Digital Design Workflows To Reduce Non-Conformances in The Power Industry

Digital design workflows to reduce non-conformances
in the power industry

Mark Upston – Senior Director
1 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated © 2018 Bentley Systems, Incorporated
2017 USA Energy Infrastructure Report Card – What is the Gap?
https://www.infrastructurereportcard.org/wp-content/uploads/2017/01/Energy-Final.pdf
2 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated
Recommendations to Improve USA Power Infrastructure

Brownfield Plant Projects – Design Challenges
• Determining as-built conditions

• Evaluating engineering integrity of
existing facility
• Evaluating and selecting facility
expansion alternatives (new design)
• Coordinating new proposed design
with on-site conditions
• Coordinating progress across
teams, offices, and disciplines

Bentley Solving Multi-Discipline Team Collaboration

AGENDA
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
Brownfield Project: Laser Scan to 3D Modeling to Engineering
Analysis for Checking Structural Integrity

Where is Structural Integrity Needed Most?
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/
Brownfield Projects – Industry Problem
Plant Pipe Racks are failing with increasing downtime Corrosion is

leading to significant production losses Everywhere!
• The Structural Integrity is deteriorating due to

age and corrosion
▪ Plant has been in operation for over 20
years.
• Pipe racks are failing due to increased loads.
▪ As operations have increased further steel
and pipe work has been added.
• There are no 3D models available for the
structure.
▪ The only viable solution is ‘As Built’ capture.
Brownfield Projects – Design Solution
• Aging Plants – Integrated Design Models using STAAD for

Structural and AutoPIPE for Piping
LaserScan

Brownfield Projects – Design Solution
• Aging Plants – Integrated Design Models using STAAD for

Structural and AutoPIPE for Piping
Optioneering
Engineering (Scenario
Analysis Services)
3D CAD (STAAD &

model e.g. AutoPIPE)
OpenPlant
LaserScan

Bentley Solution – Model and Analyze Failing Structures
▪ 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

Design Integrity and Asset Management
ProjectWise
Document Management
1
5 4
3
2
AssetWise Reliability
Server
6 RBI SIM Assessment

Engineering Analysis
Benefits
Assets that are structurally at risk can be
identified quickly and accurately.
Accurate modeling of ‘as built’ assets
Integrate brownfield project

extensions to existing plant Use of existing tools and design
resources already in house
Reusable 3D intelligent plant Rapid Efficiency savings as

and analysis models for high as 75% compared to
future Plant sustainability traditional design methods

Power Plants Using Integrated Design Technology
200MW - Coal-Fired Power Plant – Philippines 600MW Gas Power Plant – Cairo
Doosan Heavy Industries Projenia S.r.l
“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”
Biomass - ESI Inc of Tennessee 42MW Gas-Turbine Power - Giprotyumenneftegaz
The integrated software facilitated exchange of information

among disciplines, reducing mistakes and automating processes
STAAD Pro and AutoPIPE saved ESI a such as collision detection and generation of specifications and
combined 700 resource hours on the project estimates. The time savings reduced costs by about 15%.

582MW Clean Coal Plant – Mississippi 375MW Combined Cycle Plant in India –
Southern Company L&T & Sargent Lundy
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%.

540MW Sewaren 7 Combined Cycle Plant Flue Gas Desulfurization Plant in North Carolina
New Jersey, Black & Veatch Utility Engineering
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
A Brownfield Plant Retrofit Project – Design Integrity Check

The As-Built System AutoPIPE
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

Revise Piping System and Investigate
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

Revise Piping System and Investigate
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)
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

3D Clash Detection

Evaluating Model for Clashes AutoPIPE
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

Case Study – Hot Operation Clashes
Samcheok Green Power Unit 1 and 2, South Korea
KEPCO Engineering & Construction Company Image Courtesy of KEPCO E&C

