italteleco laser scanning engineering rfid applications

Italteleco was founded in 1986, as a Software House specializedin industrial software solutions.

Since 1995 our core business is to provide integrated solutionsfor large-scale companies.

Since 2003 we are Business Partners ofIntergraph PP&M, the leading company in enterpriseengineering software for the design, construction, andoperation of plants, ships, and offshore facilities.

Our History

We firmly believe in continuous learning to develop the skills andknowledge of our personnel and in the application of newtechnologies as a tool to improve the processes in which we areinvolved.

Our Mission

Our Fields of Activity

Certifications

Existing documentation often unreliable and inconsistent with real fieldsituation.

Critical points:

Design based on unreliable data.

Additional EPC costs.

Leica HDS6100Range: 79 m.

Speed: 508.000 pt/s

Leica ScanStation C10Range: 300 m.

Speed: 50.000 pt/s

Z+F Imager 5010Range: 187.3 m.

Speed: 1.016.000 pt/s

Field Survey

Creation of a topographic controlnetwork,

Placement of the targets (at least 4visible from each scan)

Execution of the scanning from theselected scanning positions.

Acquisition of the targets coordinateswith a total station.

Field Survey

Single scans are executed fromdifferent positions so that all thevolume of interest is covered. Targetson each scan allow for precise pointcloud registration (roto translation to acommon coordinate system.)

Registration

Single scans are registered according to the coordinates of the targets oneach scan, surveyed with a total station: the final result is a point cloudrepresenting the entire plant, with correct plant coordinates.

3D Model

Modeling is performed by means of dedicate software(Cyclone/LFM/PDS/CadWorx): piping components are modelled accordingto applicable piping classes.

Isometric Drawing

Isometric Drawing

Piping Layout

Clash check allows for a precise identification of clashes between newpiping/equipment/structures (3D model) and existing plant (point cloud)

Issue of “Clash Check Isometrics” helps piping specialists to quickly identify andsolve every single clash.

Engineering

•Reliable as-builtdocumentation

•Accurate measurements

•Clash check

•Faster & Safer survey

•Constructability

Maintenance

•Minimize shut-down timewith accurate pipingsubstitution isometrics, critical lift simulations

•Identify in advance the best construction sequences

Operations

•Use 3D models for safeoperators training

•Integrate intelligent 3D model with RFIDtechnology for positive item identification, intelligentinspection&model markup

Scaffolding

• No need of scaffolding in most cases: survey costs are thus greatly reduced

Survey Time

• Minimize survey time: 2 operators with 1 scanner can survey an entire process plant(of average size) in about 15 days with an accuracy of 5 mm.

Shut-downTime/Construction

Time

• Shut-Down times are minimizedusing accurate and reliabledocumentation, critical lift simulations: no additional shut-down time costs, no additionaladjustment costs.

• Construction time are minimized using clash checktools, interactive 3D modelsconstruction sequencesimulations

Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person

2007

FCC - Regenerator - Phase

1

Laser scan, various

interference check testsSaras (Sarroch) 4000 50 Della Vedova R.

V1 Vacuum PlantLaser scan, 3D model and

critical lift simulationSaras (Sarroch) 3600 30 Cotza M.

RT1-RT2 PlantLaser scan, 3D model and

critical lift simulationSaras (Sarroch) 7500 40 Cotza M.

GPL UnitLaser scan, 3D model,

piping layouts extractionSaras (Sarroch) 2700 10 Cadeddu M.

IGCC UnitLaser scan, dimensional

checksSarlux (Sarroch) 4400 40 Puddu D.

Alkylation UnitLaser scan, plot plan

extractionSaras (Sarroch) 6000 30 Della Vedova R.

Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person

2008

FCC UnitLaser scan, shutdown

critical lifts simulationSaras (Sarroch) 24200 50 Cotza M.

Alkylation Unit

Laser scan, 3D

model,piping layouts

extraction

Saras (Sarroch) 6000 30 Della Vedova R.

