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Italteleco Laser Scanning Engineering RFID Applications

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  • Non siamo più business partner di intergraph, al limite mettiamo CSP LFM

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  • 1.  Italteleco was founded in 1986, as a Software House specialized in industrial software solutions.  Since 1995 our core business is to provide integrated solutions for large-scale companies.  Since 2003 we are Business Partners of Intergraph PP&M, the leading company in enterprise engineering software for the design, construction, and operation of plants, ships, and offshore facilities. Our History
  • 2. We firmly believe in continuous learning to develop the skills and knowledge of our personnel and in the application of new technologies as a tool to improve the processes in which we are involved. Our Mission
  • 3. Our Fields of Activity
  • 4. Certifications
  • 5.  Existing documentation often unreliable and inconsistent with real field situation.  Critical points:  Design based on unreliable data.  Additional EPC costs.
  • 6. Leica HDS6100 Range: 79 m. Speed: 508.000 pt/s Leica ScanStation C10 Range: 300 m. Speed: 50.000 pt/s Z+F Imager 5010 Range: 187.3 m. Speed: 1.016.000 pt/s
  • 7.  Field Survey  Creation of a topographic control network,  Placement of the targets (at least 4 visible from each scan)  Execution of the scanning from the selected scanning positions.  Acquisition of the targets coordinates with a total station.
  • 8.  Field Survey  Single scans are executed from different positions so that all the volume of interest is covered. Targets on each scan allow for precise point cloud registration (roto translation to a common coordinate system.)
  • 9.  Registration  Single scans are registered according to the coordinates of the targets on each scan, surveyed with a total station: the final result is a point cloud representing the entire plant, with correct plant coordinates.
  • 10.  3D Model  Modeling is performed by means of dedicate software (Cyclone/LFM/PDS/CadWorx): piping components are modelled according to applicable piping classes.
  • 11. Isometric Drawing
  • 12. Isometric Drawing
  • 13. Piping Layout
  • 14.  Clash check allows for a precise identification of clashes between new piping/equipment/structures (3D model) and existing plant (point cloud)  Issue of “Clash Check Isometrics” helps piping specialists to quickly identify and solve every single clash.
  • 15. Engineering •Reliable as-built documentation •Accurate measurements •Clash check •Faster & Safer survey •Constructability Maintenance •Minimize shut-down time with accurate piping substitution isometrics, critical lift simulations •Identify in advance the best construction sequences Operations •Use 3D models for safe operators training •Integrate intelligent 3D model with RFID technology for positive item identification, intelligent inspection&model markup
  • 16. Scaffolding • No need of scaffolding in most cases: survey costs are thus greatly reduced Survey Time • Minimize survey time: 2 operators with 1 scanner can survey an entire process plant (of average size) in about 15 days with an accuracy of 5 mm. Shut-down Time/Construction Time • Shut-Down times are minimized using accurate and reliable documentation, critical lift simulations: no additional shut- down time costs, no additional adjustment costs. • Construction time are minimized using clash check tools, interactive 3D models construction sequence simulations
  • 17. Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person 2007 FCC - Regenerator - Phase 1 Laser scan, various interference check tests Saras (Sarroch) 4000 50 Della Vedova R. V1 Vacuum Plant Laser scan, 3D model and critical lift simulation Saras (Sarroch) 3600 30 Cotza M. RT1-RT2 Plant Laser scan, 3D model and critical lift simulation Saras (Sarroch) 7500 40 Cotza M. GPL Unit Laser scan, 3D model, piping layouts extraction Saras (Sarroch) 2700 10 Cadeddu M. IGCC Unit Laser scan, dimensional checks Sarlux (Sarroch) 4400 40 Puddu D. Alkylation Unit Laser scan, plot plan extraction Saras (Sarroch) 6000 30 Della Vedova R.
