Integration of Analytical Software and 3D Platform in Plant Design and Engineering-Presentation.ppt

Integration of Analytical Software and 3D Platform in Plant Design and Engineering

1. Integration of Analytical Software and 3D
Platform in Plant Design and Engineering –A
Paradigm Shift for the Upcoming and
Revamped Process Plants
AnirbanDatta
Manager –Mechanical & Piping, Richard Design Services India Private Limited (A fully owned Subsidiary
of Richard Industrial Group, USA), MIE, CEng (India), PE (India)
GautamGangopadhyay
Head of the Department –Mechanical & Piping, Richard Design Services India Private Limited (A fully
owned Subsidiary of Richard Industrial Group, USA), MIE, CEng (India)
33rd Indian Engineering Congress, The Institution of Engineers (India)
Udaipur, 2018
Theme : Integration of Technologies: Emerging Engineering Paradigm

2. DESIGN ENGINEERING FOR A MEGA PROCESS
PLANT EPC PROJECT
Following Engineering Disciplines are involved:
•Process
•PlantLayout
•Geo-technical
•Mechanical
•Civil
•Structural
•Piping
•Electrical
•InstrumentationandControls
Typical Overall Layout for a Process Plant

3. Challenges
Execute EPC “mega-projects” within budget and on schedule
Minimize construction delays due to lagging information, material
or equipment
Track progress and maintain contingency plans to stay on
schedule
Document project progress in terms of installed quantities
Intelligently apply IT/CAD/CAE tools to the EPC environment for
the advantage of constructors and their clients
Push progression of 2D to 3D, 4D and even 5D

4. Coordinating EPC Functions
COORDINATION
ENGINEERING
•Budgeted Deliverables, i.e. Design Calculations, Construction Drawings, Specifications
•3D Model with attribute data, from which drawings would be generated
•Bill of Materials
PROJECT MANAGEMENT
•Schedule
•Definitive Cost Estimate
•Progress Monitoring
PROCUREMENT
•Order Placement
•Prioritization
•Material Receipt/Release
CONSTRUCTION
•Work Scope Packaging
•Resource Management
•Field Work

5. EPC Project Engineering Sequence
Feasibility Studies
Cost Estimate
Detailed Project Report
Basic Engineering
Design Criteria & Specifications
Material Take-Off Estimate
Purchase Requisitions
Design Calculations
Detailed Engineering
Definitive Estimate
Issue “Engineering Deliverables” to Construction
“As-Built”
Project Close-Out

6. Procurement Sequence
Develop Vendor’s List
Floatation of Enquiry
Purchase Order Proforma
Contract Proforma
Transportation & Logistics
Specification –From Engg.
Quantities –From Engg.
Bid Evaluation
Award Purchase Order / Contracts
Shop Inspection
Track Delivery Status
Expedite
Receipt of Shipment
Warehouse
Release to Construction

7. Construction Sequence
General Construction Plan
Site Layout Plan
Enabling Work & Temporary Facilites
Geo-Technical
Mass Earth-Work
Foundation
Structural Steel Work
Equipment Erection –Mechanical & Electrical
Piping
Cable Raceway
Ducting
Instrumentation & Controls
Start-up & Commissioning
Performance Guarantee Tests
Plant Hand-over to End User
Note: Construction is supported by Field Engineering

8. Project Controls Sequence
Milestone Schedule
Code of Accounts
Cost Estimate
Budget Definition and Tracking
Level 3 CPM Schedule
Trend Program
Contingency Tracking
Schedule Optimization

9. Levels of Modelling
A. 2DDrawings and Sketches (E)
•Traditional format
•Inter-drawing design coordination subject to error
•Change management requiresrigorousdocument control process.
B. 3D CAD Model with data attribute links (Intelligence) (E)
•Used for EPCover the past 20+ years (PDS, PDMS, SmartPlant)
•Requires changes to traditional work processes
•Component attribute data is the “intelligence”
•Clash Checking
•Automatic Drawing Creation
•Material Take-Off Reports
•Data Consistency Reports
Integrated 3D Model of a Process Unit

10. Levels of Modelling (Contd.)
C. 4DConstruction Simulation Model (EC)
•Construction Planning & Sequencing
•Resource Management and Construction Machineries Movement
•Links 3D model components with L3schedule
•Construction StatusagainstTime
•Real-time Visualization
D. 5DCost Tracking Model (EPC)
•Material Cost Model
•Resource Distribution Model
•Expended Cost Tracking Model

11. A Typical Process Unit –Its 3D Model and Actual View after Construction

12. Way Forward
LASER Scanning of existing plant & facilities for ease of Revamping

13. Thank You