case studies: aveva plant in china - · pdf file[case studies: aveva plant in china] [2009] 3...

Source: Extracted from AVEVA China Plant Paper Collection 2009

Case Studies: AVEVA Plant in China

[Case Studies: AVEVA Plant in China] [2009]

1 | P a g e

Table of Content No. Title Page No.

1. The Implementation of Design Workflow and Model Navigation in AVEVA NET Shanxi Electric Power Exploration & Design Institute

……………...2

2. Application of Multi-discipline Collaborative Design in Power Plant Project Shanxi Electric Power Exploration & Design Institute

……………...6

3. Study of the applications of AVEVA PDMS in Metallurgical Industry Design BERIS Engineering and Research Corporation

…………….16

4. Application and Study of Electric & Instrumentation in 3D Collaborative Design Hebei Electric Power Design & Research Institute

…………….21

5. The Application of AVEVA NET in the field of Engineering Construction China Nuclear Power Engineering Co., Ltd. (Shenzhen)

…………….29

Source: Extracted from AVEVA China Plant Paper Collection 2009


2 | P a g e

The implementation of design workflow and model navigation in AVEVA NET

By: Deng Xue Fei, Shanxi Electric Power Exploration & Design Institute Foreword Design companies today are facing a more complicated market place as competition within the power generation design industry becomes stiffer. This is compounded by the increasing demands of Owner Operators for greater and more comprehensive digitalisation of design. Adopting more advanced technology is therefore essential to the success and growth of power design companies. As improvements in computer technology drive design to higher levels, AVEVA NET, AVEVA’s Information Management solution, has been implemented in the digitalisation of design. Its uses range from cross-referencing all project data and documents, whatever their format or data type, and including the 3D model, to linking the construction processes of the entire project, and laying a strong foundation for handover to Owner Operators. Once the basic information storage and query functions of AVEVA NET have been created, we can implement further applications in a number of areas. AVEVA NET in the design workflow AVEVA Plant solutions support the entire plant lifecycle from design to procurement and construction. AVEVA PDMS enables 3D design collaboration across multiple disciplines; AVEVA VPE manages P&ID diagram data and process equipment; AVEVA VPRM manages project resources and materials; and AVEVA NET provides a comprehensive platform for information management. AVEVA NET has the capability to manage 3D models, ISO drawings, P&ID schematics, floor plans, and many other types of plant information and data. Using KKS coding, 3D models, ISO drawings and P&ID diagrams are connected, to facilitate the search and review of information. Such detailed information benefits Owner Operators on handover, as it provides detailed information for the implementation of the digital power plant. During the design stage, PDMS models are regularly updated into AVEVA NET. ISO and P&ID schematics are also imported into AVEVA NET with data import tools. There are many review stages throughout the plant design process, from initial setup to initial design, accreditation by professional bodies, composite review, command map, command map professional review, command map composite plan review, construction drawing design review, and so on. There are also many parts to each stage. For example, in the piping design stage, equipment models must be drawn according to information provided by their suppliers, followed by the modelling of piping layout, stress calculations, and so on. With so many processes involved, it is vital to establish design workflows that segregate the various parts of the design stage, in order to more fully benefit from the use of AVEVA NET. AVEVA NET can then effectively support these design


3 | P a g e

workflows, which need information contained within the 3D models imported from AVEVA PDMS. The establishment of a workflow makes it possible to segregate various parts of the design. We can then clearly observe the various design processes, organise them in real time and progressively improve them. Because specialist knowledge and expertise is embodied in the workflow, we can build up an expert knowledge base. For minor workflows, we can easily obtain the model data and carry out workflow-based projects with the support of 3D technology. These workflows can then be combined to form a large expert system to provide technical support to the entire design workflow. The fact that AVEVA NET needs to import data regularly from PDMS is inconvenient with a rapidly changing design. An important next step will be to enable AVEVA NET to directly read data files from PDMS, as a result of which AVEVA NET and the workflows will complement each other.

Figure 1: A simple workflow in AVEVA NET.

Figure 2: A more complex workflow in AVEVA NET. AVEVA NET in modelling applications This case study relates to our company's EPC contract for 2 × 330MW flue gas desulphurisation engineering projects at the Liupanshan power plant. The main layout features The first segment is from the flue to the main flue gas interface leading into the booster fan. The next segment is from the booster fan to the entrance of the


4 | P a g e

absorption tower, followed by a segment from the exit of the absorption tower to the main flue interface. The bypass flue is the last section. The model designs of the reinforcement structure, internal supports, and internal angled fixture are improved versions of the original design of the HVAC duct. The following sequence of figures illustrates the ability to view a 3D plant model using AVEVA NET. Although model rendering and navigation are not as powerful as the functions provided by AVEVA Review, they are, nevertheless, effective.

Figure 3: The complete 3D plant model in AVEVA NET.

Figure 4: Zooming in towards the 3D model.