2009

Mild Hydrocracking UnitLaser scan, reactor lifting

simulationSaras (Sarroch) 13000 40 Caredda R.

FCC UnitLaser scan, dimensional

check nozzle K1R2-K1E58Saras (Sarroch) 900 40 Cotza M.

Biomass Power Plant

Laser scan, 3D model and

critical lift simulation for

boiler substitution

Sicet (Ospitale di Cadore) 18000 20 Vascellari M.

U400 Desolphoration Unit

Laser scan, isometric

extraction for piping

replacement

Saras (Sarroch) 2400 40 Pili A.

Biomass Power PlantLaser scan, 3D model,

existing structuresSicet (Ospitale di Cadore) 18000 20 Vascellari M.

U400 Desolphoration Unit

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

2400 40 Pili A.

CCR UnitLaser scan, dimensional

checks on CCRD19 Saras (Sarroch)9000 40 Cotza M.

Visbreaking UnitLaser scan, battery limits

cross section extraction Saras (Sarroch)4200 30 Spanu U.

Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person

2010

Topping 1 UnitLaser scan, battery limits

cross section extraction Saras (Sarroch) 4200 30 Spanu U.

Main Stack

Laser scan, dimensional

check for elevator

installation Saras (Sarroch)

400 80 Aymerich S.

Z3 UnitLaser scan, stack vibrations

monitoring Saras (Sarroch)- 130 Cozza R.

2011

Topping 2 Unit

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

9000 40 Corvetto F.

CCR Unit

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

9000 40 Corvetto F.

CCR Unit

Laser scan, 3D model,

design of overhead

travelling crane

modifications

Saras (Sarroch) 2000 25 Cotza M.

Centro Olio Val d'Agri

Laser scan, 3D model,

virtual as-built survey on

P&IDs Saipem (Viggiano)

62500 15 Sirignano A.

Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person

2012

Alcoa

Laser scan, dimensional

checks

Alcoa Trasformazioni s.r.l.

(Portovesme)2500 15 G. Meloni

RT2 Unit

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

3000 30 Cocco W.

Vacuum 1 Unit

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

4500 45 Cocco W.

2013

SG10 Area

Laser scan, 3D model,

isometric and piping

layout extraction Isab (Priolo)

45000 10 Giuliano G.

CR27 -FCC UnitLaser scan, dimensional

check Isab (Priolo)400 40 Giuliano G.

LPG Storage Plant (LPG

spheres and bullets)

Laser scan, 3D model,

isometric extraction virtual

as-built survey on P&IDs Saras (Sarroch)

28000 15 Di Monte D.

Products StorageTanks

Laser scan, 3D model,

isometric extraction virtual

as-built survey on P&IDs Saras (Sarroch)

200000 15 Di Monte D.

FCC unit/Expander

Laser scan, .LFD dataset

generation (LFM Server)

Saras/Foster Wheeler

Italiana (Sarroch)

10000 30 Stefanini L.

FCC unit

Laser scan, .LFD dataset

generation (LFM Server)

Foster Wheeler Italiana

(Ploiesti, Romania)45000 65 De Angeli P.

Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person

FCC unit

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

15000 60 Garau L.

Topping 1

Laser scan, 3D model,

isometric extraction for

piping replacement Saras (Sarroch)

12000 50 Vargiu M.

MHC UnitLaser scan, 3D model,

clash check Saras/IDI (Sarroch)500 15 Pagani W.

2014

Biogen Idec PlantLaser scan, .LFD dataset

generation (LFM Server)Foster Wheeler Italiana

(Hillerod, Denmark)

50000 5 Mencarelli A.

Furnace Exhaust Duct

Laser scan, Dimension

Check

Topping Units, Sarlux

/Kirchner, (Sarroch)- 20 Donzelli C.

