SmartPlant Spoolgen

Automatic Isometrics for Fabrication & Erection

Kim, Kyung Deck – Intergraph Korea

1/28/2015
Traditional Fabrication Workflow

N
Design
contractor Fabricator
PL1
Pipeline Iso

Construction Red lining

1-8 man hours per spool sheet
Drawing
Drawingerrors
N

Manual re-drafting and Material

re-entry of material data
office
errors PL1

= Loss of design integrity + wasted

Spool Sheets

Fab man hours Material

shop SP1
Control
SP2
SP3

Materials
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Smarter Fabrication – SmartPlant Spoolgen

 Proven industrial strength application

Image provided courtesy of Heerema Zwijndrecht B.V.

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Smarter Fabrication – SmartPlant Spoolgen

 Proven industrial strength application

EPCs:-

Use to manage and Image provided courtesy of Heerema Zwijndrecht B.V.

track progress of
fabrication and erection
sub-contractors without
tying up valuable plant
design seats and
expertise

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Smarter Fabrication – SmartPlant Spoolgen

 Proven industrial strength application

Fabricators:-
Image provided courtesy of Heerema Zwijndrecht B.V.

Use to create a
competitive advantage
by minimizing costs and
boosting productivity

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Smarter Fabrication – SmartPlant Spoolgen

 Proven industrial strength application

Owner Operators:-
Image provided courtesy of Heerema Zwijndrecht B.V.

Specify as a tool to
optimize the design,
procurement,
fabrication, and erection
of piping systems

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Smarter Fabrication – SmartPlant Spoolgen

 Proven industrial strength application

 Digital bridge between engineering design

and fabrication

 Easily introduced into an existing work process Image provided courtesy of Heerema Zwijndrecht B.V.

 Shop and field detailing of design (AFC)

isometrics

 Part of Intergraph’s integrated Procurement,

Fabrication and Construction enterprise

solution

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SmartPlant / SmartMarine Enterprise

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SmartPlant Enterprise Integration

PDS, Smart3D SmartPlant Materials

MTO compare (+/-):
AFC vs. Fabrication +
AFC MTO Erection MTO

Procurement:
- Requisition
- Expedite
- Inventory
IDF/PCF Actual MTO: - Warehouse
Fabrication MTO - Issue
(AFC MTO) Fabrication MTO +
Erection MTO
Erection MTO

Fabrication MTO
Erection MTO Actual MTO
Erection isos Erection isos

SmartPlant SmartPlant SmartPlant FIWP:

Spool isos Spoolgen Foundation Construction Spools +
Erection isos +
Erection MTO

Pre-fabricated pipe spools & assemblies

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SmartPlant Spoolgen

 Windows® application built on ISOGEN™

 Input is IDF/PCF from ISOGEN enabled systems

 Paper input also supported

 Pipe editing not piping design

 Design integrity maintained – value added

 No redrafting or re-entry of material data

 New deliverables produced automatically

– High quality, consistently presented drawings

 Shop spool isometrics

 Field erection isometrics

– Data driven, accurate reports

 Material take-offs (MTOs)

 Cut lists, Weld lists etc

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Workflow Overview

PCF:-

Electronic IDF:- • S3D • Unigraphics NX

piping data • CADWorx • Catia
input from 3D • PDS • AutoPlant • Pro/Engineer
design systems • PDMS • PlantSpace • SolidWorks
• Plant4D • SolidEdge
• Plant3D • AIP

Import IDF/PCF

- Line list
- NDT
- Heat treatment Intelligent
Get External Data Isometric Add fabrication & erection detail
(POD)

Spool isometrics Erection isometrics

Piping reports

Fabrication shop Construction site

SmartPlant Materials,
Weld control,
ERP, SAP etc

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Demonstration – Basic Features & Workflow

 Importing design isometrics

 Editing welds to define spool breaks

 Automatic spool isometrics for shop fabrication

 Automatic field isometrics for site erection

 Integrated workflow management

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Value Proposition

 Elimination of redrafting and material data re-

entry – fewer errors, significant time and cost
savings

 Reduced material costs - through more

accurate procurement and improved utilisation
of materials

 Reduced project schedule – through ease of

use, quick detailing, data and drawing
automation

 Reduced overall project cost – through more

efficient use of materials, machinery, facilities
and man power

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Value Proposition

 Enables adherence to rigorous manufacturing

standards and stringent quality assurance
processes

 Minimized rework - through adoption of a high

quality, high accuracy, digital piping work process

 Valued business partner – enables you to deliver

high quality, fit for purpose pipe spools on
schedule, meeting demanding construction
deadlines

 Gives you a competitive advantage

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Business Benefits

 Simple to learn and easy to use Tenfold

improvement in
drawing production
 Minimal training required, short implementation period

 Low cost of ownership – operation and administration Up to 95%

reduction in
 No CAD or drafting skills required to operate or produce deliverables manual data entry

 High quality industry standard deliverables produced easily and quickly

 Eliminates the need to redraw isometrics and manually re-create material take-offs

 Reduced engineering man-hours through data customization and deliverables automation

 Delivers value standalone - significantly more as part of an integrated enterprise solution

 Fast payback / ROI - compared to drafting isometrics using conventional 2D CAD

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Payback / Return on Investment

