & MARINE

Keppel O&M completed its trial of SmartMarine 3D in 2007. Its Mumbai engineering office sub-sequently became the first to use SmartMarine 3D as its modeling tool for a new-build semi-submersible drilling tender for its customer Seadrill. This drilling tender is built to Keppel’s SSDTTM proprietary design which caters to op-erations in the deepwater regions in the Gulf of Mexico, Brazil, West Africa and Southeast Asia.

“SmartMarine 3D improved our productivity by re-ducing the man-hours required to design projects. Its user-friendly interface and excellent graphics are an added advantage for us,” said Merchant.

Intergraph has partnered with Keppel O&M extensively on this project and has provided site support and consultation to optimize the usage of SmartMarine 3D. The SSDT project for Seadrill is now close to completion.

“From the time we first used PDS, the technical

support we have received from Intergraph has

been very good. This was one of the key factors

we considered prior to making the decision to

take the next step with SmartMarine 3D.

“We will continue to build on our win-win

partnership with Intergraph to further develop

the use of SmartMarine 3D to enhance our de-

sign processes,” added Merchant.

Keppel O&M will soon start another pilot proj-

ect to integrate SmartMarine 3D with its other

SmartMarine Enterprise software, including:

n SmartPlant P&ID

n SmartPlant Electrical

n SmartPlant Foundation

n SmartPlant Materials.


49Insight

MAXA Award 2008

Keppel FELS was named the overall winner of Singapore’s annual MAXA awards, which recognizes manufacturing excellence. MAXA is run in partnership by Singapore’s Economic Development Board, McKinsey & Co., and the Singapore-MIT Alliance.Keppel FELS Ltd. has grabbed a dominant share of the world’s oil rig market by running its operation more like a manufacturing plant instead of a construction yard.Oil rig makers typically run their business like a project-based construction job: most com-panies build these incredibly massive struc-tures one-by-one, from the bottom up. Keppel FELS has turned its shipyard into a large as-sembly line, building rigs in modules that are made at workstations by specialized crews that do only that.Keppel has also set up subcontractors’ yards, where suppliers make components right on site. Creating a vendor yard encourages com-panies to work more closely together. “This is very Toyota-like thinking,” says Chinta Bha-gat, managing partner of McKinsey’s Singa-pore offi ce. “you don’t expect to see that in a shipyard.”Operational excellence – on everything from the technical equipment used by factories to how staff are trained and incentivized – underpins the success of any manufacturing company, no matter what it makes, says Mr. Bhagat.“I work across the region and while compa-nies in Singapore could embrace lean produc-tion more fully, many are particularly good on the operations side,” says Mr. Bhagat. One example: the level of investment com-panies make in technical tools and systems, especially information-technology systems, is much higher in Singapore than the rest of the region, he says.“Singapore-based companies tend to outper-form, partly because they have to. Companies here have had to move aggressively up the value chain,” he says.

About Keppel Offshore & Marine

Keppel Offshore & Marine is one of the world’s largest offshore and marine groups. It has a strategic network of 20 yards serving regions such as Asia-Pacifi c, Gulf of Mexico, Brazil, Caspian Sea, Middle East and the North Sea. Established in 2002, it is a wholly-owned subsidiary of Keppel Corp.The company integrates the experience and expertise of Keppel FELS, Keppel Shipyard, Keppel Singmarine and its yards overseas. Quality solutions to customers are enhanced by proprietary technology and critical engi-neering expertise.Keppel O&M is the world leader in fl oating, production, storage and offl oading (FPSO) and fl oating, storage and offl oading (FSO) conversions. It is a leading ship repairer for liquefi ed natural gas (LNG) and liquefi ed pe-troleum gas (LPG) carriers and a niche player in specialized conversions and construction.Its expertise in specialized new-building ex-tends to a wide range of small to medium-sized customized vessels including anchor handling tug supply vessels, multipurpose support vessels and cable ships for a world-wide clientele.

This integration will further improve the de-sign to production information and materials information generated.“SmartMarine 3D is one of our key 3D solu-tions and reinforces our position as the pro-vider of choice and partner for solutions in the offshore and marine industry,” said Merchant.

