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
Anirban Datta
Manager – Mechanical & Piping, Richard Design Services India Private Limited (A fully owned Subsidiary
of Richard Industrial Group, USA), MIE, CEng (India), PE (India)
Gautam Gangopadhyay
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
• Plant Layout
• Geo-technical
• Mechanical
• Civil
• Structural
• Piping
• Electrical
• Instrumentation and Controls
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. 2D Drawings and Sketches (E)
• Traditional format
• Inter-drawing design coordination subject to error
• Change management requires rigorous document control process.
B. 3D CAD Model with data attribute links (Intelligence) (E)
• Used for EPC over 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. 4D Construction Simulation Model (EC)
• Construction Planning & Sequencing
• Resource Management and Construction Machineries Movement
• Links 3D model components with L3 schedule
• Construction Status against Time
• Real-time Visualization
D. 5D Cost 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