5 | P a g e

Figure 5: Zoomed in to the 3D model to begin navigating its information. Using AVEVA NET, it is even possible to simulate construction and maintenance procedures in a similar way to using AVEVA Review. Conclusion AVEVA NET provides users with a powerful platform for managing information throughout the entire design process. However, it is up to the users to work out and build the linkage of the data itself. One way of doing this is by creating a design workflow, enabling AVEVA NET to play a pivotal role in the design process. It also makes possible more in-depth applications of AVEVA NET in design institutes. Although designing a workflow takes time, its long-term value progressively becomes apparent. AVEVA NET also offers many other opportunities that need to be explored. It can be used in modelling to simulate maintenance procedures, which is particularly useful for Owner Operators, enabling new employees to understand a plant’s construction and operational processes. Furthermore, AVEVA NET is open-sourced, enabling customisation to fit the specific needs of the organisation.


6 | P a g e

The application of multi-discipline collaborative design in a power plant project

Cao Hui Wen, Shanxi Electric Power Exploration & Design Institute Foreword Competition in the electrical power design industry has become increasingly intense in recent years. Design enterprises are facing a more complicated market environment than ever before, and the survival of these enterprises depends on their ability to make technological advances. We must focus on integrating a range of resources to create a highly effective collaborative operational system. As computer and telecommunications hardware and software become more advanced, the possibilities inherent in collaborative design are beginning to become apparent. Multi-discipline collaborative design will entirely transform the conventional work model. It can greatly shorten the time required for engineering design, and it is becoming the optimum development path for the methodology of the design industry. The number of large-scale power generation engineering projects handled by the Design Institute continues to increase, often demanding collaboration between various disciplines. This means a greater need for integration, collaboration and information sharing among designers. Engineering design is a composite outcome of multiple disciplines which depends on the collaboration and cooperation of the whole concern. As a result, the entire design process is one of constant collaboration between multiple disciplines. The final design outcome is not the result of simply linking up various disciplines – it relies on mutual give and take among them. Collaborative work is an important part of the design process, and the quality of the designed product depends largely on the level and quality of this collaboration. PDMS collaborative design platform As an integrated, multi-discipline design platform, PDMS solves the most difficult problem of power generation engineering design – the detailed design of piping. It solves problems concerning items of equipment, structure construction, HVAC, cable tray, hangers and detailed design in various disciplines, and it is being used more and more widely in the power and petrochemical design industries. The Institute has implemented the PDMS 3D design system to good effect in numerous power generation engineering projects. However, the scope of its application has been limited to the 3D process design layout, while other disciplines continued to use conventional 2D design. A large amount of professional cooperative work is still carried out using these conventional methods. After trials on a number of projects, we have started to develop methods of multi-discipline collaborative design, based on the PDMS platform, in order to further improve our 3D design capabilities.


7 | P a g e

The implementation of collaborative design in power generation engineering The objective of collaborative design The objective of collaborative design is not merely the creation of data. More importantly, it is to focus on the exchange and management of information. Our objective is to maximise design efficiency through integrated collaborative work among designers from different disciplines, distributed among various design departments. We aim to use PDMS to construct the integrated digital 3D model of the entire project while, at the same time, using the model as the platform from which cooperative information is passed down, and engineering drawings and reports for the various disciplines are extracted. The basis of collaborative design Collaborative design demands work from numerous design disciplines and personnel. As a result, the collaborative design platform must fulfil the needs of every discipline. Although PDMS provides numerous modules to support the various design disciplines, it needs a large amount of localisation work before implementation. To achieve this, and to meet the engineering application requirements of our Institute, we began a large amount of preparatory work to construct the basic database for a range of disciplines. Through participation in the Integrated Power Engineering Consortium of China's Power User Cooperation Group, the development of various application programs required for multi-discipline collaborative design have been completed. This has created a good environment for the development of collaborative design. The main development results are as below: • steam pipelines and piping components library • standard valves library • cable trays library • HVAC ventilation, boiler smoke airways database • parametric electric control equipment library • general layout pathways and duct layout tool • integrated information handling tool for embedded components, loads, holes,

foundations, ducts, pits and ponds • multi-discipline hanger design tool • steam pipelines hanger design tool • hydraulic and chemical water piping design tool • calculation tool for cost and materials quantities estimation • piping pressure analysis tool • construction calculation software interface • cabling software interface Management of the collaborative design process Collaborative design means more than just combining design engineering data; it needs a large amount of collaborative work. The 3D collaborative design platform uses the entire 3D design method and demands a radical change from conventional design ideas. A new integrated specification must therefore be established. Specifications must be made for the content and depth of collaborative designs in


8 | P a g e

different design phases for the various engineering disciplines, as well as the interconnection and cooperation systems for the various disciplines in the design process. To this end, we have established SXED (Specifications of Content and Depth of 3D Design in Multiple Disciplines of Power Generation Engineering) specifying, in detail, the requirements and depth of the design content of different engineering phases. Each discipline begins development work by referring to these specifications to ensure an orderly design process. At the same time, since all disciplines are working on the integrated platform, we have established PDMS naming conventions, to ensure accurate and standardised engineering data. These specify, in detail, the naming conventions for various types of component used in the model, and the requirements of the index structure of the model, to facilitate the implementation of information sharing, navigation and transfer among the various disciplines. The collaborative design project workflow Figure 1 shows the classification of the power engineering survey and design stage, according to the requirements of the Specification of Classification of Power Engineering Survey and Design Stage（DLGJ 159.1-2001).