Jana Miller is editorial director of Insight and is based in Huntsville, Alabama, U.S.

www.keppelom.com

As Signapore’s economy matured dur-ing the 1980s and 1990s, many multina-tionals began to move lower-end manu-facturing operations to cheaper Asian locations. The manufacturing companies that are located here today focus instead on high-value high-end production, tapping Singapore’s pool of highly-educated engi-neers and researchers, the city-state’s strong intellectual property laws and its position as a hub for Asian markets.Singapore’s manufacturing sector still contrib-utes one-quarter of the city-state’s GDP today. In 2005, the EDB announced that it aimed to double manufacturing output to US$200 billion and value-added to US$53 billion by 2018.Keppel FELS is a unique example of a compa-ny that’s improved its operational model, and turned its Singapore-based site into a world-leading operation. Innovations in both its op-erating system and its products have helped this Singaporean company grab a dominant share in the oil rig construction business. Kep-pel FELS has delivered over 50 percent of the world’s jack-up rigs and 45 percent of the submersible rigs in the last fi ve years.The company’s proprietary submersible rigs can operate in deep waters up to 10,000 feet and drill down to 30,000 feet. These oil rigs feature sophisticated dynamic positioning capabilities, which allow the rig to maneuver smoothly and maintain its position and head-ing at sea, in place of the traditional moor-ing systems, which are less fl exible. To meet demand as oil exploration moves into ever deeper water, Keppel has developed a rig called the deep draft submersible, which is ideal for areas like the Gulf of Mexico, Brazil and West Africa.“We have succeeded in integrating the best of both project and manufacturing approaches into our process,” says Tong Chong Heong, managing director of both Keppel FELS and its parent, Keppel Offshore & Marine Ltd.

Smart 3D

50 Insight


Grenland Group Chooses SmartPlant Enterprise to Maximize Offshore ProductionIntegrating huge amount of data in tight timeframe

n By Terje Tvinnereim

Grenland Group needed to be able to deliver all engineering and manufacturing information for the Low Pressure Modification Project at the Oseberg field in the Norwegian part of the North Sea. The project involved two offshore platforms connected by a bridge.

Owned and operated by StatoilHydro, the Norwegian oil and gas company, the enormous and complex Oseberg field modification effort required 170,000 engineering labor hours. The project deadline was also extremely tight.

meeting the challengeAt Oseberg, the project goal is to be able to produce more oil from the wells as the field

enters the final portion of its life cycle. Low

pressure modification means that, with a lower

pressure production method, StatoilHydro will

maximize the amount of oil it can extract dur-

ing the end-of-life of these wells.

The project is a huge challenge with great

potential gain. To succeed will require a monu-

mental effort in integrating disparate data,

including manual drawing information, existing

3D models converted from PDMS, use of new

3D laser scanning technology and new model-

ing data. The modification project also demands

new process information and instrumentation

tasks to be generated, in addition to the update of existing P&IDs and instrumentation.

The company faced extreme difficulty when it routinely used a wide variety of design engi-neering applications. The various applications did not work together, compounding workflow problems. As the company and its business grew, design engineering system activities became increasingly harder to support and more expensive to manage.

Desired integrationGrenland’s new integrated design engineering system had to deliver information as clash-free 3D models and structural, piping, equipment,

CASE STuDY: GRENLAND GROUP


51Insight

structural design, piping isometrics and P&IDs. Generally speaking, the internal design control workflows and acceptances will be performed inside SmartPlant Foundation. SmartPlant Enterprise and SmartPlant Foundation have great potential to be the key information source for the entire project’s development and completion.

“Intelligent tools on a common platform are feeding the main information into a single data source,” said Ørbeck. “That means you get control of your design and can achieve your project goal on time and within budget.”

Quick trainingAfter Intergraph’s initial implementation and educational services, Grenland took over the ongoing training and project implementation. Grenland now has the ability to manage huge, multidiscipline projects in a reliable and easy-to-use manner on a common platform.

“Our business requires many contractor resources. It’s crucial that training be easy for these people,” said Ørbeck. “They won’t have SmartPlant Enterprise experience, but we must get them productive in the project as soon as possible.”

proven technology“SmartPlant Enterprise has proven to us that this will work. It’s intuitive and easy to learn,” said Ørbeck. “This is a really big plus for Grenland.

“SmartPlant Enterprise is a great project tool. Of course, you must have excellent IT people on the front end to prepare for, adapt and implement this platform. But the reward comes for the general user who can learn the system quickly and put it to work right away.”

Terje Tvinnereim serves as senior vice president of the Technology Centre at Grenland Group. He is based in Sandefjord, Norway.

www.grenlandgroup.com

SmartPlant Enterprise met and even exceeded our expectations.

Terje Ørbeck CAD manager and 3D coordinator, Grenland Group

support and raceway modeling elements, as well as structural assembly and manufacturing draw-ings, all the way down to the cutting details.

The system would be expected to routinely and rapidly produce piping isometrics, P&IDs, instrument loop drawings and materials take-off data – all while maintaining a seamless connec-tion with the purchasing system. On top of that, Grenland’s system would be required to act as the central source for all engineering informa-tion, integrating data from several other systems.

