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Conversion of PDS Catalogs and Specifications to SmartPlant 3D

Conversion of PDS Catalogs and Specifications to SmartPlant 3D. Toshio Hayashi Project IT Group Manager Toyo Engineering Corp. Oct , 2009. Global Toyo – EPC Offices. Toyo EU. Toyo USA. Toyo Brazil. Toyo China. Toyo Korea. Toyo Malaysia. Toyo Thai. Toyo India. 3D + Marian 3D

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Conversion of PDS Catalogs and Specifications to SmartPlant 3D

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  1. Conversion of PDS Catalogs and Specifications to SmartPlant 3D Toshio Hayashi Project IT Group Manager Toyo Engineering Corp. Oct , 2009

  2. Global Toyo – EPC Offices Toyo EU Toyo USA Toyo Brazil Toyo China Toyo Korea ToyoMalaysia Toyo Thai Toyo India 3D + Marian 3D Marian 300 Toyo Korea (Seoul) Toyo EU (Luxembourg) TOYO JAPAN Toyo USA (Houston) 2800 Toyo India (Mumbai) Toyo China (Shanghai) 1500 All Global Toyo 5800 Toyo Malaysia (Kuala Lumpur) Toyo Thai (Bangkok) Toyo Brazil (Rio de Janeiro)

  3. Toyo’s Business Segment History Industrial Systems Facilities & Environment Number of project Gas & Petroleum Energy Solution Petrochemical Chemical Fertilizer 2010 1961

  4. Toyo-Japan 3D-CAD History 1990 2000 2009 1980 1987 1983 1998 CAPES - Toyo Own Developed 3D-CAD - 30 Projects completed - Working with Host Computer 1993 1995 Intergraph PDS - 50 Projects completed - Toyo Own Customization for QC Tools / Dwg Issue Control / Physical Piping Support Library - Interface to SPMaterial 2005 R&D phase Intergraph SmartPlant 3D Actual Project Ready to apply to Actual Project NOW !! 4

  5. Introduction Background - Why Toyo chose Conversion in 2007 Development stage of SP3D @Toyo Manpower limitations Cost Evaluation (Remodel / RDB only / Full Conversion) Conversion Project (for Reference) Petrochemical Process Plant 350 Equipment, 4000 Piping lines, 8000 sheets of Piping Iso. Full PDS Modeling including U/G system 5

  6. Outline of PDS  SP3D Conversion Work • Task-1 PDS RDB -> SP3D RDB Translation • By Intergraph Conversion Center • 3 months for Piping / Structure / Raceway RDB • Task-2 PDS model -> SP3D model Migration • By Intergraph Conversion Center • 8 months for all PDS models migration • Manual Touch up and Confirmation for Converted SP3D model • By TOYO • 4 months for manual touch up • 2 months for all Piping Iso extraction Catalog DB preparation Model DB migration SP3D Finalization

  7. Schedule of Conversion Work Work By TOYO Work By Intergraph Dec.2007 Feb.2008 Sep.2008 Mar.2009 PDS V7.2 As-Built Task-1 : 3 months Upgrade PDS V7.2  8.0 PDS Spec Translation Confirmation Task-2 : 8 months Deliverable - Excel file for Bulkload PDS Model Migration Confirmation Deliverable - Plant Backup file (.bcf) SP3D Model Touch up & Confirmation 4 + 2 months 7

  8. RDB Translation (Task-1) - Outline • Piping Specifications • 35 Piping Specifications translated with PDS Datatranslator.exe • 2500 Piping Specialty and Instrument items creation • Symbol mapping + 30 custom EDEN (User symbols) creation • Structure Sections • 2700 Structure sections translation with assistance of DCC tools • 40 Custom sections creation • EE Raceway Specifications • 242 Specification creation with assistance of DCC tools • PDS/SP3D Code List creation • Additional Toyo specific PDS code creation 8

  9. Model Migration (Task-2) - Outline • Piping Models • 130 Piping models migration • Creating connectivity and tapping manually about 3000 points • Equipment Models • 95 Equipment models migration (Import as G-Types + Manual remodeling) • Structure Models • 73 Structure models migration + General Solid Import as G-Types • EE Raceway Models • 12 EE Raceway models • ( HVAC Models  No HVAC model available ) 9

  10. Manual Touch up and Quality Confirmation @ Converted SP3D model • Incorporated additional field change (as built conditions) • 500 Field Revision incl. all discipline • Physical Piping support modeling • Only critical items available on PDS (before conversion) • PDS Civil General Solid model  SP3D G-type • PDS FrameWorks Solid  PDS Equipment  SP3D G-Type shape • Manual selection by each item wise • Confirmation for Quality of Converted SP3D Model • Extraction of all Piping Isometric Drawing (8000 sheets) 10

  11. Model Migration - Limitations • Piping Models • Model migration by PDS model basis  Piping line connection through PDS models created manually for Piping Iso creation by line wise • Equipment Models • Connection between equipment shapes are not maintained. • Ladders, stairs and handrails are migrated as individual columns and beams. • Structure Models • Migrated Structure models don’t have connectivity between structure members. 11

  12. Summary RESULTS and FEED BACK For RDB Translation Successful use of semi-automated tools for Piping Successful manual effort for other RDB data (steel, tray, etc) Translated specifications provide a basis of Toyo standard RDB in SP3D For Model Migration Results not identical to native SP3D due to known limitations ~70 % of PDS data migrated by tools, ~30% manual rework Quality assurance issue, How to validate?? 12

  13. For more detail on legacy data conversions and Intergraph tools and capabilities contact you local Intergraph office or Richard Smykay Richard.smykay@intergraph.com Thank you !!

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