The Kusile Power Station project in South Africa leveraged 3D modeling and simulation technology to improve project execution, maximize returns, and deliver an integrated information asset. By using Bentley software like MicroStation for 3D modeling and simulation tools, the project achieved benefits like improved commissioning, training, and lifecycle management. This supported delivering the large, complex plant faster while enhancing safety and operational readiness.
This document describes a proof of concept project using 3D laser scanning technology at Lethabo Power Station in South Africa. The project demonstrated how laser scanning data can be leveraged across the entire asset lifecycle using Bentley software tools. 346 laser scans were performed and integrated into a point cloud containing over 10 billion data points. The project was completed ahead of schedule and identified numerous applications of the scan data to improve operations, maintenance, training and safety.
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Merwyn Cheruvathur is seeking a full-time position utilizing his skills in engines, design, testing, modeling, simulation, and CAD. He has a MS in Mechanical Engineering from Michigan Technological University and a BS from University of Pune. His experience includes design engineering internships at Kohler Co. and National Chemical Laboratory. He has skills in CAD software like CATIA, ProEngineer, and Simulink. He also has experience in research related to engines, vehicle modeling, and exhaust gas recirculation systems.
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Mohammed Islam Elshiekh Elsmani is seeking a position that utilizes his qualifications in business development, project management, operations management, team leadership, automation systems, and electrical engineering. He has over 15 years of experience managing construction and maintenance projects in various roles in Sudan and Saudi Arabia. His background includes expertise in SCADA systems, electrical installations, reliability engineering, and contract management.
This document describes a proof of concept project using 3D laser scanning technology at Lethabo Power Station in South Africa. The project demonstrated how laser scanning data can be leveraged across the entire asset lifecycle using Bentley software tools. 346 laser scans were performed and integrated into a point cloud containing over 10 billion data points. The project was completed ahead of schedule and identified numerous applications of the scan data to improve operations, maintenance, training and safety.
Overview of the Exascale Additive Manufacturing Projectinside-BigData.com
The Exascale Additive Manufacturing (ExaAM) project aims to accelerate the adoption of additive manufacturing by enabling the fabrication of qualifiable metal parts with minimal trial and error. ExaAM will couple high-fidelity sub-grid simulations within a continuum process simulation to determine microstructure and properties at each time-step using local conditions. ExaAM involves multiple computational codes, including ALE3D, Diablo, Truchas, MEUMAPPS, and AMPE, which model different additive manufacturing physics across continuum, meso, and micro scales. The goal is to utilize exascale concurrency and locality to dynamically bridge scales through an adaptive, task-based approach.
Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?
Maptek's BlastLogic software is adding new tools to help miners better manage their drill and blast operations. The new tools allow blast engineers to preview blast designs, detonation timing, and sequences. This helps engineers optimize blast performance and ensure safety. Maptek is committed to enhancing their software based on customer feedback to deliver the best solutions for drill and blast planning and management.
A Review on Scheduling in Cloud Computingijujournal
This document reviews scheduling techniques in cloud computing. It discusses key concepts like virtualization and different scheduling algorithms. The review surveys various scheduling algorithms for tasks, workflows, real-time applications and energy efficiency. It analyzes algorithms based on parameters like makespan, cost, energy consumption and concludes many algorithms can improve resource utilization and performance while reducing energy costs.
Merwyn Cheruvathur is seeking a full-time position utilizing his skills in engines, design, testing, modeling, simulation, and CAD. He has a MS in Mechanical Engineering from Michigan Technological University and a BS from University of Pune. His experience includes design engineering internships at Kohler Co. and National Chemical Laboratory. He has skills in CAD software like CATIA, ProEngineer, and Simulink. He also has experience in research related to engines, vehicle modeling, and exhaust gas recirculation systems.
