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Detail Engineering in 3D-CAD

3D planning enables realistic images of the system at an early stage.
3D planning enables realistic images of the system at an early stage.

Three-dimensional CAD planning shows a realistic 1:1 image of a system at an early stage. This enables the relevant operating staff to be involved in the earliest planning stages and to integrate their specific requirements in the
planning. The basis for this consists of the documents prepared in basic planning, the GMP requirements specified in valid planning guidelines and the defined pipe classes and specified space.

 

Why plan in 3D?
With 3D planning, the system operator can intervene at an early stage in the planning and can thus ensure optimal configuration, operability and maintainability of the system. The use of 3D planning is suitable not only for large-scale projects but for smaller remodeling projects as well. It reduces remodeling, assembly and installation times and increases the precision of the planning and implementation as well as planning and implementation certainty.

 

The structure of 3D models
Three-dimensional detailed planning takes place in three stages:

  • Basic model: building, primary steel structures, pipeline bridges, etc.
  • Layout model: apparatuses and mounts, foundations, secondary steel structures, EIC conduits, switch cabinets, ventilation, etc.
  • Full piping model: complete piping of the system with all fittings, instruments and pipeline mounts

 

Required planning basis for detailed planning

To achieve optimal planning quality, quality-assured basic documents are required (approved for detailed planning):

  • building drawings with existing infrastructure
  • PI diagrams
  • apparatus drawings approved for execution)
  • pipe classes (pipeline components and fittings)
  • MIC instruments /fittings
  • special components (e.g. safety valves, compensators, etc.)

If these basic planning documents are not or are only partially available at the start of 3D planning, this can adversely affect the quality of the 3D planning and result in longer processing times and higher subsequent costs.

 

Integration of surveying
For conversion projects in existing systems it is extremely important that the building structures and the remaining system parts and integration points are documented to prevent collisions with the new system.


Surveying is done:

  • tacheometrically (axis model): building, fixed and installation axis points must be imported in the 3D model
  • via laser scans (volume model): the point cloud is imported in the 3D model

 

Results of the 3D planning
All of the documents required for the construction of the system are generated from the 3D system model:

  • building layout drawings (not construction drawings)
  • building zone drawings
  • steel structure drawings for primary and secondary steel structures
  • installation drawings for apparatuses
  • foundation and recess drawings
  • ventilation and EIC conduit drawings
  • isometrics for pipeline assembly
  • mount designs and drawings
  • special component drawings
  • material lists (MTO) for the procurement of pipeline material

 

Quality assurance in the 3D model
The 1:1 image should be used to test the 3D model in the following steps:

  • building and steel structure layout
  • apparatus installation
  • piping study (feasibility study, conduits, vertical piping shafts, etc.)
  • system piping according to the PI diagram (including all instruments and special components)
  • isometrics check (approved for execution)
  • collision check for system components

 

Economic aspects of 3D planning

  • Planning in a short time with high quality
  • Review by the operator and acceptance of the planning results in the 3D model
  • Reduction of planning costs in detailed engineering
  • Up to 100% prefabrication of pipelines and mounts
  • Cost reduction (15 – 20%) for prefabrication of pipelines and mounts in the workshop
  • Assembly/installation adjustments < 2%
  • Considerably shorter assembly/installation times (20 – 25%)
  • Shorter downtimes during conversion projects
  • Execution certainty (scheduling, costs and quality)

 

Results for system assembly /installation
The best, most accurate planning and surveying are all in vain if they are ruined by imprecise placement of the components during system installation.

Thus, it is important that all system components (apparatuses, ventilation and EMIC conduits, bases, breakthroughs, etc.) are calibrated in the specified axis grid from the 3D model (XYZ). It is also important that the production tolerances for the apparatuses (e.g. support positions) are kept as low as possible to prevent having to make adjustments at the construction site. The calibration of the apparatuses should be done by competent specialist companies.

 

Three-dimensional preview
Thanks to 3D CAD planning, the relevant operating staff can be involved from the very beginning and take a virtual tour of the new or upgraded system. Chemgineering uses the following CAD software:

  • TRICAD MS System Planning (standard as of 2015)
  • PDS Intergraph (upon customer request)
  • visualization and processing of the laser scan using LFM servers
  • visualization and model acceptance with Autodesk Navisworks

All Chemgineering sites are networked, so that planning can be done from various sites for the same project as required by the customer without loss of data in real time.

Thanks to the process systems already planned, Chemgineering has the expertise and the 3D CAD specialists to implement your specifications within the desired time frame in high planning quality.

 

Klaus Genter|Head of CAD Group|Chemgineering|The Technology Designers

 

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