SmartPlant 3D Materials Handling - Intergraph … · SmartPlant ® 3D Materials Handling ... •...
Transcript of SmartPlant 3D Materials Handling - Intergraph … · SmartPlant ® 3D Materials Handling ... •...
SmartPlant® 3D Materials Handling
Taylor D. ColeTaylor D. ColeVice President, IntergraphVice President, IntergraphGlobal Metals & Mining Industry Global Metals & Mining Industry
676872
2007 2015
3544
54 66
2007 2012 2017 2022
1926
33 38
2007 2012 2017 2022
8441136
1421 1624
2007 2012 2017 2022
Global Outlook - Commodities
Source: Rio Tinto – May and July 2008. Million MT per annum demand forecast.
Global Seaborne Iron Ore Global Copper
Global Aluminum Global Seaborne Coal
2 X 2 X
2 X 1.3X
Materials Handling Problem
Time to Market Solution:Work-sharing Skilled Resources
Higher Productivity and Quality for Same Hours
Re-use of Design
Reduce Interfaces and Re-work
Supply Chain Efficiency Vendor Integrated
Problem
2008 2015
Prod
uctio
n
Time to Market
Demand
Supply
Enablers:Technology: Intergraph SmartPlant Enterprise Workflow: Front-end Loaded and Rule Based
Standardisation: Intelligent Re-usable Catalogue
Leverage: Synergies with Other Industries
Accuracy: Total Installed Schedule and CostOptimise: Layout, Pre-assembly, Design Std’s
Safety: Reviews: Hazop, Constructability, O&M
Knowledge: Asset Lifecycle and Re-use
Benefits:
– 4 –
Business Values for Change
““ …… over 80% of a projectover 80% of a project’’s total cost are committed withins total cost are committed withinthe first 20% of the total projectthe first 20% of the total project’’s design time s design time …”…”
Profit
Time
FasterStart‐up
TraditionalStart‐up
CapitalCost Savings
FasterProfitability
IncreasedProfit
Traditional Project Cost/Breakeven Curve
Digital Plant Project Cost/Breakeven Curve
Cost
ReducedCapital Spend
CapitalCost Savings
ConceptualDesign
DetailedDesign
Fabrication &Construction
Commission& Test Plant Operations & Maintenance
According to a Construction Industry Institute study of 53 major projects, projects which included the most effort on conceptual plant studies averaged:
• 20% Lower Engineering costs• 39% Schedule reduction• 15% Plant Utilization/ Capacity increase
compared to projects that spent the least effort on conceptual plant design studies as part of pre-project planning.
Plant Hand-over
Plant Lifecycle
Intelligent Design Reduce Time on Task
• Comparison• Microstation
• Old technology [1980’s]
• Fantastic change for the time
• PDS• Newer technology
• Faster design time – improvement over Microstation
• SmartPlant® 3D• Latest technological advance
• Data base engineering
• Significant improvement over PDS in design time
• Improved integration between disciplines
Proof of Concept Project Background / Purpose / Status
Problem – industry demand and resource supply needs a ‘step change’ solution
Document centric (2D) project delivery compared to Process Industries
Proof of Concept initiates the step change
Industry requirements specifiedSolution concepts established and tested
Initiated solution configuration and developmentConcept proved - confidence to continue
Pilot project for ‘project readiness’objective
SmartPlant 3D Materials Handling Benefits for Projects and Assets
Schedule
Standardisation
Workflow
Interfaces
Productivity
Cost
Optimisation
Re-use
Wastage
Rework
Risk
Work-share
Tracking
Forecasting
Integration
Safety
Reviews
Pre-assembly
Simulation
Education
Knowledge Management and Re-use
Handover and Asset Lifecycle
SmartPlant 3D Materials Handling Conveyor Design Workflow
Current Scenario – Profile & Data Sheet Drawing
Solution – Conveyor & Parts Catalogue Specification
SmartPlant 3D Materials Handling Chute Catalogue Workflow
Current Scenario – Chute Arrangement Drawing
Solution – 3Di Design to Catalogue and Re-use
SmartPlant 3D Materials Handling Benefits for Projects and Assets
Schedule
Standardisation
Workflow
Interfaces
Productivity
Cost
Optimisation
Re-use
Wastage
Rework
Risk
Work-share
Tracking
Forecasting
Integration
Safety
Reviews
Pre-assembly
Simulation
Education
Knowledge Management and Re-use
Handover and Asset Lifecycle
SmartPlant 3D Materials Handling Knowledge Management & Re-use
Critical Information Transfer
Design
Operate
Commission
Build
Critical Feedback Loop
Critical Feedback Loop
Critical Information Transfer
Critical Information Transfer
SmartPlant 3D Materials Handling Knowledge Management & Re-use
Design
Operate
Commission
Build
SmartPlant® Foundation
Application Integration
Engineering Data Handover
Engineering Information Management
SmartPlant 3D Materials Handling Handover & Asset Lifecycle
By establishing a “holistic” strategy for plant asset lifecycle management, Owner Operators can
manage their assets for short and long term
profitability rather than the traditional “sweat the
assets” strategies
Measurable Value• Expedited Commissioning & Startup (2-3% of TIC) - through expedited commissioning & start-up
resulting from as-built data validation, transformation & loading into operating systems • Minimized Plant As-Built Verification (1-2% of TIC annually) - through auditable plant asset
information management of change• Reduced Production Loss (0.2-0.5% of revenue annually) – through elimination of unplanned
outages as a result of decisions based upon inadequate / incomplete plant data • Increased Turnaround Intervals (20% annually) – Through application of reliability in design and
asset performance management principals
SmartPlant Enterprise Financial Benefits
Base W/ SPE ChangeSales (Revenue) 1,000 1,020 +2.0%Less:Operating CostDepreciation
- 500- 100
- 494.7- 85
-3.0%-15%
Operating Profit 400 440.3 +10.1%
Base Scenario Savings / Revenue Improvement w/ SPE
CAPEX Savings: -15% - Initial and Depreciation
OPEX Savings: -3% annually
Revenue Increase: +2.0% annually and 7 to 10% earlier project completion (approximately +20% revenue increase in Y1 on a three year CAPEX project life).
SmartPlant 3D Materials Handling Next Steps
• Pilot Project• Australia• Q4 2008
• BETA Version• Q1 / Q2 2009
• Commercial Version• SmartPlant® 3D v9 Release
Materials Handling Solution
Questions?
Taylor D. ColeVice President, Intergraph Global Metals and [email protected]