To support multidiscipline projects in the onshore, offshore and marine markets cost-efficiently and on time, Grenland needed an integrated design system that used traditional 3D models and 2D CAD drawings as a design basis. The desired system would act as a single platform for all engineering information, espe-cially in large-scale projects.

putting it all togetherThe timeframe for StatoilHydro’s project completion is very critical. This puts a heavy burden on Grenland to be able to automate the information flow to avoid delays. The project’s financial success, both for client and owner operator, depends on this.

“SmartPlant Enterprise is essential to achiev-ing our goal,” said Terje Ørbeck, CAD manager and 3D coordinator at Grenland Group. The major requirements influencing the com-pany’s selection of SmartPlant Enterprise, and SmartPlant Foundation in particular, included the following:

n An integrated system for all design disci-plines that uses a common user interface

n Modern system architecture that can be built upon for the future

n An “easy to learn” user inter-face with modern graphics

n A serious supplier with depth of experi-ence in the plant design market

n A local, knowledgeable support team with sufficient resources to follow through.

Setting the standard“To put it mildly,” Ørbeck admits, “there was a lot of very different engineering software in use at Grenland.” Information had to be integrated from general drafting systems, like AutoCAD and MicroStation 2D drawings, and from 3D modeling, such as from PDS, PlantSpace and PDMS. There was a need for standardization in order to minimize costs and maximize resources.

Grenland chose the SmartPlant Enterprise suite, including SmartPlant 3D, SmartPlant Foundation, SmartPlant P&ID and SmartPlant Instrumentation.

“SmartPlant Enterprise met and even exceeded our expectations,” says Ørbeck.

Approximately 20 designers in the Oseberg project use the system for 3D modeling, struc-tural design, piping and equipment design and raceway design. Layout and structural fabrica-tion drawings, piping isometrics and spools are all extracted from the system. In addition, seven process engineers and five instrument engi-neers perform design work using SmartPlant Enterprise. SmartPlant Foundation is used as the information source for a wide range of people who need access to project data.

Straight from the sourceThe use of SmartPlant Foundation as the main design engineering data source for the project will be further extended to also include publishing of drawings like layout, manufacturing drawings for

Smart 3D

52 Insight


Vietsovpetro Stays on Top of Offshore DesignUpgrade from PDS to SmartPlant 3D improves productivity

n By Dang Dinh Nguyen

CASE STuDY: VIETSOVPETRO

Vietsovpetro (VSP) is a Vietnamese-Russian joint venture focused on the production of oil and gas from offshore sources; exploration and survey work for the oil and gas industry; well drilling; and the design, assembly and repair of offshore facilities. Responsible for approximately 80 percent of the nation’s oil and gas output, VSP helps Vietnam rank third in oil production and export in Southeast Asia.

VSP has produced more than US$33 billion of oil and gas and continues to grow fields through new discoveries and the enlargement of existing fields. The company contributes about 25 percent of Vietnam’s national rev-enue, making it the largest contributor to the state’s economy.

Advanced technologyWhen it comes to maintaining and managing our assets, we face a number of challenges. It is important that we invest in and embrace good technology to address these needs.

With Intergraph technology, we are able to

quickly visualize, question and analyze situa-

tions so that we don’t make costly mistakes.

We have been a longtime user of Intergraph

applications, beginning with PDS. We chose In-

tergraph because it offers a complete solutions

portfolio to satisfy project execution needs.

When we first learned about the advanced

concepts that SmartPlant 3D offered such

as relationships, associations and rule-based

engineering, we knew without a doubt that

SmartPlant 3D is the future of engineering.

We began to migrate our PDS seats to Smart-

Plant 3D seats soon afterward.

Data integrityAt VSP, we perform a large number of de-

signs and modifications for new and existing

offshore platforms. It is a challenge to keep

track of the changes and the related docu-

mentation updates when we use a traditional CAD-based approach.

With Intergraph SmartPlant Enterprise solu-tions, design and documentation activities are synchronized. This means we can ensure the data integrity of the design or model.

Keeping track of existing, new and future data is also important when we work on proposals. When a change occurs, we want to make sure that there are no clashes or operability or main-tainability issues.

Because of the number of changes we make on our facilities, we chose the SmartPlant Enterprise platform. Specifically, SmartPlant 3D was our top priority.

With SmartPlant 3D, we can easily manage data in both the 3D model and in outputs such as drawings. Once our model for a platform is built, it serves as an as-built model of the facility. This enables us to query, report and ex-


53Insight

We have received excellent service from Cre-dent for both training and customization. We customized catalogs, specifications, symbols, drawing templates and more.

