SmartPlant Engineering & Schematic

in Production

Frank Joop
Global Business Development
Intergraph

November, 2011
Proof of Value is with the Customers

ƒ Use cases of SmartPlant Engineering & Schematic

– Bayer Antwerp

– OMV Petrom Petrobrazi Refinery Romania

– ORLEN Projekt SA Poland

– ECM Mining Brazil

ƒ Different industries
ƒ Different driver
ƒ One common goal:
Improve business and lower operational risk

June 2011 SmartPlant Engineering & Schematics

SmartPlant Enterprise

June 2011 SmartPlant Engineering & Schematics

Engineering & Schematics Seat count
(SP P&ID, SP Instrumentation, SP Electrical)

41,000*
40 000 36,000
36,000
35 000
31,000
28,000 29,000
30 000

25 000
21,000
20 000
16,000
15 000

10 000

5 000

0
2005 2006 2007 2008 2009 2010 2011
* Estimated
June 2011 SmartPlant Engineering & Schematics
Solving the Business Problems

ƒ Overall Solution Focus

– Cost of ownership
– Value proposition
– Integration
– Automation (API)
– Task focused
– Complete and reliable

June 2011 SmartPlant Engineering & Schematics

Putting the Solution in Perspective
ƒ Designing the Process Safety
– SP P&ID
ƒ Safety and Risk Mitigation Power
– SP Process Safety
ƒ Controlling the Process
Controls
– SP Instrumentation
ƒ Powering the Process
– SP Electrical B&D
ƒ Value add Engineering
– SmartSketch
– SP Explorer Process
ƒ Validating the Design
– ETAP Motor Operated Control valve
– SmartPlant P&ID Engineering Integrity
June 2011 SmartPlant Engineering & Schematics
From Requirement to Implementation
The SmartPlant Difference
PFD

Relationships
Rules

June 2011 SmartPlant Engineering & Schematics

Bayer Antwerp Belgium
Plant owner

SmartPlant Engineering & Schematics

June 2011 SmartPlant Engineering & Schematics
 112,500 employees
Full year sales: EUR 35.1 billion
291 subsidiaries
R&D expenditures: EUR 3.1 billion
As of December 31, 2010 / Employees: March 31, 2011

June 2011 SmartPlant Engineering & Schematics

 Key Locations / Regions

Europe
North America

Asia / Pacific
Africa / Middle East

Latin
America

The Bayer Group is a global enterprise

with companies in almost every country
June 2011 SmartPlant Engineering & Schematics
 SPPID / SPI @ Bayer in facts & figures

SPPID SPI
2 Data / Application Servers 3 Data / Application Servers
(Leverkusen, Caojing) (Pittsburgh, Leverkusen, Caojing)

All use Version SPID 2009 SP1 All use Version SPI 2009, SP2
Local installations at small sites
+- 25 User +- 200 User
3.500 P&ID’s 80.000 Loops

ƒ Licenses covered by “Global Alliance Agreement” (BTS)

ƒ Other used SmartPlant products:
– SmartSketch
– SmartPlant Electrical
– SmartPlant Explorer

June 2011 SmartPlant Engineering & Schematics

 Engineering

PDS ®
documents

June 2011 SmartPlant Engineering & Schematics

The Engineering & Design Basis

June 2011 SmartPlant Engineering & Schematics

Integration concept
ƒ Basic idea
– Multidisciplinary sharing of plant information
– One point of entry to ensure consistent as built documentation
– One stop shop principle to gather information
– Documentum folders structured according the plant naming convention
– Automated interfaces with engineering tools and SAP
ƒ Benefits
– Guaranteed consistent as built data Æ Safety!
– Reduce the search time for accurate information by maintenance
personnel (“An engineer spends 40 % of his time just by searching the
right document”)
– Low cost solution, no investment needed
– Super fast maintenance workflow, initiated in the SAP notification

