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Digital Design Workflows To Reduce Non-Conformances in The Power Industry
Digital Design Workflows To Reduce Non-Conformances in The Power Industry
Digital Design Workflows To Reduce Non-Conformances in The Power Industry
https://www.infrastructurereportcard.org/wp-content/uploads/2017/01/Energy-Final.pdf
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Recommendations to Improve USA Power Infrastructure
With the digital data integration of design and analysis applications across
key engineering disciplines like structural and piping, companies are
abandoning traditional paper workflows and managing engineering projects
more efficiently and with less risk. Engineering content can be easily
managed in a central distributed document management system for handover
and operational asset management.
– Digital data transfer of structural and piping design engineering information
and richly integrated design models for asset management
– Improved 3D Visualization and digital clash detection to avoid costly non-
conformances
– See how integrated design analysis applications are being used to manage
ageing assets on brownfield projects
Q&A
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Brownfield Project: Laser Scan to 3D Modeling to Engineering
Analysis for Checking Structural Integrity
Area $Billions /
Year
Drinking Water / Sewage 36
Petrochemical 3.7
Oil & Gas 1.4
Pulp & Paper 6.0
Electrical Utilities 6.9
Bridges 8.3
Gas & Liquid Pipelines 7.0
Source: 2002 Report http://www.nace.org/Publications/Cost-of-Corrosion-Study/
8 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated
Brownfield Projects – Industry Problem
LaserScan
Optioneering
Engineering (Scenario
Analysis Services)
LaserScan
▪ Descartes
▪ Advanced point cloud data processing
▪ Pipe centrelines modelled with one click from point cloud data
▪ ProStructures
▪ 3D modelling environment for structural steel and metal work
▪ Modelling from 300 databases and International Standards
▪ Open Plant Modeler
▪ 3D Plant design and modelling
▪ Attachment of point cloud data for pipe modelling
▪ STAAD.Pro
▪ Analyze and design virtually any type of structure.
▪ Steel, concrete, timber, and aluminum design codes from all International Standards
▪ AutoPIPE
▪ Advanced Analysis Features for Varied Piping Environments
▪ Interface with AutoPIPE Vessel, STAAD.Pro, Plant Design CAD Systems, and
ProjectWise
ProjectWise
Document Management
1
5 4
3
2
AssetWise Reliability
Server
6 RBI SIM Assessment
“50% Reduction in interference checking “15% Design time savings, Faster Erection
80% Reduction in Site Non-conformances Schedule just 14.5 months and Clash Free”
95% on-time delivery”
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Power Plants Using Integrated Design Technology
Biomass - ESI Inc of Tennessee 42MW Gas-Turbine Power - Giprotyumenneftegaz
AutoPlant was configured for each engineering discipline and all models were The team used Microstation, Bentley Navigator, Structural Modeler and
managed through a controlled workflow in ProjectWise. eB Data Quality Manager STAAD.Pro for integrated analysis ad modeling which enabled
enabled efficient asset location and transfer of approx. 75,000 vendor assets and engineers to identify hindrances and optimize the layout in the turbine
design information vital to construction, operation and maintenance
As a result, the startup and commissioning group will save nearly 6000 man-hours.
building. These efficiencies reduced engineering cycle time by 8%.
Design Teams shared information using i-models which improved Designs were changed in the model before procurement errors and
multi-disciplined collaboration. Bentley Navigators view and installation conflicts, which helped minimize interferences and
review capabilities provided self service in the clash detection and eliminate redesign and construction rework. Additionally, the project
model review processes by putting the software in every project team conducted weekly model reviews with the client using an up to
professionals hands. date and accurate design model via the internet
18 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated
A Brownfield Plant Retrofit Project – Design Integrity Check
AutoPIPE
– Stress analysis of piping system
– Piping in isolation (no structure)
– Acceptable stresses in piping
– Export to STAAD.Pro using pipelink
format
STAAD.Pro STAAD.Pro
– Read in pipe support locations and
applied reactions from pipelink
– Analyze structure and run design
code checks on steel members
– All members pass checks
AutoPIPE
– Upsize main lines from ø350 to
ø450
– Rerun stress analysis 350 mm Dia. 450 mm Dia.
– Verify piping design passes
• Pipe stresses
• Equipment e.g. pump loads
• Support design
– Update Pipelink data exchange file for
use in structural analysis design in
STAAD.Pro
STAAD.Pro
– Read in updated pipelink file
– Rerun analysis and code checks
– The revised piping imparts higher
forces on portions of the structure
– Some members now fail code checks
– Add bracing to add stiffness and
strength
– Rerun the analysis and design
– All members now pass code checks
After
Before
(Braces Added)
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Revised System - Combined Piping-Structure
AutoPIPE
– Read updated pipelink structure into
AutoPIPE
– Includes revised structure designed in
STAAD.Pro
– Re-run stress analysis as final check
– Check possible increase in pipe support
loads and pump loads
AutoPIPE
– Publish AutoPIPE model to i-model
– Optionally consider deformed
geometry
– Upload to Bentley Cloud Services
project Bentley Navigator
Bentley Navigator
– Create a clash detection job
– Identify specific clashes
– Leave markups so other team
members can easily review and
update
LP Bypass Line
ProjectWise
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Structural Integrity Dashboard in Asset Management System
• Asset
Summary &
Health
• SIM KPI’s:
RSR,
Inspection
Compliance,
CP Readings,
Anomalies,
Trends
• Role specific
• GIS
Interface
• Select and
report on
assets and
equipment
• Surface
Alarms and
KPIs
IPL used Bentley's AssetWise Asset Reliability to track specific indicators and indicator states for manholes, vaults.
network transformers. and network protectors The team used the application to calculate an overall health score for
each asset based on weighted values To date, monitoring 300,000 indicators for 20,000 assets and associated work
order priorities has decreased equipment failures the network from 49 in 2011 to 15 2016 Substation transformer
failures followed a similar downward trend.
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Digital Surveys of Existing Assets
Point Clouds
➢ Traditional Laser Scanning Technology.
Photogrammetry
➢ 3D meshes created from photos.
Managing
information
Chemical Plant
➢ Drone – Falcon 8
➢ Camera – Nikon D810
➢ Capture - 4500 Photos
➢ Processing- 2 Hours
https://www.youtube.com/watch?v=o4xgf8
883dU
Not only a dimension but a window into the condition of your asset!
Allow 3D Coordination on Brownfield Projects with Ease
38 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated
Reality Modeling
Analysis of Transmission Tower, South
Korea, GeoINT
File Sharing
– Share models and files
– Notify teams members
automatically when files are added
or revised
Issues Resolution
– Review punchlist items created in
Navigator
– Coordinate status of each markup
Q&A