We wanted to start from scratch with Smart-Plant 3D, so no data migrations were per-formed. All of the catalog and specification items were created by referring to the softcopy documentation and manufacturer catalogs.

Constant support from Intergraph and Credent was very helpful in guiding us along our initial path. We started our first SmartPlant 3D proj-ect within just two months. We definitely see productivity benefits in using SmartPlant 3D.

Smartplant EnterpriseVSP uses a variety of Intergraph SmartPlant Enterprise solutions:n SmartPlant 3Dn PDSn SmartPlant Foundationn SmartPlant Instrumentationn SmartPlant P&IDn SmartPlant Reviewn SmartPlant Spoolgen®.

In the future, we plan to expand our use of Smart-Plant 3D in conjunction with our other SmartPlant Enterprise solutions to ensure that other relevant information such as P&ID and instrumentation data is maintained in an as-built status.

We recognize that having access to new tech - nology is vital. One of our most important tasks is to help our employees enhance their profes-sional knowledge, apply technology and gain project execution knowledge. This is the biggest value we add to our organization – by building up our greatest asset, our employees.

Dang Dinh Nguyen is manager of the process, piping and offshore design department for the Science Research and Design Institute at Vietsovpetro Joint Venture. He is based in Vung Tau City, Vietnam.

www.vietsov.com.vn

About Vietsovpetro

During its 28 years of experience, Vietsovpetro has accomplished a number of noteworthy achievements. The company has built a synchronized and advanced technical system onshore and offshore to supply oil and gas production.

VSP was the first to discover and efficiently exploit Vietnam’s unique basement oil reser-voirs, such as White Tiger, Dragon, Big Bear and Eagle. The company has developed technical solutions for optimal exploitation of subsoil resources. These techniques have attracted the attention of foreign investors to petroleum exploration and production on Vietnam’s southern continental shelf, and the attention of worldwide scientists as well.

The joint venture has become the main force of Vietnam’s petroleum industry and economy. VSP has produced nearly 161 million tons of crude oil from its White Tiger, Dragon and Big Bear oilfields, with total crude oil turnover at approximately US$33 billion.

VSP has boosted Vietnam’s economy across a broad spectrum of industries. The supply of gas from the White Tiger field has brought the development of energy, fertilizer-chemicals and fuel gas industries in addition to improving shipping repair, port and warehouse services, petroleum products distribution and even tourism.

The company plays an important role in the development of local economy and culture. VSP has contributed millions of dollars from both its corporate fund as well as employee voluntary contributions for building infrastruc-ture, historical-cultural care, schools, hospitals, and supporting victims of poverty and both domestic and foreign natural disasters.

The president of Vietnam has twice given VSP the nation’s highest award, the Hero of Labor Golden Star of Vietnam, along with many other honors. Such great achievements are the results of tireless efforts of the company’s 6,500 employees.

tract any type of deliverable depending on the request. We also intend to use the model as an initial data set when we engage contractors for major modification projects.

VSP’s Science Research and Design Institute (NIPI) division is focused on design and engineering. NIPI uses SmartPlant 3D for the design and update of our offshore platforms. Since there are very few changes to the structural members on these facili-ties, the majority of the work is related to mechani-cal and piping.

NIPI uses SmartPlant 3D for tasks such as design and installation of new pipelines and equipment items, extraction of general arrangement drawings, piping isometric drawings, equipment layouts, ipe support drawings and various types of reports.

As-built modelSmartPlant 3D manages the as-built 3D model of our RP2 offshore platform. We use SmartPlant 3D to model the existing process system and main structure of the platform. With Intergraph’s ad-vanced solution, we designed and modeled the new process system, including equipment, piping, auxiliary structure and pipe support.

SmartPlant 3D helped us perform design check and review. We were able to generate deliv-eries to meet VSP’s standard formats for 2D drawings as well as equipment and piping plans, piping isometric drawings and MTOs.

ServicesHaving experienced and knowledgeable local partners gives us confidence in upgrading our Intergraph technology. We chose Intergraph because of the high level of support we re-ceive from Intergraph and its local partner in Vietnam, Credent Technology.

The Intergraph consultants are experienced and very knowledgeable. Most of them have experience in working for large EPC compa-nies. They bring to the table not only software experience but also project execution knowl-edge, which is very important to us.

Our PDS users took a SmartPlant 3D training course. Intergraph and Credent training staff were available in the office to offer assistance afterward for approximately four weeks. This was perfect for the users to get used to the new system.