Figure 1: The classification of the power engineering survey and design stage. In power generation engineering, as shown above, a large amount of collaborative work among design disciplines is completed in the preliminary design, guiding drawing design and construction drawing design stages. The development of collaborative design should be carried out in these few stages. The workflow is shown in Figure 2, below.


9 | P a g e

Figure 2: The multi-discipline collaborative design workflow of power generation engineering. Preliminary design stage The main strategy in preliminary design work involves comparison, selection and optimisation. First, in the general layout discipline, the 3D design work is started by describing the site topography and planning for the structure and piping in the plant area. After preliminary model building, the first professional review will be carried out. The model is then modified and improved, based on the outcome of this review. This establishes the basic placement and flow directions of the various pathways, ducts and pipelines of the buildings and structures. The various design disciplines then enter the model to start 3D design and construct their models within the layout of the buildings, structures and pipelines established by the general layout. All disciplines carry out preliminary design professional review and, simultaneously, professional inspection of the model. Any problems identified at this stage are resolved by each discipline improving and modifying its respective parts of the


10 | P a g e

model. Similarly, the composite review is carried out on the preliminary design while, at the same time, the model is inspected. In response to problems identified during the composite review, each discipline then improves and modifies its respective model in preparation for the guiding drawing stage.

Figure 3: Engineering model of the preliminary design stage. Guiding drawing stage The guiding drawing stage is based on the preliminary design of the 3D model and, according to work progress and materials data, the various disciplines gradually develop and optimise their respective content. At the same time, through the information transfer and integration tool, further tasks are carried out by the relevant disciplines. The guiding drawing then undergoes a professional review and the model is simultaneously inspected. Again, each discipline’s models are refined and optimised to address any problems or requirements brought up during the review. Next, the composite professional review is carried out, and the various disciplines again refine their models in preparation for the start of the construction drawing design phase.


11 | P a g e

Figure 4: Loaded information transfer interface.

Figure 5: Engineering model of the guiding drawing design stage.


12 | P a g e

Construction drawing stage The 3D model is then further refined and improved to meet the requirements for publishing the construction drawing. The model is inspected again before the publishing of the construction drawing. Where approval is needed from a particular discipline, that discipline is asked to carry out the verification of model data to avoid any rework being caused by problems that are discovered after the commencement of the construction drawing. The table below shows the depth of the specifications during the construction drawing level of SXED’s Specifications of Content and Depth of 3D Design in Multiple Disciplines of Power Generation Engineering.

Stage Discipline Work content Depth requirement

Construction drawing

General Layout

Location of plant building

Modify

Pathways and ducts of plants

Modify

Publishing of general floor plan layout drawing

Accurate

Structure

Shape outline of various buildings in plant

Accurate

Professional equipment for conveying coal

General shape outline

Coal-crushing room Accurate Equipment and piping of air-cooling system

Accurate shape outline

Electrical

Trays and cabinets in main plant room

Accurate

External electric distribution device

Accurate

Closed bus wire Accurate Overhead cables and cable tunnels in plant

Accurate

All cable trays Accurate, publish layout construction drawing

Lighting of boiler Accurate, publish layout construction drawing

HVAC

All external HVAC piping

Modify the direction of main pipe, ascertain incoming branches, publish construction drawing

Heating of main plant room

Refine, publish construction drawing

Air-conditioning in main plant room

Check if the space meets requirements

Air-conditioning of control room

Check if the space meets requirements, publish main air hose construction drawing


13 | P a g e

Stage Discipline Work content Depth requirement Coal-conveying system (coal unloading duct, bunker room, various transfer stations)

Check if the space meets requirements, publish main air hose construction drawing

Reheating station, cooling station

Accurate, publish layout construction drawing

Water Process

Plant pipelines Accurate Firewater piping Accurate, publish layout

construction drawing Equipment and piping of integrated water pump room


Equipment and piping of circulated water pump room


Heat Machines

Plant pipelines Accurate, publish layout construction drawing

Structure and construction of main plant room


Subsidiary and auxiliary equipment of main plant room


Structure, construction, equipment and piping of fuel pump room


Structure, construction, equipment, and piping of boiler starting room


Pipelines of main plant room


Ash removal

Plant pipelines Accurate, publish layout construction drawing

Structure, equipment and piping of room


Structure, equipment and piping of ash cellar


Waste removal equipment and piping


Ash removal equipment and piping


Chemical

Equipment and pipelines in plant

Check if the space meets requirements, publish piping construction drawing

Equipment and piping of polishing treatment system


Structure, equipment and piping of chemical workshop


After the completion of the model layout at the construction drawing stage, each discipline can start the statistical calculation of the Bill of Materials. Drawings and reports are created directly from the model.


14 | P a g e

Figure 6: Model of chemical water workshop construction drawing stage.

Figure 7: Cable tray construction drawing. The construction drawing model is modified during construction, in response to the contents of the engineering connection and modification lists, so that the final model is consistent with the final as-built drawing.


15 | P a g e

Conclusion The application of multi-discipline collaborative design is still at an early stage in our Institute. A few problems encountered during the application process need to be gradually improved and resolved. It is believed that, as the engineering process develops, the value of collaborative design will be clearly demonstrated. At the same time, collaborative design is system engineering, not merely software. Every design unit has different requirements regarding collaboration. No single system design software can be universally suitable. Every design unit should implement their own collaborative design system according to their own practical situations.