2x1,000MW Ultra Supercritical Thermal Power Plant Samcheok Green Power Unit 1
Samcheok, South Korea and 2 Project, Be Inspired 2014
Case Study – Hot Operation Clashes
The Solution – Run Full 3D Clash Detection of AutoPIPE 3D ‘Hot’ deflected DGN
model in Bentley Navigator, or MicroStation or OpenPlant
LP Bypass Line
3 Critical Hot Clashes Identified

during Design Phase Warm Up Line
KEPCO Engineering & Construction Company
2x1,000MW Ultra Supercritical Thermal Power Plant
Samcheok, South Korea Image Courtesy of KEPCO E&C Samcheok Green Power
Unit 1 and 2 Project, Be Inspired 2014
Summary Highlights
These Case Studies highlights the speed and accuracy of a

solution to evaluate structural integrity of aging plants
Benefits:
➢ Coupled analysis provides more accurate, cost effective
seismic designs
➢ Explore alternative design options quickly with efficiency
savings
➢ A structural integrity solution can verify remaining life and
easy to adjust for design modifications
➢ 3D-Models help coordinate on and off-site assembly and
fabrication of brownfield projects and reducing site non-
conformances
Engineering Document Management Using ProjectWise and
Asset Reliability

Engineering Document Management using ProjectWise
• ProjectWise – industry leading

global engineering content and
"With ProjectWise we can easily manage over collaboration server
9,000 transmittals and 20,000 technical
documents in a single repository. Also, it’s easy • Optimized for engineering
for the EPC subcontractor to collect the related software integration, model
documents/drawings for closed-out reports. management, drawing
ProjectWise has shortened the preparing time of management, large file
closed-out reports." management, review and
– Bao Jia Chen, Project Manager, CPC Corporation markup
• Link from Asset Reliability
providing access to models,
drawings, specifications,
inspections, etc
ProjectWise
Structural Integrity Dashboard in Asset Management System
• Asset
Summary &
Health
• SIM KPI’s:
RSR,
Inspection
Compliance,
CP Readings,
Anomalies,
Trends
• Role specific

Assets – Navigate by Hierarchy, Map, Listing
• GIS
Interface
• Select and
report on
assets and
equipment
• Surface
Alarms and
KPIs

How does Immersive Asset Reliability help?

Asset Performance
T&D Implementation of Asset Risk at Indianapolis Power & Light
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.
Digital Surveys of Existing Assets

Reality Modelling – Capture
Point Clouds
➢ Traditional Laser Scanning Technology.
Photogrammetry
➢ 3D meshes created from photos.

Photogrammetry – 3D Reality Mesh Models
Capturing the Aligning new designs
context with existing conditions
Managing
information
Inspecting operational assets

Better understanding Richer Information Models are available with 4D
via 3D is great!
37 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated (Time), 5D (Cost) and 6D (Operations Management)
What is the level of 3D Detail with Photogrammetry?
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
Reality Modeling
Analysis of Transmission Tower, South
Korea, GeoINT
Aerial Photogrammetry and ContextCapture reduced resource hours required for

surveying on site, improving safety and enabling the team to build realistic 3D Mesh at
30% of actual project costs and deliver the final model in just two weeks
Office to Site Coordination

Bentley Cloud Services – ProjectWise Project Share
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

Mobile 3D Visualizations and Interactive Inspections
Visualize 3D i-Models Punchlist of Issues

Thank you for Attending…
Q&A
Product Management: Mark Upston

Mark.Upston@Bentley.com
Marketing: Samantha Langdeau
Samantha.Langdeau@bentley.com

Digital Design Workflows To Reduce Non-Conformances in The Power Industry

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Digital design workflows to reduce non-conformances

in the power industry

3 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

• Determining as-built conditions

4 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

5 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

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Plant Pipe Racks are failing with increasing downtime Corrosion is

• The Structural Integrity is deteriorating due to

• Aging Plants – Integrated Design Models using STAAD for

10 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

• Aging Plants – Integrated Design Models using STAAD for

3D CAD (STAAD &

11 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

12 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

13 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

Accurate modeling of ‘as built’ assets

Integrate brownfield project

Reusable 3D intelligent plant Rapid Efficiency savings as

14 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

The integrated software facilitated exchange of information

16 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

17 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

19 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

20 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

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KEPCO Engineering & Construction Company Image Courtesy of KEPCO E&C

3 Critical Hot Clashes Identified

These Case Studies highlights the speed and accuracy of a

29 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

• ProjectWise – industry leading

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Inspecting operational assets

Aerial Photogrammetry and ContextCapture reduced resource hours required for

40 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

41 | WWW.BENTLEY.COM | © 2018 Bentley Systems, Incorporated

Visualize 3D i-Models Punchlist of Issues

Product Management: Mark Upston

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