Smart 3D

54 Insight


Intergraph Expands SmartMarine 3D Design Software Capabilities for Offshore MarketSingle, integrated environment offers increased productivity to accelerate offshore projects

Intergraph has released the newest version of its next-generation 3D design solution with significantly expanded offshore capabilities. SmartMarine 3D reduces engineering man-hours, improves design quality and consistency, increases data integrity and improves cross-discipline collaboration.

SmartMarine 3D, a key component of Intergraph’s multidiscipline SmartMarine Enterprise portfolio, provides all the capabilities needed to design and build offshore devices and ships from design to fabrication to operations and maintenance – all in a single, integrated environment. It is a data-centric, rule-driven solution for streamlin-ing design processes while preserving existing data and making it more usable/reusable over the operation, maintenance and modifica-tion life cycle of the device. SmartMarine 3D’s design reuse wizards also enable companies to inventory their best-in-class design configura-tions, allowing them to respond more quickly and accurately to requests for proposals and fast-track project requests.

SmartMarine 3D offers additional offshore-spe-cific functionality: n Rule-based Joints govern joint behavior. For

example, a parametric gap between incoming

members is defined as part of the rule-based joint. This gap is then maintained by the soft-ware as the incoming members change.

n Built-up members are defined and modified as a single member, but are actually composed of multiple plates that can be independently fabricated.

n Advanced plate Systems are parametric rule-driven plates that in combination define complex nodal connections. The Advanced Plate Systems update automatically as the incoming members change. The whole nodal connection can be placed in the catalog for later reuse.

n Automated Detailing trims bounded parts such as tubes and places end-cuts, chamfers, welds and weld bevels automatically based on customizable rules.

SmartMarine 3D represents a step-change in the marketplace. Where competing solutions use two or three different applications that are at best loosely coupled, SmartMarine provides a single environment to perform structural, hull, piping, equipment, HVAC and electrical model-ing, with automated detailing and drawings for offshore and ship design, which ensures overall design consistency with high-speed execution.

A powerful, 2D drafting system is embedded in SmartMarine 3D, which eliminates the need for third-party drafting applications.

“At COSCO Shipyard Group, we have been using SmartMarine 3D in production on numerous offshore projects,” said Liang Guoming, deputy general manager, Technical Center, COSCO Shipyard Group. “SmartMarine 3D is helping us achieve greater productivity and higher quality designs. The enhancements included in the newest version of SmartMarine 3D will assist us in gaining a further competitive edge during these challenging times within the marine industry.”

Gerhard Sallinger, Intergraph Process, Power & Marine president, said, “Intergraph has been involved in the offshore and shipbuilding indus-tries around the world for more than 20 years. SmartMarine 3D, with its impressive list of new offshore capabilities not available in any other commercial solution, builds upon our tradition of technical innovation and provides our customers real value in challenging times.”

www.intergraph.com/products/ppm/sm3d

DID YOu KNOW?: SMARTMARINE 3D


55Insight 55InsightMarine Industry

Across disciplines and around the world, SmartMarine® 3D is delivering the future of shipbuilding design and manufacturing – today. SmartMarine 3D is the most advanced ship design software offered in decades. It provides all the tools you need to prosper in a highly competitive, dynamic environment in which you can design and build many different types of ships. Optimize and streamline your workflows with global and concurrent engineering. SmartMarine 3D, as part of our SmartMarine Enterprise solutions, provides a single, integrated environment for all internal and external disciplines involved in ship engineering and building.

Visit www.intergraph.com/go/offshore/ and learn how to gain project, schedule, and cost benefits throughout the ship’s entire life cycle.

Intergraph, the Intergraph logo, and SmartMarine are registered trademarks of Intergraph Corporation. ©2009 Intergraph Corporation. 10/09

gain the competitive edge with intergraph® smartmarine 3d.

Changing the way ships are designed and builtSmartMarine® 3D

56 Insight


56 Insight

Intergraph SmartMarine Enterprise Boosts Productivity Solutions manage data through the marine life cycle

n By Tom Szoka

DID YOu KNOW?: SMARTMARINE ENTERPRISE

Advances in the software tools available to shipbuilding, marine engineering and produc-tion organizations have enabled them to move forward. While these trends are likely to continue, they will only produce step-wise improvements in their vertical segment.

To achieve major productivity breakthroughs, manage the accelerated speed of changes and provide significant returns on investment in technology and tools, a broader, more horizon-tal strategy is needed that extends the domain across engineering, business, material manage-ment, and production systems.

Given the scope of such a task, no single product or vendor will likely address all the requirements. What is needed is a scalable, open solution that can serve as an integration

and data repository platform such that global project information cannot only be created, but managed in a controlled and integrated man-ner throughout the project life cycle.

