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Virtual Reality in Plant Engineering: VDC-Whitepaper

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Overview of applications of Virtual Reality and Virtual Engineering in plant engineering, created by the Virtual Dimension Center (VDC), Fellbach

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Virtual Reality in Plant Engineering: VDC-Whitepaper

  1. 1. Whitepaper Virtual Reality in Plant Engineering Applications, Benefits, Technologies © Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC) Dr.-Ing. Dipl.-Kfm. Christoph Runde Virtual Dimension Center (VDC) Fellbach Auberlenstr. 13 70736 Fellbach www.vdc-fellbach.de ϭ Applications, Benefits, Technologies
  2. 2. Construction & Retrofit Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Environment: Plant engineering as a technical business segment aims at the realization of technical plants. Plant engineering includes various technical disciplines: Process engineering Energy / Electrical engineering Plant Engineering Basics 2 engineering Supply technology Production technology Plant planning Mechanical engineering Image: VRMMP
  3. 3. Construction & Retrofit Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Stages in development process [Source: Wikipedia http://de.wikipedia.org/wiki/Anlagenbau ] 1. Process development in the laboratory and technical center as well as an extrapolation to the industrial scale ("scale-up") 2. Determination of the administrative, economic and technical conditions as well as the requirements 3. Feasibility study with technical and economic comparison of different concepts 4. Concept phase ([pre-planning]): selection of the final concept and initial estimations of the technical system scope 5. Elaboration of the technically and economically most favourable concept and determination of all expected costs Basics 3 expected costs 6. Approval planning to obtain the necessary permits 7. Detailed design and description of all necessary components and measures (execution planning or detail engineering) 8. Request of the described (specified) components and services 9. Offer comparison and order 10. Construction of the plant 11. Commissioning of the system 12. Proof of the agreed services of the plant (material & energy turnover, quality, warranty data) 13. Handover of the system to the operator
  4. 4. Construction & Retrofit Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Assessment of costs vs. Cost incurrence Problem intensified with project duration and complexity Basics 4 Example [Source: Munroe & Associates]
  5. 5. Construction & Retrofit Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Product lifecycle vs. Factory lifecycle Different life cycles require adaptability of the means of production and integrative planning Basics 5 Image: Institut für industrielle Fertigung und Fabrikbetrieb, Universität Stuttgart
  6. 6. Construction & Retrofit Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit VR in plant engineering: across all planning steps Basic Engineering Detail Engineering sequence Application across all planning steps 6 3D model as an integration platform for different trades 3D model as a communication platform for different disciplines Documentation & knowledge management Reconstruction, renaturation Construction Commissioning Operation Roughprocesssequence /ŵĂŐĞ͗ ^/ /͘/K
  7. 7. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit 3D-model for integration and communication Integration of geometry and kinematics Integration of geometry and control Integration with material flow and logistics Integration of geometry and physics simulation (structure, flow) Integration of documentation Image: Fraunhofer IPA Daimler, Rastatt: Robotics, supply, material flow Application across all planning steps 7 Integration of documentation Image: Fraunhofer IFF Image: ESI IC.IDO Visualization of flow conditions in plant Interactive documentation on equipment (Example: barrel extruder, Extricom GmbH, Lauffen)
  8. 8. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Basic Engineering: VR application fields 3D model for authority planning Presentation of plants and buildings in the overall context Use of 3D model for planning General construction: terrain model, roads, railways, existing buildings Image: VRMMP Complete overview on plant Basic Engineering 8 roads, railways, existing buildings Planning variants: longer retention of variants in the planning process: definition only when necessary Virtual inspections, intuitive presentation of the planning project for foreign disciplines and non-specialists Image: VRMMP Image: Fraunhofer IFF Highlighting of areas, e.g. variants Virtual walk-through
  9. 9. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Basic Engineering Image: Fraunhofer IPA Planning desk for 2D-3D-tasks Basic Engineering 9 Image: VRMMP Overall view with terrrain, roads, gates, cooling water reservoir
  10. 10. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Basic Engineering Consideration of accidents, incidents Representation of dispersion direction pollutants in the course of time With digital terrain model: representation of flooded areas Image: Hydro Image: Visenso Pollutant dispersion at drilling platform Basic Engineering 10 representation of flooded areas Passing interpretation, diagnosis, search for impurities, correction Image: VRMMP Image: VRMMPImage: VRMMP Presentation of flood in 3D-terrain model Image left: fire on electrical components Image right: leakage Image: VirtualCitySystems Simulation drop test (above real, below simulation) Images: ESI for Areva NP
  11. 11. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Basic Engineering Consideration of accidents, incidents Escape routes planning Evaluation warning signs and escape routes Presentation of unclear paths in several levels Image: VRMMP Escape routes via upper floors Basic Engineering 11 levels Visibility in different weather conditions In the event of an incident, blocked paths (fire, pollutants) Image: VRMMP Image: Visenso Visibility in the event of snowfall: the next sign? Blocked escape route in the event of leakage / fire
  12. 12. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Detail Engineering Construction/ design support Design support, geometry planning, ensuring absence of collisions Avoidance of multiple occupancy of assembly space Installation / removal inspections: Image: VRMMP Pipeline construction Detail Engineering 12 Installation / removal inspections: sequences, lifting devices, consideration of limp materials (hoses, cables) Geometric integration of different trades: Virtual Mock-Up Means of transport, conveyor technology Variant planning Image: Fraunhofer IPA Image: ESI IC.IDO Central pump station in mine: possibility for side- tilting loader to pass? Review on production plant, Gabler GmbH, Ettlingen