16 | P a g e

The application of AVEVA PDMS in metallurgical industry design By: Yue Lei, BERIS Engineering and Research Corporation Background Successful application in piping disciplines BERIS Engineering and Research Corporation has been promoting the application of PDMS in various power piping disciplines since 2007, and has achieved solid results. After two years' work, PDMS can meet the design requirements of the oxygen, gas, heat, water supply and drainage and ventilation disciplines. It can also support the normal design and operation of various projects. In mid-2009, the company plans to fully apply PDMS to iron and steel production and steel-rolling, with the aim of then formally employing it on actual projects. Promoting PDMS demands training Since PDMS use is different from conventional AutoCAD methods in operation and application, design concept, organising and formation, professional training is needed to promote its use. Since early 2009, our company has been gradually carrying out PDMS training in various disciplines, to generate the skills needed for its in-depth use. Steel manufacture Laigang 100-ton BOF (Basic Oxygen Furnace) simulation project With the support of the company, we started carrying out the simulation of this steelmaking project in April 2009. The main objective was to prove that PDMS can be used to complete design tasks in disciplines such as iron and steel production and steel rolling. The Laigang 100-ton BOF simulation project was completed by our institute and has just moved into production. The main task of this simulation was to recreate the design from the existing construction drawing. The whole simulation project took around 1,450 man-hours. During the project, the team was joined by new employees and newly trained personnel, some of whom had not fully mastered the use of PDMS. If this disadvantage is factored out, the time required to carry out a similar project could be reduced to 850 man-hours. From our experience in the Laigang simulation project, we identified the points below which will need attention when using PDMS to carry out factory design in the metallurgical industry.

• Complete equipment serial numbering systems must be created. • A certain level of man-hours must be put into the effort of model building of

the equipment for preparation. • Construction works such as structures and buildings must be carried out

under suitable conditions. • The collaboration between various disciplines should be procedurised and


17 | P a g e

supported by clear scheduling work. Project outcome This simulation has proved that PDMS can be used by BERIS and the metallurgical industry to complete the designs for a complete steelmaking process project, given reasonable scheduling and workflow arrangements. The engineering quality and progress can also be guaranteed.

Steel rolling Ikawa Electric Power’s aluminium tape project After the completion of the steelmaking simulation project, BERIS engineering technical personnel started to use PDMS on actual projects. Ikawa Electric Power’s Aluminium Tape Project is the first formal metallurgical project that BERIS has completed using PDMS. There were certain problems to overcome in using PDMS as the design platform. The main ones related to the depth of equipment model building, the process and detailed arrangement of equipment model building, the collaboration between the construction and the process and piping disciplines, and the central process discipline. First, the depth of equipment model building. Since metallurgical equipment is more complicated, and projects more complex, producing equipment models imposes a greater workload. To mitigate this, equipment modelling should be simplified, to show only the general outlines of the equipment, its base, bolt positions related to the construction, the location of lifting points, functional interfaces, the equipment positioning block and other key details. Next, problems in model construction need to be resolved. The problems in collaboration between the construction and process disciplines are very clear. In the actual engineering operation, discussions between different technical professionals need to take place, and the steps outlined below must be taken.


18 | P a g e

a

b

c

c

• During the process of building the equipment model, the information defining the equipment base, anchor bolts and other details needed for construction is essential. Information on other areas is used only for the completion of the equipment model.

• Once the equipment model can fulfil the construction design, it may be refined and improved.

• When the building of the construction and equipment model is completed, the process equipment and construction disciplines should carry out verification and inspection on the model to ensure design accuracy.

Thirdly, collaboration between the piping and construction disciplines is more easily resolved than problems in the equipment discipline. The resolution is similar to the collaboration between the equipment and construction disciplines. The piping discipline develops the piping model, checks the positions of hangers and embedded parts, and provides them to the construction discipline. It then continues to complete the piping model, and deals with problems such as further modifications in refining the model. These should be referred directly to the construction discipline. When the construction and equipment model building are completed, the process equipment and construction disciplines should carry out verification and inspection of the model to ensure design accuracy. Expected result It is expected that, after project completion, the advantages of PDMS will be fully demonstrated. Further improvement of design quality can be achieved in areas of material statistics, equipment management and construction material management. It also provides important information for subsequent plant operation and staff training. Numbering Management Purpose of numbering The ultimate purpose of numbering is to better manage the equipment and materials. If numbering is not managed, this will directly cause disorder in the design data storage layer. This will damage the areas of query and statistical analysis, and


19 | P a g e

will greatly reduce the potential management benefits provided by PDMS functions. Managing equipment numbering BERIS carries out a large amount of numbering. First, the equipment types and models are defined and categorised. This includes all the steelmaking and steel rolling equipment, as well as defining the abbreviation codes. No Items Codes 1 LF stove LFE (LF stove) 2 AOD stove ADO (ADO stove) 3 EAF stove EAF (EAF stove) 4 Drainage, guide, guide roller, output devices, shifting devices, feeding

systems, belt machine GUD (guide device)

5 Pulley PUL (pulley) 6 Carrier vehicle CAV (carrier vehicle) 7 Electrical stove ELF (electrical stove) 8 Fire-blocking gate, feeding gate, steel output gate, waste output gate GAT (lockage gate)