Effective ERP implementationA growing trend in the shipbuilding industry is for shipbuilders to implement enterprise resource planning (ERP) systems like SAP®. One of the keys to effective ERP implementation in a ship-yard is effective data exchange and integration between ERP elements of work planning and material management, engineering and design systems, and production systems like nesting and shop floor management. Effective integra-tion can yield up to an 8x benefit to that derived from automation alone (see Reference 1, page 30). This article will outline production-proven

methodologies for implementing effective data exchange and integration between ERP, engi-neering and design, and production systems.

Required data exchangesFigure 1 outlines the effective data exchanges that will be the basis of the discussion.

Arrows marked with 1 represent the exchange between materials management and design systems. A major source for Bills of Material (BOM) in a typical shipyard is from design tools. Arrow 1a represents that exchange. For any effective data exchange to ERP’s material man-agement system, there must be synchronization from the design tool’s material codes and ERP’s material codes. The arrow marked 1b represents the synchronization of material codes with ERP.


57Insight 57Insight

Arrows 2 represent the exchange between pro-duction applications like pipe fabrication, plate nesting and profile nesting. These applications create BOM (arrow 2a) and require synchroni-zation of material codes (arrow 2b).

Arrow 3 represents publishing data from design to production applications. This exchange includes part information and geometry for plate and profile nesting and piping materi-als and connectivity for fabrication. The data exchanged inherits material codes from ERP.

Arrow 4 represents the publishing of top-down early design production planning information to seed the work breakdown structure (WBS) in the ERP project services system.

Arrow 5a represents WBS information pub-lished from ERP to detailed design tools so the detailed design tools can do further bottom-up assembly planning. Arrow 5b represents WBS published from ERP to production systems.

Arrow 6 represents data exchange between design tools – for example, functional-to-detailed design for hull structure and outfitting piping.

Managing data exchangesConsider exchanges 1 through 5 in the context

of steel plates. Exchange 1a and 3 contain

duplicate information but for different contexts.

In the case of 1a, early in the design cycle, the

exchange is primarily for refining steel estimates.

Later it provides detailed BOM information in

the context of WBS (5a). Exchange 3 contains

the same information that each individual part

contained in 1a, plus the additional geometric

information required for nesting. However, the

detailed “bottom-up” assembly information

exchanged in 1a is not required during number 3 data exchange. 2a contains the individual parts from 3 plus the additional plate and pro-file stock information.

Three conditions exist in this scenario:

n Three systems (design, production and ERP) share common information about steel.

n The shared information needs to stay consistent.

n Each system needs to add, modify and delete its data throughout the project life cycle while maintaining consistency.

Data exchanges for arrow 6 in Figure 1 often have the same conditions.

A solution to ensuring data exchanged is complete, consistent and correct is to have a common technical data and document repository as in Figure 2 with the data exchanges from Figure 1 moving in and out of the common repository as a central hub rather than point- to-point exchanges.

Common data and document repository characteristicsIn order for the common data and document repository to be effective in maintaining complete, consistent and correct data, it must contain the following characteristics:

n Integration with leading ERP, design and production tools out of the box to reduce implementation costs and the time to productivity

n Open and extensible to enable exchange with data and documents with other vendors’ design and production tools and in-house systems

n Provide change information – what specifi-cally changed, who changed it and when – all in an easy-to-understand context.

Material management integrationsThere are three parts to material management inte-

grations from the scenario presented in Figure 1:

n BOMs from design and production tools

contain correct material codes for ERP (1b, 2b

from Figure 1)

n BOM information from design and production

tools to ERP (1a, 2a from Figure 1)

n BOMs contain work breakdown consistent

with ERP (5a, 5b from Figure 1).

These parts must contain the required

characteristics of:

n Standard integrations “out of the box”

n Open and extensible

n Manage change.

Material catalog synchronizationEach piece of the integration triad – ERP, design

and engineering, and production – require

different material information for their tools.

Let’s consider two examples from hull and outfit-

ting: steel plates and valve information (Figure 3).figure 2 Data exchanges with common repository

figure 3 Steel plates and valve material requirements

figure 1 Data exchange

Smart 3D

58 Insight


58 Insight


figure 5 SmartPlant Materials E&PI and ERP integration

figure 4 AVEVA integration

In both examples and for most materials, the

ERP system contains information for purchasing

that is not explicitly required in design and

production tools. In both examples and for most materials, there must be a way of identifying materials that are common to more than one application. This is indicated by the overlaps of all three circles with material code in the middle.

In the case of plate parts, raw stock sizes (length

and width) are required for nesting while this data is not widely used in design applications.