June 2011 SmartPlant Engineering & Schematics

OMV Petrom
Petrobrazi Refinery
Plant Owner

SmartPlant Engineering & Schematics

June 2011 SmartPlant Engineering & Schematics
P L R C

O
Petrom – A

R O

Petrom – P
L P

3
1 2
R V

R P

S R

Petrom is the largest refinery owner and

operator in Romania, accounting for 40%
of country’s

June 2011 SmartPlant Engineering & Schematics

D OMV P

ƒ B
– R

– I 205 P OMV G
– 207 OMV P

ƒ C
–
–

June 2011 SmartPlant Engineering & Schematics

D I
ƒ I
– S P E
– S P PID
– PDS
– S P I
– S P R D B

ƒ G
–
–
–

June 2011 SmartPlant Engineering & Schematics

D I
ƒ C I
– I T
–
–

ƒ U I
–
– checking OPC’s
–

ƒ M

June 2011 SmartPlant Engineering & Schematics

D I
ƒ I
– SP E D
ƒ

ƒ I OMV D D I

–
–
– R D B
– I

June 2011 SmartPlant Engineering & Schematics

W

ƒ P R 201 2015
– investment program of 750 0 0 EUR P

ƒ P

ƒ Working for projects with Intergraph tools –

ƒ own set-up’s
ƒ D G

– SPID

– PDS OMV P PDS P

– RDB PDS SP I SP 3D
– SP

June 2011 SmartPlant Engineering & Schematics

B I

ƒ A

ƒ D

ƒ I

ƒ U

ƒ P

ƒ S

ƒ S

June 2011 SmartPlant Engineering & Schematics

N

ƒ C

ƒ C I

ƒ G S P 3D PDS

ƒ D

ƒ P

June 2011 SmartPlant Engineering & Schematics

ORLEN Projekt SA
EPC

SmartPlant Engineering & Schematics

June 2011 SmartPlant Engineering & Schematics
Who is ORLEN Projekt SA ?

ƒ Almost 40 years on the

market

ƒ 180 employees

ƒ Cooperation with biggest

European companies

ƒ Entering into EPC market

June 2011 SmartPlant Engineering & Schematics 25

Who is ORLEN Projekt SA ?

… Since 1998 we have

delivered over 2500 projects
for oil & gas, refinery,
chemical, power generation
and environment protection
industries.

June 2011 SmartPlant Engineering & Schematics 26

Who is ORLEN Projekt SA ?

June 2011 SmartPlant Engineering & Schematics 27

Co-operation with Intergraph

1998 2006 2007 2008 2010 2011

SPPID & PDS First tests General Agreement with

integration with SPF Intergraph for software and
services

Engineering Engineering, Procurement & Construction

June 2011 SmartPlant Engineering & Schematics

Why SP Engineering & Schematics

SmartPlant 2D main features:

ƒ Data centric tools

ƒ Rules-driven software

ƒ Basic source of technical

information for 3D model

ƒ Working with P&ID is a real

designing
not only sketching

ƒ Life cycle control system solution

from specification to ordering,
installation, construction, and
operations

June 2011 SmartPlant Engineering & Schematics 29

SP E&S applications
integrated environment

SPP&ID in use:

ƒ produce drawings and reports

faster and with high quality

ƒ holds all process data we need in

one place

ƒ propagate data to other tools

without retyping them

ƒ propagate topology of pipelines

to 3D

June 2011 SmartPlant Engineering & Schematics 30

SP E&S applications
integrated environment

SPP&ID customization:

ƒ new attributes for valves, instruments

ƒ ItemTag.dll configuration

ƒ Templates for dwgs, reports

June 2011 SmartPlant Engineering & Schematics 31

SP E&S applications
integrated environment

SPI in use:

ƒ produces loop drawings,

ƒ generates specifications of instruments and cables

ƒ stores data for junction boxes

ƒ propagates list of instruments

and their dimensions to 3D

June 2011 SmartPlant Engineering & Schematics 32

SP E&S applications
integrated environment

Cable Schedules
JB Layout

Spec Sheet

Process Data
SPI Instrument Index

Enhanced
Calculations
Smart Loop

June 2011 SmartPlant Engineering & Schematics 33

SP E&S applications
integrated environment
Calculation of wall thickness, corrosion allowance, etc.
Data import also for small none integrated projects

Piping spec remote access

SPE publish/retrieve

SPI – DDP

June 2011 SmartPlant Engineering & Schematics 34

Benefits

Integrated SPE environment is more effective

ƒ One input data – then only reuse

ƒ It is faster to publish/retrieve versus exchange of paper documents

between departments

ƒ No problem with version of dwgs, data –

the latest have been just published

ƒ Rule-based designing with real influence for 3D model

ƒ Easy upgrade to the newest product version of 2D applications

June 2011 SmartPlant Engineering & Schematics 35

ECM Brazil
EPC Mining

SmartPlant Engineering & Schematics

June 2011 SmartPlant Engineering & Schematics
 • ECM is a Brazilian engineering
company, founded in 1984