Equipment numbering uses: Codes + Serial Number + Location of Equipment, where a three-digit number is suitable for the serial number, and the codes for equipment location are mainly standardised by the company. For example: The equipment number LFE002STK001 represents the No. 2 LF stove in the No. 1 BoF area. Managing piping numbering As BERIS started using PDMS earlier to carry out piping design, its numbering is more mature. Piping numbering is mainly divided into the numbering of pipelines, valves and special piping components. The piping number shows the medium, pipe diameter, area of the pipeline, insulation status, grade and the serial number of the pipes. The numbering convention is: Medium + Area of the Pipeline + Serial Number + Pipe Diameter + Grade + Insulation Status. For example, Ox-STK001-02-100-L1B-C represents the DN100 oxygen pipeline No. 2 in the No. 1 BoF area, and the pipeline package is using a heat insulation layer. Valve numbering is divided into two types: normal valves and special valves, including adjustment valves and large-sized valves. Normal valves include cut-off valves, gate valves, check valves, butterfly valves, etc. The numbering shows the types, nominal pressure, nominal diameter, material, connection form and numbering sequence of the valves. The numbering convention is: Type + Nominal Pressure + Nominal Diameter + Material + Connection Form. For example: ZL50TFB means a DN50 0.25MPa convex flange connecting brass valve. The numbering of adjustment valves generally uses the schematic diagrams from the instrumentation discipline to define the numbering. Large-sized valves include plug valves, blind plate valves and large-sized butterfly valves. The numbering convention is: Type + Nominal Pressure + Nominal Diameter + Weight + Plug Condition. For example: VDK2600I0 represents a DN2600 plug valve, plug condition is closed, and the weight is more than 10 tons. Management of special numbering


20 | P a g e

In an actual project there are situations where the piping components and equipment need distinct numbering. The main piping components that need distinct numbering are the compensators and, for these, we carried out classified numbering. Since there are too many types of compensator, a naming convention has been uniquely established for them. The numbering convention is: Compensating Method + Nominal Diameter + Compensating Capacity + Pre-Stretched Condition. For example: EH500d80A represents an axial-type compensator, DN500, with a compensating capacity of 80mm and which has not been pre-stretched. Workflow adjustment under PDMS Model building workflow of a PDMS project There are certain differences involved in using PDMS to organise and manage design as compared to previous models of management and production. To resolve conflicts between PDMS and the existing systems of design and operation, BERIS recreates the design workflow, in order to make sure that design tasks are carried out in order. Below are the registered flowcharts that need to be carried out for the use of PDMS in a design project. Firstly, the central process discipline requests the necessary records from the technology quality management department and the production scheduling department. Through the management department, it requests production collaboration from other production disciplines. After the management department approves the request, it starts to coordinate various production departments to carry out design tasks using PDMS. Application for the use of PDMS original database Adjustment of production process There are still some remaining problems in our use of PDMS to carry out design and production but, as time goes by, these problems will certainly be resolved. Space does not permit them to be described in detail here. Conclusion Through the use of PDMS design software, our institute has constructed a preliminary 3D design system for iron and steel plants. This has created a strong foundation for increasing the iron and steel industry’s competitiveness through the increase in design level, quality and speed achievable. PDMS will be widely used in our institute to ultimately realise the total digitalisation of iron and steel plants.


21 | P a g e

Application and study of electrical and instrumentation disciplines in 3D collaborative design By: Zhang Yan, Mi Jing Ping & Wang Jian Ning, Hebei Electric Power Design & Research Institute After several years of evaluation and development, AVEVA PDMS is now widely used in various disciplines in our institute. For the electrical discipline, the initial application of PDMS mainly includes the modelling of the cable trays, the main enclosures and shared enclosures. With further in-depth development and application of PDMS, we are making increased use of PDMS-based professional tools. This article focuses on the application of the PDMS thermal measuring point auxiliary tools in live projects, and on the difficulties involved. By studying and resolving these problems, electrical control design personnel can better understand the design concept of the thermal measuring point auxiliary tools. The new tools can then be continuously improved to combine perfectly with the actual engineering design. This will strengthen the in-depth application of PDMS for 3D design in electrical control, to achieve 3D collaborative design of electrical control systems. The PDMS electrical control auxiliary tools include lighting, fire prevention, communications and the corresponding low-voltage sockets, slip lines, parametric equipment electronic control library, cable layout, thermal measuring points and instrumentation connection drawing. Here, we will focus on thermal measuring points and instrumentation connection drawing auxiliary tools in electrical control. A metered control system is necessary in power plant pipelines for real-time monitoring of temperature, pressure and other parameters. Therefore, the installation types of pipeline measurement devices, and the design layout and material properties of piping components are very important in thermal machine design. When designing the layout of thermal piping components, the positions of the measurement devices can be difficult to fix due to clashes with other piping. Also, because of changes in the piping itself, the selection of measurement devices which are based on the pipe specification cannot be fixed. This not only causes uncertainties in the design stage, but clashes involving measurement devices can also affect the project’s progress. This means that, if the 3D layout design of thermal measurement points can be introduced during the piping components design stage, their design positions can be intuitively determined, while the measuring points on the pipes themselves can be assigned identifications enabling their full attributes to be completed after the layout is finished. The corresponding clash checks are carried out to make modifications where clashes occur. By using the measurement device information obtained from the 3D model design through the thermal measuring point auxiliary tool, the design drawings extracted from the PDMS publishing function are accurate and logical. This will