  • 18. Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person 2008 FCC Unit Laser scan, shutdown critical lifts simulation Saras (Sarroch) 24200 50 Cotza M. Alkylation Unit Laser scan, 3D model,piping layouts extraction Saras (Sarroch) 6000 30 Della Vedova R. 2009 Mild Hydrocracking Unit Laser scan, reactor lifting simulation Saras (Sarroch) 13000 40 Caredda R. FCC Unit Laser scan, dimensional check nozzle K1R2-K1E58 Saras (Sarroch) 900 40 Cotza M. Biomass Power Plant Laser scan, 3D model and critical lift simulation for boiler substitution Sicet (Ospitale di Cadore) 18000 20 Vascellari M. U400 Desolphoration Unit Laser scan, isometric extraction for piping replacement Saras (Sarroch) 2400 40 Pili A. Biomass Power Plant Laser scan, 3D model, existing structures Sicet (Ospitale di Cadore) 18000 20 Vascellari M. U400 Desolphoration Unit Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 2400 40 Pili A. CCR Unit Laser scan, dimensional checks on CCRD19 Saras (Sarroch) 9000 40 Cotza M. Visbreaking Unit Laser scan, battery limits cross section extraction Saras (Sarroch) 4200 30 Spanu U.
  • 19. Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person 2010 Topping 1 Unit Laser scan, battery limits cross section extraction Saras (Sarroch) 4200 30 Spanu U. Main Stack Laser scan, dimensional check for elevator installation Saras (Sarroch) 400 80 Aymerich S. Z3 Unit Laser scan, stack vibrations monitoring Saras (Sarroch) - 130 Cozza R. 2011 Topping 2 Unit Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 9000 40 Corvetto F. CCR Unit Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 9000 40 Corvetto F. CCR Unit Laser scan, 3D model, design of overhead travelling crane modifications Saras (Sarroch) 2000 25 Cotza M. Centro Olio Val d'Agri Laser scan, 3D model, virtual as-built survey on P&IDs Saipem (Viggiano) 62500 15 Sirignano A.
  • 20. Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person 2012 Alcoa Laser scan, dimensional checks Alcoa Trasformazioni s.r.l. (Portovesme) 2500 15 G. Meloni RT2 Unit Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 3000 30 Cocco W. Vacuum 1 Unit Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 4500 45 Cocco W. 2013 SG10 Area Laser scan, 3D model, isometric and piping layout extraction Isab (Priolo) 45000 10 Giuliano G. CR27 -FCC Unit Laser scan, dimensional check Isab (Priolo) 400 40 Giuliano G. LPG Storage Plant (LPG spheres and bullets) Laser scan, 3D model, isometric extraction virtual as-built survey on P&IDs Saras (Sarroch) 28000 15 Di Monte D. Products StorageTanks Laser scan, 3D model, isometric extraction virtual as-built survey on P&IDs Saras (Sarroch) 200000 15 Di Monte D. FCC unit/Expander Laser scan, .LFD dataset generation (LFM Server) Saras/Foster Wheeler Italiana (Sarroch) 10000 30 Stefanini L. FCC unit Laser scan, .LFD dataset generation (LFM Server) Foster Wheeler Italiana (Ploiesti, Romania) 45000 65 De Angeli P.
  • 21. Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person FCC unit Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 15000 60 Garau L. Topping 1 Laser scan, 3D model, isometric extraction for piping replacement Saras (Sarroch) 12000 50 Vargiu M. MHC Unit Laser scan, 3D model, clash check Saras/IDI (Sarroch) 500 15 Pagani W. 2014 Biogen Idec Plant Laser scan, .LFD dataset generation (LFM Server) Foster Wheeler Italiana (Hillerod, Denmark) 50000 5 Mencarelli A. Furnace Exhaust Duct Laser scan, Dimension Check Topping Units, Sarlux /Kirchner, (Sarroch) - 20 Donzelli C.