• ECM’s core business is Mineral

Industry

• 600 professionals

ABOUT ECM
 Mineral processing plants

Pellet plants

Ore handling, stockyards and

on shore port facilities

Pipelines & pumping stations

Hydro-metallurgical plants

ECM’s CORE BUSINESS

 ITABIRITOS CONCEIÇÃO
– VALE, 2008-2012

Itabira / MG – Brazil

12 million t/year of pellet

feed from low grade
compact ore

Greenfield

U$ 1 billion investment

Under construction

MAJOR PROJECTS
 ADEQUAÇÃO DE
CONCEIÇÃO AO ROM de
2014 – VALE, 2010-2014

Itabira / MG - Brazil

19.4 million t/year of sinter

e pellet feed

Brownfield

U$ 550 million investment

Under detailed engineering

MAJOR PROJECTS
 The benefits of
Engineering & SmartPlant
About ECM
Schematics Enterprise at ECM
Solutions
 • Performance assurance.
• Safety during construction
and operation.
• Compliance to CAPEX and
schedule.
• Constructability and
maintainability assurance.
• Effective bulk materials
control.
• Effective physical and
financial progress control.

CLIENT’S NEEDS AT PROJECT’S IMPLEMENTATION

 Better inter and multi-
disciplinary information
management and control during
all stages of the design –
CONSISTENCY

• Less re-work

• Shorter engineering schedule

• Lower engineering cost due

to productivity increase

THE BENEFIT OF ENGINEERING & SCHEMATICS

 CONCEPT DEFINITION OF
MINERAL PROCESS & ALL THE OPERATIONS
UTILITIES
AND SYSTEMS
SPPID
• PFD´s

• LEM (Mechanical
GENERATION OF INFORMATION
Equipment List)
TO BE DIRECTLY USED BY
• P & ID´s OTHER DISCIPLINES –
ELECTRICAL & INSTRUMENTATION
• List of lines
MECHANICAL & PIPING

THE USE OF SPPID TO IMPROVE ENGINEERING RESULTS

 GENERATION OF
ELECTRICAL
INFORMATION TO
SPEL BE USED BY
Input from SPPID
• single line OTHER
LEM (MOTORS RATING)
diagrams DISCIPLINES /
• power demand
PHASES
calculation

• data sheets INSTRUMENTATION

Input from ELECTRICAL
DESIGN CRITERIA • equipment list ELECTRICAL

• cables list (SP3D – detailed

engineering)

THE USE OF SPEL TO IMPROVE ENGINEERING RESULTS

 INSTRUMENTATION
GENERATION OF
SPI INFORMATION TO
• basic engineering: BE USED BY OTHER
instrument list & DISCIPLINES /
PHASES
instruments data sheets
Input from SPPID
• detailed engineering: INSTRUMENTATION
instrument lists,
cables lists, (SP3D – detailed
I/O list, engineering)
interconnection diagrams

THE USE OF SPI TO IMPROVE ENGINEERING RESULTS

MORE RELIABLE INFORMATION TRANSMISSION BETWEEN DISCIPLINES
Î “ON LINE” UPDATE

ELIMINATION OF REPETITIVE TASKS AT THE DEVELOPMENT OF

INSTRUMENT LISTS (GENERAL AND SPECIFIC PROPERTIES) Î ERRORS
MINIMIZATION

EXPRESSIVE TIME REDUCTION FOR DELIVERABLES EXECUTION

CHALLENGES

TO IMPROVE SOLUTION TO DELIVER INTERCONNECTION

DIAGRAMS AS PER LOCAL ENGINEERING AND CONSTRUCTION
PRACTICES

TO DEVELOP SOLUTION TO ALLOW “COPY & PASTE” OF

TYPICAL INTERCONNECTING DIAGRAM

THE USE OF SPI TO IMPROVE ENGINEERING RESULTS

 The benefits of
Engineering & SmartPlant
About ECM
Schematics Enterprise at ECM
Solutions
 FOURTH PELLET PLANT
PROJECT – SAMARCO, BASIC
& DETAILED ENGINEERING

610 mechanical equipment

600 lines

50 MW

4,900 instruments

AUTOMATION PROJECTS
 ITMS – MINA DO PICO –
VALE, BASIC ENGINEERING

1,178 mechanical equipment

1,900 lines

140 MW

6,600 instruments

AUTOMATION PROJECTS
ENGINEERING & SCHEMATICS EXCELLENCE AWARD 2010
Conclusion

ƒ Benefits for EPC and Owners

ƒ Proven on Projects and in Operations
ƒ Fit different business models
ƒ SP Engineering & Schematic used and driven by the users

June 2011 SmartPlant Engineering & Schematics

 Integrating the
Engineering
Enterprise…

September 2011
2011 SmartPlant Engineering & Schematic 2011