RFID-BasedPlant Data Collection&Management Systems

Blind Flanges Management

SmartPlant P&ID Mobile

Inspections&Maintenance

RFID-BasedPlant Data Collection&Management Systems

Software Requirements

All the applications will be used in petrochemical plants duringconstruction, operation and maintenance, they must therefore comply with the following

requirements:

1) It must be possible to install the applications on mobile devices2) It must be possible to use the applications in explosion risk areas3) Items identification must be univocal4) It must be possible to write information on the RFID tags5) Applications must be interfaceable with other DB-based applications6) It must be possible to access data from Intranet/Internet

RFID-BasedPlant Data Collection&Management Systems

Chosen Technology

Development Environment: Microsoft .NET Compact Framework

Palm Sized PC (PPC) characteristics :

Operating System: Windows Mobile RFID Scanner: 125 kHz ATEX Certification

RFID-BasedPlant Data Collection&Management Systems

RFID TAG characteristics (Other TAG types can be used on Customer’s request):

Operating Frequency: 125 kHz Chip: HITAG S 2048 (read/write) ATEX Certification Easily identifiable (yellow colour)

Low operating frequency and RFID scanner’s characteristics require physical contact between RFIDscanner and tag in order to complete any operation:It is therefore impossible either to operate on the wrong tag or to record wrong information.

About 2000 blind flanges are involved in the shutdown of a medium-sized plant. Flanges are inserted and then removed in about 40 days.

This process must be correctly managed and controlled, in order to ensure high safety levelsand avoid problems that could lead to unwanted accidents and/or delays.

It is therefore necessary:

To verify the status (inserted/removed) of every blind flange.

To verify the status of every interference blind flange (common to several blinding plans)

To verify the completion status of every blinding plan

To easily identify any potential problem

Blind Flanges Management

Blind Flanges Management

Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of eachequipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.

Blind Flanges Management

Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of eachequipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.

Blind Flanges Management

Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of eachequipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.

Blind Flanges Management

Information concerning blinding plans and blind flanges positions are loaded into the DataBase (in this case: Intergraph AIM-Directa): Relations are created between objects.

Database is synchronized daily with data from the field.

Blind Flanges Management

Properties shown in the figure are associated to every blind flange (fully customizable on request)

Blind Flanges Management

For every blind flange position, an RFID tag is initialized with the blind identification code and initial status: initial status is set to “To be identified”, meaning the blind flange position has to be identified on the field.

Initialized tags are then mounted on a metallic support which is then placed in the correspondent blindflange position.

User registers, with the PPC, the correct placement : status is set to “Identified”

During the shutdown operations, users , using the PPC, register insertion/removal of blind flanges: Status is set to “Inserted”/”Removed”

Removal of interference blinds can be registered on the system only when all the operations concerning the blinding plans on which the interference blind flange appears have been completed. Users are constantlyreminded that they are working on interference blind flanges.

Blind Flanges Management

Application login (using an RFID tag) Main Menu

Blind Flanges Management

Blinding plans list Blinding plan: checking general status

Blind Flanges Management

RFID Tag Reading Setting status to “Identified”

Blind Flanges Management

Setting Status to “Inserted” Setting Status to “Removed”

Blind Flanges Management

Interference Blind Flanges: setting status to “Inserted” and registering start of activities

Blind Flanges Management

Data from the field is synchronized daily (or at every shift change) with the main DB: users can accessinformation via the document management system (in this case: Intergraph AIM/Directa)

Icons are coloured according to the blind status.

SmartPlant P&ID Mobile

SmartPlant P&ID Mobile has been developed to allow plant operators, construction and maintenance personnel, to access, view and modify SmartPlant P&ID information using a Palm Sized PC (PPC) Using RFID tags to identify equipments, instruments, piperuns, piping components, etc. queries on the system are automatically performed.