  13. 13. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Detail Engineering Simulation in 3D models Process technology/ engineering Structure and flow: ensuring functionality, optimization Automation technology: design automation system Image: VRMMP Presentation process simulation Detail Engineering 13 system Image: Visenso Image: VDC Flow simulation in turbine supply Programmable logic controler on 3D model Simulation assembly process of a turbine, taking into account deformation by welding process Image: ESI for Skoda Power
  14. 14. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Detail Engineering Ergonomics and Usability Strains, sight and gripping spaces Usability, understandability Noise/ vibration/ harshness, odour Image: ESI IC.IDO Interactive assembly and accessibility inspection with 3D human model Detail Engineering 14 Noise/ vibration/ harshness, odour Verification based on simulation models Safety technology, accident prevention Checking gripping areas Checking separation systems, barriers, sensors, processing (security concept) Image: VRMMP Image: Fraunhofer IPA Virtual display Safety cell
  15. 15. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Detail Engineering Safety cell with separating fences, light barriers, switches, transfer boxes and an automation system Detail Engineering 15 Image: Fraunhofer IPA Image: Fraunhofer IPAImage: Fraunhofer IPA
  16. 16. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Construction Retrofit: VR-application fields Return of the realization status in planning documents Laser scan + 360°-photography Support project controlling Change management Construction Retrofit 16 Combination of laser scan and geometry for transport studies Image: eSZett Laser scan Laser scan, 360°-photography Image: Scantec 3D Image: Scantec 3D
  17. 17. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Construction Retrofit: VR-application fields Mixed data processing Augmented Reality (AR) Comparison reality digital 3D data: Schedule newly constructed objects in inventory Image: Scantec 3D Mixed data processing: laser scan plus 3D-geometry Construction Retrofit 17 in inventory Review of digital documentation Image: metaio Image: Volkswagen AR-planning in existing system: infrastructure AR-planning in existing system: new series
  18. 18. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Construction Retrofit: VR-application fields AR-planning in existing system: conveyor technology Measuring function in AR Construction Retrofit 18 Image: TU München Image: Volkswagen Image: Volkswagen
  19. 19. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Commissioning Start-up support by partial simulation Hardware-in-the-Loop: development and evaluation of sensors, actuators, control Procedures, emergency stop, startup, shutdown Image: Fraunhofer IPA Overall diagram system simulation Commissioning 19 Image: Fraunhofer IPA Image: Fraunhofer IPA Hardware-in-the-Loop: control model, control of real plant Integration trades: robot - robot cell – cell with conveyor technology
  20. 20. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Commissioning Training and qualification Knowledge types which possibly have to be managed in virtual environments: 1. Position knowledge 2. Structural knowledge 3. Behavioral knowledge Image: VRMMP Location and message of a display Commissioning 20 3. Behavioral knowledge 4. Procedure knowledge Possibilities of learning in virtual environments: 1. Spatial exploration 2. Conceptual learning 3. Learning motoric abilities 4. Procedural learning Image: Fraunhofer IPA Image: VRMMP Functionality of a process Operating a virtual control using a Head-Up-Display
  21. 21. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Commissioning Training and qualification Learning levels: explain, accompany, examine Introduction of documentation Introduction of simulators Image: ESI IC.IDO Explanation of functionalities in front of Powerwall Commissioning 21 Introduction of simulators Scenario simulation Visualization of the hidden Image: VRMMP Image: VRMMP Element which has to be replaced, designation View in turbine
  22. 22. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Commissioning Training and qualification: Example high voltage transformer station Mediation of all circuits via interactive wiring diagram Insulators and breakers can be opened and closed in the circuit diagram Image: 5DT 3D view of a transformer station Commissioning 22 and closed in the circuit diagram In the background, a high-voltage safety program checks the correctness of all operations In the next step, operations are performed via a simulated operator console Image: 5DT Image: 5DT Circuit diagram with spatial assignment Simulated operator console
  23. 23. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Commissioning Commissioning 23 Image: VRMMP Plant training simulator by the Virtual Reality and Multimedia Park Turin: definition of scenarios, processing of scenarios, linked 2D and 3D view
  24. 24. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Operation: VR-application fields Training and qualification AR process support Teleservice AR-supported Image: ESI IC.IDO Tool change under collision and slipping conditions Operation 24 Image: Fraunhofer IPA Image: ESI IC.IDO Safety inspection of the virtual plant at a scale of 1: 1 Additional information, superimposed via AR- display
  25. 25. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Revamp Revision: VR-application fields • Return inventory and level of realization in planning documents, variant consideration • Support project controlling • Change management • Mixed data processing: Laser scan- point cloudImage: Scantec 3D Revamp Revision 25 • Mixed data processing: scan plus new construction • Accident/ incident consideration • Removal, installation, disassembly and accessibility inspections • AR-supported scheduling of new geometries in inventory Image: ESI IC:IDO Discussion in front of Powerwall (visualized laser scan geometry) Laser scan- based geometry generation Image: Scantec 3D
  26. 26. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Overview application areas In the respective planning stages Benefit 26
  27. 27. Construction Retrofit Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit Potential benefits Integrative 3D planning model reduces voting errors Transparency in planning, faster decision-making Inclusion of all disciplines Cost reduction due to Optimizing ergonomics and usability Merging reality and digital 3D world Fast, easy, understandable documentation; use as a Benefit 27 Cost reduction due to decreasing errors and consequential costs Shortening downtime Optimized transport and escape route planning Assembly and disassembly optimization documentation; use as a knowledge management platform Training already during planning/ without occupancy of the plant/ harmless using scenario techniques Image improvement through modern technology
  28. 28. VDC members and partners regarding this topic 28
  29. 29. Thank you very much for your interest! You are interested in this topic and you are looking for contact persons/ implementation partners? Please contact us. © Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC) Virtual Dimension Center (VDC) Fellbach Auberlenstraße 13 70736 Fellbach www.vdc-fellbach.de 29

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