22 | P a g e

undoubtedly increase design accuracy and work efficiency. The work flow is shown in Figure 1. Conventional method Method using electrical control auxiliary tool Figure 1: Comparing the two methods. In the conventional method, modifications are carried out only after clashes arise during on-site construction. This reduces project efficiency. By using the PDMS electrical auxiliary tool, clashes can be identified early in the design stage, and the layout of piping components can be modified in time. This offers great advantages in increasing the project’s design efficiency. The application of our institute’s PDMS thermal measuring points auxiliary tool is described below. From the construction of the thermal measuring points model to the publishing and the statistical analysis of the material, many areas need detailed operation and settings in order to achieve the desired results. Piping instrumentation components The measuring piping component models are built on pipes of the thermal plant design. Firstly, this needs to be supported by a whole set of measuring component library items. In the 3D model, measurement piping components can be viewed as different combinations of pipes, valves, flanges and tees. Figure 2, below, shows an example of a pressure piping component. After the documents library is built, the 3D model is constructed, based on the instrument pipes connection drawing. In accordance with industry standards, the piping discipline must establish various instrument pipe connection drawings, and then construct each corresponding 3D model group. Through 3D modelling, we use the Drafting function to extract instrument pipes connection drawings as in Figure 3, and extract the materials sheets as shown in Figure 4.

Design construction drawing for thermal measuring point piping components

Construction of power plant

Modify design drawings Rework

Clashes

3D layout of measuring points piping components by PDMS auxiliary tool

Clashes

Modify 3D layout drawing

Construction at power plant


23 | P a g e

Figure 2: Creation of piping components.

Figure 3: Publishing piping components.

Figure 4: Components information display.


24 | P a g e

When using the PDMS thermal measuring point auxiliary tool, the interface shown in Figure 5 will appear. When selecting the model, follow the hook-up drawing to select different measuring piping components. This step needs support from the database, which is built based on the Installation of Thermal Measurement and Control Instruments published by China Electric Power Press.

Figure 5: A settings interface.

Figure 6: Libraries classification. The engineering library documents can be constructed according to the database construction classification as in Figure 6. The instrument panel and cabinet size library, the instrument components library and the library of installation material for the instrument can be realised with the use of the PDMS components library. This can be achieved by gradually adding the instrument pipes connection drawing templates into the library documents, according to the needs of the project.

Constructing the instrument pipes connection drawing templates

Libraries

construction


25 | P a g e

Installation of measuring piping components on plant pipelines With the instrument pipes connection components required by the discipline, the next step is the installation of measuring piping components on the pipelines. Before this, we must improve all the library documents for the grades of tees or connectors required by the project. This is because, to install measuring components on the pipes, one needs to have tees and connectors to make the connections. After we have established the comprehensive grading in the PDMS basic library documents, all the piping components required by the project can be listed. If any of the settings for pipe diameter grades are incomplete, it will not be possible to install the measuring components on the model construction of the pipes. This problem often occurs in engineering design and it needs our attention.

Figure 7: Displaying diameter. When installing the piping components on the pipelines, the editing of the intermediate files is very important. Every line in the intermediate files is formed by instrument number, pipeline number where it is located, the used hook-up typical drawing number, and the typical drawing number of the connector in use. The pipeline number where the intermediate file is located must match the pipeline names in the PDMS model, in order to construct measuring components on the pipelines. This is not clearly stated in the instruction manuals provided, and it means that professionals need to understand and master this process of practical application.


26 | P a g e

Figure 8: An intermediate file.

Figure 9: The new tools settings interface. From Figures 8 and 9 we can see that, before installing the measuring point components on the 3D model of the pipelines in PDMS, users need to edit the pipeline numbers in the intermediate files to ensure that they are consistent, and then import them into the intermediate files. Only in this way can users accurately construct the measuring piping components model. This area needs attention in the process of using the new tool. Calculating the Bill of Materials After the construction of measuring components on the pipelines, any clashes and positioning logic can be checked and the Bill of Materials compiled. During the process of compilation, the auxiliary tool provides the report and one-time piping calculation functions. However, when compiling the Bill of Material for the thermal measuring points, the method of formation of the piping components, including valves and the model number and quantity of flanges, is listed in CAD drawing format, as in Figure 10. Export in Excel format is not supported. We can, however, modify the code to extract the resulting files in Excel format, which improves the statistical calculation of the materials.


27 | P a g e

The foundation of digital power plant design As an important part in the construction phase, the design of the digital power plant must build the foundation with the coding of equipment materials, specifications of flowchart design and specifications of quantity design that meet industrial standards. This work is of considerable value to the EPC.