2D CAD SmartPlant Spoolgen

1-8 hrs / spool sheet ~ 2 mins / spool sheet

( 1 man day / pipeline ) ( ~ 15mins / pipeline )

Typical Actual

( Quoted by customers ) ( Proven by customers! )

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Global Customers

EPCs & Fabricators Owner Operators

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Saipem S.p.A, Italy

 Challenges
Project statistics:
– Easily create shop drawings from PDS data • 11,500 isometrics
– Produce weld data for in-house production • 41,500 fabrication spools
• 21,000 assembly spools
analysis software and shop NDT evaluation • 200,000 welds

– Conduct a daily cross-check of AFC vs. actual

construction material usage

 Benefits
– Quick and easy system implementation
– Amount of manual data entry and rework
dramatically reduced
– Time to produce input data for material and
weld management activities reduced by 80%
per isometric
– Graphical interface - improved communication
between engineering and fabrication disciplines
Image provided courtesy of Saipem S.p.A

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Heerema Group, The Netherlands

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Rosetti Marino, Italy

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Integrating the
Engineering Enterprise

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MAJOR FEATURES
Integrated Workflow Management

 Integrated workflow control

– Import

– Pipeline Status
 Pending

 InProcess

 Complete

– Check-out

– Undo Check-out

– Check-in

– Replay

– Revisions
Business Value / Benefit:
– 3D visualization (I-View)
• Avoids duplication of work effort
• Prioritization and schedule control
• Revision monitoring and notification

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Revision Management

 Replay

– Auto-adds original edits on revised pipeline

 Repeat Data

– Maintains spool identifiers, drawing split points,

weld and part nos. between revisions

 POD Compare

– Auto-graphical identification - differences

highlighted
– Enables user to make decisions based on
current status of physical spools in shop
Business Value / Benefit:
• Empowers users to deal with change
• Data continuity between revisions
• Reduced rework, material control

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Weld Control

 Weld types

– Site / Field

– Workshop

– Offshore

– Field fit (allowance) Site / Field

– Special site (non-spooling)

– Automatic
Workshop
– Support (trunnion)

 Weld Gaps Business Value / Benefit:

• Welds specified correctly for shop/field
– Retrofit (if not in IDF/PCF)
• Accurate cut lengths
– WeldGap property (I-Configure) • Elimination of waste

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Weld & Part Numbering Control

 Explicit or implied?

 Pipeline start point

 Weld Numbers

– Clear

– Check

– Assign to New
 Highest Weld Number

 Assign to All

 Part Numbers
Business Value / Benefit:
– Controlled in exactly the same way
• Empowers user to deal with change
• Continuity of data between revisions
• Avoidance of duplicated numbers

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Productivity Tools

Components cut
 Isometric detailing options from pipe A and
– Selections (multiple edits)

– Auto Straight Split

– Cut & Paste

– Annotation – messages etc

– Additional materials Pipe A showing cut

components as
– Cut Piece Allowances continuation items
– Wall, floor penetrations
pasted into
pipe B

Business Value / Benefit:

– Detail sketches / Info notes
• Fabricate constructible spools
• Detailed drawings for fabrication/construction
• Fast detailing - reduced engineering man-hours

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Elbow to Bend Conversion

 Support for pipe bending, hole cutting

Elbow
– Bending report
– Numerical control interfaces
 InCopR

 Automatic and rule based

– Only converts elbows if sufficient pipe either side

– ElbowConversion configuration (I-Configure)

– Automatic replacement Bend

 Whole pipe
 Selected elbows
Business Value / Benefit:
– Equivalent bend geometry
• Reduced fabrication costs (fewer shop welds)
 1.5D bend for 1.5D elbow • Reduced construction costs (fewer site welds)
 Welds removed • Reduced inspection costs (fewer welds to inspect)

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Get External Data

 Easily configured, powerful XML based data

automation

 Auto-population of attribute data

– Pipeline

– Spool

– Component

– Weld

 Information held in external data sources

– Spreadsheets, databases
 Pipeline attributes Business Value / Benefit:
 Weld inspection details • Improved data quality
 Heat treatment / NDT data • 95% reduction in manual data input
• Feed richer piping data downstream

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ISOGEN™ Automation

 Market leader

 Industry de-facto standard

 Automatic outputs

– High quality isometrics

– Consistent presentation

– No human intervention

– Zero editing / clean up

– Accurate data driven MTO reports

 Data centric

– Variety of deliverables Business Value / Benefit:

 Check, Spool etc • Tenfold drawing productivity via automation
• Elimination of human errors – no drafting
– In a variety of formats
• High quality drawings and reports
 DXF/DWG/DGN/IGR

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Data Integration & Interoperability

 Data integration
– Fixed format text / legacy formats
– Access
– Excel
– XML
 With
– In-house systems
 Material control, ERP etc
 3rd party vendor systems
 SAP

 Interoperability
– CAESAR II (via PCF)
– PDS, Smart3D
– SmartPlant Isometrics
– SmartPlant Foundation Business Value / Benefit:
– SmartPlant Materials • Multi-system support - MATC, ERP etc
– SmartPlant Construction • Zero manual data input, no human errors
• Reduced engineering man-hours

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