The overlap between nesting and 3D CAD

includes material, grade and thickness. No

additional information is required in 3D CAD.

In the case of valves, 3D information is required

for 3D CAD while all information required for

intelligent P&ID is contained in the overlap

between 3D CAD and intelligent P&ID. Examples

of characteristics include valve types and sizes.

The Intergraph SmartMarine Enterprise offers

SmartPlant Reference Data to manage and syn-

chronize catalogs between ERP and design and

production systems. SmartPlant Reference Data

is a Web-based application that offers a single

database catalog for all disciplines and tools. It

contains standard integrations to Intergraph and AVEVA design tools (Figure 4), and SAP MM.

SmartPlant Reference Data is configurable with supported input/outputs in Microsoft Excel®, XML, comma delimited, etc.

Design and production BOM to ERPAs discussed, exchange 1a (design BOM to ERP) and 3 (design nesting information to nesting) from Figure 1 contain duplicate information but for different contexts. Early in the design cycle, exchanges 1a and 3 could be combined to provide more detailed material estimates to ERP, offer bottom-up assembly information, and provide nesting information without marking lines and beveling for pre-nesting. The data from 2a is combined with 1a to provide ERP with a complete picture of parts to be cut and where they fit in the assembly hierarchy.

SmartMarine Enterprise offers the Web-based Engineering & Procurement Interface (E&PI) module for SmartPlant Materials to manage BOM from various sources, consolidating them and providing information to procurement.

The E&PI module allows BOM verification and the addition of information before sending to procurement, including:

n Check items against catalog

n Check data consistency

n Using rules, calculate attribute values and adjust bulk quantities

n Create material summaries into requisition packages with attached documents and ven-dor document requests.

E&PI contains standard integrations to Intergraph and AVEVA design tools and SAP. The same clients that use SmartPlant Reference Data’s AVEVA integration use the E&PI integra-tion. The SAP integration allows you to preset SAP mandatory fields with defaults like network activity code, job type, material group, general ledger and more.

Of the 40 E&PI implementations, 22 include interfaces to ERP (Figure 5).

The E&PI module manages change with the following functions:

n Send individual BOMs and/or grouped materials to procurement, for example, group by block

n Summarize bulk materials into requisition packages

n Manage different phases of BOMs like esti-mate, final design and revisions

n Track what came from the design system and what was sent to procurement

n Manage changes and compare phase/revi-sions to items sent to procurement

n Analyze change to enable faster decisions.


59Insight 59Insight

figure 6 Relationships between data and documents in SmartPlant Foundation

figure 7 Comparing the data and visual representation of two document revisions

Work Breakdown Structure IntegrationConsistent WBS information is required for effective production design and exchange of BOM information.

Intergraph SmartMarine Enterprise has a general purpose application for managing exchanges of information like WBS called SmartPlant Foundation. SmartPlant Foundation comes with a built-in data model for WBS, and Intergraph’s design tools support exchange to/from this data model. This WBS exchange is used in production at plant design and owner companies like Chiyoda, Dow Chemical and Air Products.

Smart Integration FrameworkSmartPlant Foundation allows data exchange in a variety of ways, but the preferred methodology is through the Smart Integration Framework. Smart Integration provides an effective way of maintaining complete, consistent and correct data across software systems and applications.

The framework includes open, extensible com-mon schema and documented, supported soft-ware components for publishing and retrieval of data and documents. Implementations of the software components in the framework are called adapters. All of the Intergraph tools in the SmartMarine Enterprise like SmartMarine 3D and SmartPlant Materials come with sup-ported adapters that use the same software toolkit available for customers and other soft-ware vendors.

The following features come automatically to applications that integrate using the Smart Integration Framework:

n Security and audit gives you full history of all data changes with the ability to “turn the clock back in time” to see what the project looked like at any point. you can configure the system to only allow users with appropriate privileges to publish, retrieve, view or manipu-late data.

n Integrated document management with SmartPlant Foundation’s document manage-ment capabilities is available.

n Relationships between drawings and docu-ments are published with their associated data. Figure 6 shows the relationship between

equipment in SmartPlant Foundation, its draw-ing and individual graphic elements within the drawing. In this example, if the equipment item also appeared in the equipment location drawing that came from SmartMarine 3D, Smart Integration would have automatically created the relationship from the equipment item to that drawing.

n Intelligent comparisons of document revisions can be made at the data level. Figure 7 shows a comparison of two revisions of the same schematic indicating items that were added, modified and deleted, all the way down to individual attributes on specific items.

Additional value: workflow and appletsUp to this point, we have focused on the three common data and document repository

characteristics that “must exist” for effective management:

n Standard integrations “out of the box”

n Open and extensible

n Easily and effectively manage change.