SmartPlant P&ID Mobile

SmartPlant P&ID mobile manages the followingSmartPlant P&ID objects:

EquipmentsEquipment ComponentsInstrumentsInstrument LoopsNozzlesPiperunsPiping Components

Graphic P&ID can be visualized on the PPC:an intelligent zoom is performed on theselected object (not working, in this version, on piperuns)

SmartPlant P&ID Mobile

A desktop application uses “Llama” libraries (Logical Model Automation) and SmartSketchlibraries to connect to SPPID database and performs the following operations:

Reads properties values of the various objectsGenerates a mobile DB, which is transferred on the PPCConverts graphic P&IDs from .pid to .dwg formatWhen properties are modified on the PPC, updates SmartPlant P&ID’s DB

SmartPlant P&ID Mobile

Unit Selection Queries can be performed manually or using an RFID TAG

SmartPlant P&ID Mobile

Query Results Object visualizaton on the P&ID

SmartPlant P&ID Mobile

Properties are categorized like on SPPID Modification of a property on a piperun

SmartPlant P&ID Mobile

Adding appropriate values of “Construction Status” allows a simple work progress monitoring: In the above figure, piperuns with hydrotest completed are highlighted in blue (data registered with PPC). Every construction status can be traced from prefabrication to “Ready for Start-Up”

Inspections&Maintenance

Data from DB

Item Name

Item Picture from DB

Physical contact between RFID scanner and RFID TAG ensures positive identification of the item: itemdata, work orders, inspection check-lists are shown on the handeld device screen.

Inspections&Maintenance

Work Orders Management: Work Orders for the item are shown on the handheld device and managedon the field by maintenance operators.

Inspections&Maintenance

ASSET DATA VISUALIZATION

Inspections&Maintenance

ASSET DOCUMENTATION VISUALIZATION

Benefit of RFID-Based Plant Data Management Systems

Process management improvement Process monitoring is easier with consistent, verified data Problems are easily identified and managed Identification errors are not possible

Easy and fast transition to the new system Applications are designed to be as similar as possibile to the traditional working procedures (applications are fully customizable according to the Customer’s specifications Training time for a low-skilled user: 2 hours.

We started our engineering&design activities in 2001 with participation ina working group of international caliber in the petrochemical industry. Theaim was to optimize the management of physical and virtual warehousestocks. This project was to be applied to Petrochemical and Refining plants(standard materials coding, supplier agreements, purchase requisitions,automatic generation of purchase orders) with the goal of achieving asignificant reduction in operating costs.

Engineering&Design

Since 2002 we developed additional skills and we can now provide the following services:

Updating and management of piping material catalogs (according to ENI standards)

Design of piping material classes

Modification/updating of existing piping material classes (ASME/EN) forevery kind of material (carbon steel, low-alloy steel, stainless steel, duplex, monel etc.) and for every rating.

Design of pressure vessels and pressure systems in compliance withPED directive.

Engineering activities for the purchase of spare parts in compliance with D.M. 329/04 and subsequent circulars.

Engineering&Design

We can manage every stage of the project:

◦ Material requisitions

◦ Technical analysis of tenders

◦ Supplier follow-up

◦ Technical documentation review

◦ Pre-commissioning

Engineering&Design

Engineering&Design

Design of PED equipment (ASME/EN) including spherical tanks, hortontanks, fixed and floating roof tanks (API 650, API 620, API 653).

Other Activities

Engineering&Design

Fitness for service analysis - API 579

Design of repair systems (armouring) and evaluation of hot tappingsolutions for piping and equipment (API 2201, API 570, ASME PCC-2)

Finite elements analysis of pressure systems and structures

Design of piping material classes in compliance with ASME B31.3 / B31.1/ EN13480

Manufacturer of pressure equipment (in compliance with PED)

Commissioning reports for pressure systems in compliance with DM329

Inspection and testing of piping and pressure equipment.

Engineering&Design

Stress analysis (ASME B31.3)

Engineering&Design

Verification of mechanical stability for pressure equipment and structures.

Software

Puma5

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