Figure 10: Material statistical calculation interface. Conclusion The electrical thermal measuring point tool has a user-friendly interface, and comprehensive functions for constructing measuring piping components, publishing and Bill of Materials calculation. This demonstrates the good design concept and practical nature of PDMS. There are, however, some problems that need attention in use. We achieved all the necessary functions by editing the library document and coding. By resolving these problems, the user can better use the electrical-control design tool to achieve the desired design results. In using the thermal measuring point tool, I have had some thoughts which I hope would be beneficial to its development and use. Here I would like to share and study them, together with AVEVA and colleagues from various design institutes. The construction of the 3D model library of instrument piping connecting components needs to be improved and strengthened. The method for settings of the component library should be renewed to facilitate adding types of measuring point piping component. The publishing of the positions of the measuring point piping components, and the calculation of the Bill of Materials, should be further processed to assist designers to complete the calculation of supply quantities and the costs of the required components and materials.


28 | P a g e

In the process of editing the intermediate files, every pipeline number in the plant model needs to be edited, and this process is too tedious. The intermediate file can be transferred through VPE. I hope that, through VPE, the intermediate transfer file can be obtained, as shown in the work flow in Figure 11. Through the work flow chart, the generation process of the intermediate file can be seen. We can all discuss and share ideas about an easier and faster method to generate the intermediate file.

Figure 11: Work flow chart. As the new PDMS tool is being improved and developed, collaboration between design professionals and design software will be closer. The mutual aim of designers and software developers will be to transform the tool we have now into a highly efficient tool for engineering design. Our target is to reduce the level of repetitive work involved in using the design tool, and to improve its effectiveness, in order to achieve the perfect combination between software and project.


29 | P a g e

The application of AVEVA NET in the field of engineering construction By: Liu Peng & Luo Ya Lin, China Nuclear Power Engineering Co.,Ltd. (Shenzhen) Overview The Design Institute of China Guangdong Nuclear Power Engineering Co., Ltd. (‘the Design Institute’) used PDMS to build the CPR1000 model of a standard reactor type nuclear power plant, with professional 3D layout design that gained independent intellectual property rights. This was a landmark achievement for China in the field of nuclear power engineering. The Design Institute is currently responsible for designing nuclear power plants for Liaoning Province’s Hongyanhe, Fujian’s Ningde, Guangdong’s Yangjiang and Guangxi’s Fangchenggang, among others. It also participates fully in the design tasks of the China-France third-generation nuclear power project – a joint project with Guangdong Taishan. All these projects use PDMS for their 3D design layout. At present, conventional data transfer methods have not changed. For the transfer of design deliverables, for example, the medium is still drawings. The CPR1000 projects being simultaneously developed by Chinese design institutes utilise the transfer of axial maps, three-in-one layouts, composite layouts and other drawings. In contrast, our project partner, AREVA, has achieved the level of submitting only the ISO map and 3D model on a nuclear power project in France. How do we achieve this goal in a CPR1000 project? In fact, we have begun to use AVEVA NET to establish an integrated information platform for a 3D digital nuclear power plant (‘the Project’). With continuous development and the integration of various functions, this platform will soon be essential to our operations. Principles Here, we will use an image analogy to describe the use of AVEVA NET in implementing the Project. From there, we achieve data integration and publishing and, in addition, enable a certain degree of digital transfer of design deliverables.


30 | P a g e

Figure 1: Image used to explain project information structure in PDMS. In our internal communications, we frequently use the image in Figure 1 to explain key principles of the Project. The meaning of the various elements is described below. The wood in the photograph represents a particular project in PDMS. Each tree corresponds to a particular piece of information in the system, such as equipment or pipelines in the PDMS 3D layout, or the corresponding component information of the intelligent P&ID. The type of each tree is determined by its genes. For PDMS and P&ID, these ‘genes’ correspond to the materials, properties, and other information determined by VPRM or VPE in the upstream design systems. The relative position of each tree in the wood is fixed, corresponding to the spatial information in the PDMS 3D design models, or to the linked relationships of intelligent P&ID components. The shadow of each tree corresponds to the data from other sources in PDMS or P&ID. Each shadow will continuously change as the sun moves, corresponding to the various phases in the project, including design, construction, operation and maintenance. For each component, there will be a large amount of information generated during different stages and by different departments. As time passes, the shadows will change continuously, but at all times the shadows remain connected to the tree roots. As a result, the only way to link the ‘shadows’ (i.e. data) from different stages (design, construction, operation and maintenance) is through the ‘tree’ (i.e. the PDMS 3D model, or individual components of the P&ID). Therefore, through one or both of the PDMS 3D model and the P&ID, we can collaboratively publish the data from various stages. Current situations According to our initial project development plan, we are currently at Stage 2, 3. The