This section will focus on the two features that enhance “must exist” characteristics: workflow engine and enabling new applications.

Intergraph’s SmartPlant Foundation comes with a workflow engine that allows you to model work processes which can enhance the abil-ity to effectively manage change. SmartPlant Foundation’s open architecture allows clients to easily integrate work processes with workflows

Smart 3D

60 Insight


figure 8 Workflow configuration in SmartPlant Foundation

figure 9 Intergraph SmartMarine Enterprise elements playing in SAP NetWeaver portal

in ERP. Figure 8 shows a graphical view of a typical workflow along with a checklist that can be associated with a step. This same interface enables users and managers to see the status of tasks to determine where the bottlenecks are and what is behind schedule.

The engine can be configured to notify users of tasks to be done within SmartPlant Foundation with an option to have notifications done via email. It also includes the ability to attach drawings, documents or other data objects to the workflow. Workflows are fully auditable as per the rest of objects, documents and data in SmartPlant Foundation.

An additional value is to have elements of the SmartMarine Enterprise solution plug and play into a larger enterprise application to further enhance user experience in terms of manag-ing change and seeing the bigger picture. In

support of this value, SmartMarine Enterprise comes fully equipped with components that can plug into SAP’s NetWeaver® portal. This permits the exchange of critical data with instances of the SAP Business Suite family of solutions and is integrated successfully with business functions exposed through the SAP NetWeaver portal.

Figure 9 shows an example of a NetWeaver portal using SmartPlant Foundation’s 3D model to navi-gate from individual elements in the 3D model to data in SAP data and a reliability system.

Conclusionsn Implementing ERP provides an opportunity for

shipyards to transform their businesses

n A major aspect of the ERP implementation and business transformation is providing effective data exchange and integration between design, production and ERP

n Implementing a common data and document repository is an effective way to ensure data exchange is complete, consistent and correct

n For the common data and document reposi-tory to be effective in maintaining complete, consistent and correct data, it must contain the following characteristics:

– Integration with leading ERP, design and production tools out-of-the-box to reduce implementation costs and reduce the time to productivity

– Open and extensible to enable exchange with data and documents with other vendors’ design and production tools and in-house systems

– Provide information that change occurred, what specifically changed, who changed it and when, all in an easy-to-understand context

n SmartMarine Enterprise contains all of the elements required to support integration between ERP, design and production and has successfully demonstrated these capabilities at client sites around the world.

Reference: 1. Guidelines for Specifying Integrated Computer-Aided Engineering Applications for Electric Power Plants, EPRI (Electric Power Research Institute) report NP-5159M, Research Project 2514-3, May 1987

Tom Szoka serves as vice president at Intergraph Process, Power & Marine.

www.intergraph.com



61Insight

accelerate projects and gain a competitive edge

Choose the industry’s only next-generation, data-centric 3D offshore design solution from Intergraph® for the design, construction, and safe operation of your offshore facilities. With the SmartMarine Enterprise integrated suite of solutions, automated, configurable engineering rules ensure design-to-production accuracy and consistency. Boost productivity by an average of 30 percent and build safety into the design from the start. Global workshare, operations, and life-cycle asset management are also optimized with SmartMarine Enterprise engineering information management, the industry standard for maintaining your platform’s engineering design data for decades to come.

The future of engineering – today.

www.intergraph.com/go/offshore

Intergraph, the Intergraph logo, and SmartMarine are registered trademarks of Intergraph Corporation. © 2010 Intergraph Corporation. 7/10

inCrease offshore design produCtivitySmartMarine® Enterprise for Offshore

when BUilding the FUtUre, tUrn to intergraph®

In a competitive, yet fragile world, new approaches are needed. To design, build, safely operate, and sustain today’s complex, multi-billion dollar plants demands next-generation engineering software. Choose the safety management capabilities of Intergraph SmartPlant® Enterprise. The world’s leading engineering firms and owner operators rely on SmartPlant Enterprise to enable their process and power plants, ships, and offshore platforms to be created faster and more efficiently than ever by leveraging networked global resources and the industry’s only data-centric, automated, rules-based 3D design software. Trust SmartPlant Enterprise to enhance safe operations and asset sustainability with advanced data management applications that can catalog and track millions of components for decades.

How Can You Increase Safety in the Engineering Enterprise? www.intergraph.com/go/safety

Intergraph, the Intergraph logo, and SmartPlant are registered trademarks of Intergraph Corporation. ©2011 Intergraph Corporation.

a safer tomorrow has arrivedSafety Management

a publication of intergraph process, power & marine 2011 … publication of intergraph®...

Documents