  • 22. RFID-Based Plant Data Collection&Management Systems Blind Flanges Management SmartPlant P&ID Mobile Inspections&Maintenance
  • 23. RFID-Based Plant Data Collection&Management Systems Software Requirements All the applications will be used in petrochemical plants during construction, operation and maintenance, they must therefore comply with the following requirements: 1) It must be possible to install the applications on mobile devices 2) It must be possible to use the applications in explosion risk areas 3) Items identification must be univocal 4) It must be possible to write information on the RFID tags 5) Applications must be interfaceable with other DB-based applications 6) It must be possible to access data from Intranet/Internet
  • 24. RFID-Based Plant Data Collection&Management Systems Chosen Technology  Development Environment: Microsoft .NET Compact Framework Palm Sized PC (PPC) characteristics :  Operating System: Windows Mobile  RFID Scanner: 125 kHz  ATEX Certification 
  • 25. RFID-Based Plant Data Collection&Management Systems RFID TAG characteristics (Other TAG types can be used on Customer’s request):  Operating Frequency: 125 kHz  Chip: HITAG S 2048 (read/write)  ATEX Certification  Easily identifiable (yellow colour) Low operating frequency and RFID scanner’s characteristics require physical contact between RFID scanner and tag in order to complete any operation: It is therefore impossible either to operate on the wrong tag or to record wrong information.
  • 26. About 2000 blind flanges are involved in the shutdown of a medium-sized plant. Flanges are inserted and then removed in about 40 days. This process must be correctly managed and controlled, in order to ensure high safety levels and avoid problems that could lead to unwanted accidents and/or delays. It is therefore necessary: To verify the status (inserted/removed) of every blind flange. To verify the status of every interference blind flange (common to several blinding plans) To verify the completion status of every blinding plan To easily identify any potential problem Blind Flanges Management
  • 27. Blind Flanges Management Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
  • 28. Blind Flanges Management Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
  • 29. Blind Flanges Management Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
  • 30. Blind Flanges Management Information concerning blinding plans and blind flanges positions are loaded into the DataBase (in this case: Intergraph AIM-Directa): Relations are created between objects. Database is synchronized daily with data from the field.
  • 31. Blind Flanges Management Properties shown in the figure are associated to every blind flange (fully customizable on request)
  • 32. Blind Flanges Management For every blind flange position, an RFID tag is initialized with the blind identification code and initial status: initial status is set to “To be identified”, meaning the blind flange position has to be identified on the field. Initialized tags are then mounted on a metallic support which is then placed in the correspondent blind flange position. User registers, with the PPC, the correct placement : status is set to “Identified” During the shutdown operations, users , using the PPC, register insertion/removal of blind flanges: Status is set to “Inserted”/”Removed” Removal of interference blinds can be registered on the system only when all the operations concerning the blinding plans on which the interference blind flange appears have been completed. Users are constantly reminded that they are working on interference blind flanges.
  • 33. Blind Flanges Management Application login (using an RFID tag) Main Menu
  • 34. Blind Flanges Management Blinding plans list Blinding plan: checking general status
  • 35. Blind Flanges Management RFID Tag Reading Setting status to “Identified”
  • 36. Blind Flanges Management Setting Status to “Inserted” Setting Status to “Removed”
  • 37. Blind Flanges Management Interference Blind Flanges: setting status to “Inserted” and registering start of activities
  • 38. Blind Flanges Management Data from the field is synchronized daily (or at every shift change) with the main DB: users can access information via the document management system (in this case: Intergraph AIM/Directa) Icons are coloured according to the blind status.
  • 39. SmartPlant P&ID Mobile SmartPlant P&ID Mobile has been developed to allow plant operators, construction and maintenance personnel, to access, view and modify SmartPlant P&ID information using a Palm Sized PC (PPC) Using RFID tags to identify equipments, instruments, piperuns, piping components, etc. queries on the system are automatically performed.