31 | P a g e

objectives of various stages are described below. Creation of the data structure and the clean-up of the architecture of the Project will enable the integrated publishing of the 3D models and intelligent P&ID. It also establishes and improves the user authorisation mechanism to achieve the grouping of users and the control of user access permissions. Centred on the 3D design data and the P&ID, the management systems for valve data, engineering materials data, documents and other data sources are integrated and published. Fulfilling the requirements of the application also entails supplementary training, the demonstration of design deliverables, visualisation of construction progress, and on-site construction assistance systems. Together with the practical requirements for the development of the Project, digital transfer of nuclear power project data is explored and practised. Note: The intelligent P&ID of the CPR1000 model of a standard reactor type nuclear power plant island was completely drawn by the end of December 2009, making it possible to use it in the collaborative data publishing for each project. In August 2009, we had carried out a series of tests for collaborative data publishing with the Documentum Document Management System, version 5.3. However, because the Design Institute system was being upgraded to version 6.5, the work with collaborative data was delayed until January 2010. The Project has published the data for Liaoning’s Hongyanhe and Fujian’s Ningde projects. There are 13 user groups at three sites: Hongyanhe, Ningde and Lingao (Phase 2). The platform has been fully utilised to enable effective communication between all personnel across different sites. At the same time, the platform has already been providing services for use by the maintenance departments of the operating companies. In the nuclear power plant maintenance project in Lingao Phase 1 this year, maintenance personnel were able to quickly package and publish the 3D model to the platform. This played a huge role in reducing maintenance time and has created significant economic benefits. During the actual operation of the platform, a lot of user feedback has been accumulated, encouraging us to continue to promote the Project for in-depth applications in the construction industry. We have also accumulated experience in the digital transfer of engineering design data. As a result of continuous progress made in development of the group’s various projects, we can now provide specialised support in the two areas below. Visualisation of construction progress There has been testing on the collaborative use of data with the P3E system. A progress display tool module has been developed, as shown in Figure 2. Construction support The objective of an on-site construction support system is to enable data linkage between the Design Institute, the construction management department, on-site construction workers and the prefabrication workshop. The Design Institute's design data can be accessed by the prefabrication workshop and be used to assist in the prefabrication of pipes. The construction management department can obtain information about these prefabricated pipes to organise their installation. On-site


32 | P a g e

construction workers can pre-install components through the platform (the initial target is piping). Location and spatial information can be quickly accessed. This all serves to increase installation efficiency, further reducing installation time.

Figure 2: The progress display tool module. Future developments China Guangdong Nuclear Power Engineering Co., Ltd., as the general contractor for various nuclear power projects of the Guangdong Nuclear Power Group, and the Design Institute, as the general contractor for various nuclear power projects, have both the responsibility and an obligation to integrate and release the data of the design phase and the construction phase, including procurement, construction, troubleshooting, and so on. We also provide a suitable platform for engineering staff to quickly access and query the data coming from different phases and sources in the project. This facilitates subsequent nuclear power projects, where a range of data from the lifecycles of previous similar projects can be effectively reused. Operating companies, during the operation and maintenance phases of every project, where data from the design and construction processes can be fully utilised, will find this particularly beneficial. Important data support is also available for further improvement projects. Our future development is aimed at establishing a data centre, shared across the whole group, led by the Design Institute. The data centre has a group of high-performance servers that make up the server array for the Project. Our array of VizStream Servers has real potential for development, as illustrated in Figure 3. If companies in the group, or teams from different projects, need to access the


33 | P a g e

platform data, they can access the data centre via a dedicated line to obtain relevant resources and data. The Institute is responsible for data centre hardware and software, and for data maintenance, so users do not need to worry about the configuration and practical implementation of the platform hardware, software or other resources. Once a user is authorised, the data centre can be accessed using Internet Explorer. We are also working on developing an appropriate charging model, looking at some of the many current examples. In building this data centre, we seem almost to be approaching the concept of 'cloud computing'.

Figure 3: VizStream Servers, a server array with considerable potential for development. Conclusion This article introduces some thoughts and some conclusions on our experiences in using AVEVA NET to establish an Integrated Information Platform for a 3D Digital Nuclear Power Plant. This article is purely for reference by interested engineers and developers. We believe that, through our combined efforts, the platform will play a greater role in design, construction, operation and maintenance. The seemingly unattainable goal of digital transfer will also be achieved in the near future.

Americas Region Headquarters

AVEVA Inc10350 Richmond AvenueSuite 400Houston, Texas 77042USA

Tel +1 713 977 1225Fax +1 713 977 1231

Asia Pacific Region Headquarters

AVEVA Asia Pacific DivisionLevel 59, Tower 2PETRONAS Twin Towers KLCC50088 Kuala LumpurMALAYSIA

Tel +60 (0)3 2176 1234Fax +60 (0)3 2176 1334

Europe, Middle East and Africa RegionHeadquarters

AVEVA GmbHOtto-Volger-Str.7cD-65843 SulzbachGERMANY

Tel +49 (0)6196 5052 01Fax +49 (0)6196 5052 22

AVEVA Group plcHigh CrossMadingley RoadCambridge, CB3 0HBUK

Tel +44 (0)1223 556655Fax +44 (0)1223 556666

AVEVA believes the information in this publication is correct as of its publication date. As part of continued product development, such information is subject to change without prior notice and isrelated to the current software release. AVEVA is not responsible for any inadvertent errors. All product names mentioned are the trademarks of their respective holders.

© Copyright 2010 AVEVA Solutions Limited. All rights reserved. CS/CP/0810-EN

www.aveva.com

Headquartered in Cambridge, England, AVEVA Group plc and its operatingsubsidiaries currently employ more than 800 staff worldwide in England,Australia, Austria, Brazil, Canada, China, Dubai, France, Germany, Hong Kong,India, Italy, Japan, Malaysia, Mexico, Norway, Russia, Saudi Arabia, Singapore,Spain, Switzerland, Sweden, South Korea and the USA.

case studies: aveva plant in china - · pdf file[case studies: aveva plant in china] [2009] 3...

Documents