  • 40. SmartPlant P&ID Mobile SmartPlant P&ID mobile manages the following SmartPlant P&ID objects: Equipments Equipment Components Instruments Instrument Loops Nozzles Piperuns Piping Components Graphic P&ID can be visualized on the PPC: an intelligent zoom is performed on the selected object (not working, in this version, on piperuns)
  • 41. SmartPlant P&ID Mobile A desktop application uses “Llama” libraries (Logical Model Automation) and SmartSketch libraries to connect to SPPID database and performs the following operations: Reads properties values of the various objects Generates a mobile DB, which is transferred on the PPC Converts graphic P&IDs from .pid to .dwg format When properties are modified on the PPC, updates SmartPlant P&ID’s DB
  • 42. SmartPlant P&ID Mobile Unit Selection Queries can be performed manually or using an RFID TAG
  • 43. SmartPlant P&ID Mobile Query Results Object visualizaton on the P&ID
  • 44. SmartPlant P&ID Mobile Properties are categorized like on SPPID Modification of a property on a piperun
  • 45. SmartPlant P&ID Mobile Adding appropriate values of “Construction Status” allows a simple work progress monitoring: In the above figure, piperuns with hydrotest completed are highlighted in blue (data registered with PPC). Every construction status can be traced from prefabrication to “Ready for Start-Up”
  • 46. Inspections&Maintenance Data from DB Item Name Item Picture from DB Physical contact between RFID scanner and RFID TAG ensures positive identification of the item: item data, work orders, inspection check-lists are shown on the handeld device screen.
  • 47. Inspections&Maintenance Work Orders Management: Work Orders for the item are shown on the handheld device and managed on the field by maintenance operators.
  • 48. Inspections&Maintenance ASSET DATA VISUALIZATION
  • 49. Inspections&Maintenance ASSET DOCUMENTATION VISUALIZATION
  • 50. Benefit of RFID-Based Plant Data Management Systems  Process management improvement  Process monitoring is easier with consistent, verified data  Problems are easily identified and managed  Identification errors are not possible  Easy and fast transition to the new system  Applications are designed to be as similar as possibile to the traditional working  procedures (applications are fully customizable according to the Customer’s  specifications  Training time for a low-skilled user: 2 hours.
  • 51.  We started our engineering&design activities in 2001 with participation in a working group of international caliber in the petrochemical industry. The aim was to optimize the management of physical and virtual warehouse stocks. This project was to be applied to Petrochemical and Refining plants (standard materials coding, supplier agreements, purchase requisitions, automatic generation of purchase orders) with the goal of achieving a significant reduction in operating costs. Engineering&Design
  • 52.  Since 2002 we developed additional skills and we can now provide the following services: Updating and management of piping material catalogs (according to ENI standards)  Design of piping material classes Modification/updating of existing piping material classes (ASME/EN) for every kind of material (carbon steel, low-alloy steel, stainless steel, duplex, monel etc.) and for every rating. Design of pressure vessels and pressure systems in compliance with PED directive. Engineering activities for the purchase of spare parts in compliance with D.M. 329/04 and subsequent circulars. Engineering&Design
  • 53.  We can manage every stage of the project: ◦ Material requisitions ◦ Technical analysis of tenders ◦ Supplier follow-up ◦ Technical documentation review ◦ Pre-commissioning Engineering&Design
  • 54. Engineering&Design  Design of PED equipment (ASME/EN) including spherical tanks, horton tanks, fixed and floating roof tanks (API 650, API 620, API 653). Other Activities
  • 55. Engineering&Design  Fitness for service analysis - API 579  Design of repair systems (armouring) and evaluation of hot tapping solutions for piping and equipment (API 2201, API 570, ASME PCC-2)  Finite elements analysis of pressure systems and structures  Design of piping material classes in compliance with ASME B31.3 / B31.1/ EN13480  Manufacturer of pressure equipment (in compliance with PED)  Commissioning reports for pressure systems in compliance with DM329  Inspection and testing of piping and pressure equipment.
  • 56. Engineering&Design  Stress analysis (ASME B31.3)
  • 57. Engineering&Design  Verification of mechanical stability for pressure equipment and structures.
  • 58. Software Puma5
  • 59. www.italteleco.it