This document provides information on piping design engineering modules including 3D and 2D design and drafting tools. It outlines the tools used for piping modeling, equipment modeling, structural modeling, and other tasks. It also describes the tools and processes for 2D design and drafting tasks like piping layout drawings. Additionally, it lists the tasks involved in piping engineering like piping and equipment layout, material take off, and piping instrumentation drawings. Finally, it provides details on the design tools and software the engineer has experience with along with examples of projects in different regions and industries.
Mohammed Islam Elshiekh Elsmani is seeking a position that utilizes his qualifications in business development, project management, operations management, team leadership, automation systems, and electrical engineering. He has over 15 years of experience managing construction and maintenance projects in various roles in Sudan and Saudi Arabia. His background includes expertise in SCADA systems, electrical installations, reliability engineering, and contract management.
The document provides a resume for Khalil Ahmed Khalil Awwad, outlining his 22 years of experience in project management, site management, field service operations, and maintenance for various power and electricity companies in Egypt and Saudi Arabia. It details his roles and responsibilities in these areas, as well as his educational background and professional training. The resume highlights notable projects he has contributed to and aims to showcase his skills and qualifications for career opportunities in related fields.
Meramat Anak Tajak has over 25 years of experience in instrumentation engineering working for Shell Malaysia. She has led projects involving real-time pipeline modeling, smart field technology, and enhanced oil recovery. Her career highlights include implementing computer-assisted operations and contributing to production gains through neural network modeling. She is now seeking new challenges to match the needs of companies in 2016.
Sondus Ahmed has over 7 years of experience as a project engineer working on control system projects in Kuwait and Egypt. Her roles have included I/O assignment, wiring diagrams, function design specifications, and database management. She has a bachelor's degree in chemical engineering and certifications in Six Sigma, Experion PKS, and HSE trainings. Her skills include AutoCAD, Microsoft Office, and working collaboratively under pressure as part of a team.
The document outlines an agenda for a workshop on digital twin technology from a manufacturing quality perspective. The workshop will discuss using CAE simulation and artificial intelligence to create digital twins for closed-loop in-process quality improvement. Speakers will discuss applications in automotive and aerospace manufacturing and how digital twin technology can shorten lead times and ramp-up times by improving quality.
Industry 4.0: Merging Internet and FactoriesFabernovel
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The adoption of Industrial Internet has both near-term and long-term impacts and will be characterized by the emergence of new models such as the “Outcome Economy” and the “Autonomous, Pull Economy”.
We believe that INDUSTRY 4.0 is a growth opportunity for industrial companies, and have decrypted this very phenomenon in the following presentation.
The document discusses 7 engineering design projects completed by the author. It provides brief descriptions of each project including the client, objectives, design challenges, solutions developed, and project deliverables such as 3D models, drawings, and reports. The projects cover a range of industries including automotive, communications, construction equipment, and more.
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2. It aims to minimize computational costs and cooling costs by optimizing task assignment to servers based on factors like temperature, CPU, and memory.
3. The proposed approach uses a greedy algorithm to schedule tasks to servers maintaining the lowest temperature, thus reducing energy consumption and improving data center performance.
COMPARATIVE STUDY OF ACTUAL AND CRASHED SCHEDULE OF BUILDING USING MSPIRJET Journal
This document compares the actual and crashed schedules of a building construction project using Microsoft Project (MSP) software. It discusses crashing the schedule by using overtime, slack time optimization, and alternative building materials and techniques to reduce the project duration from 228 days to 198 days. Crashing activities involves adding additional resources and crews to speed up durations but at increased costs. The case study examines crashing the schedule of a residential project in Bangalore, India from 8 months to a shorter duration desired by the client, analyzing time and cost optimizations possible through alternative techniques like rat trap bonding, precast plank and joist roofing system, and using polycarbonate glass.
Najmul Saqib Maniar is a project manager with over 15 years of experience managing large scale projects for Dawlance Group of Companies in Karachi, Pakistan. He has managed projects ranging from USD $1.8 million to USD $6 million related to facility development, equipment installation, and environmental compliance. His experience includes managing teams of up to 195 direct and 556 indirect workers while ensuring projects are completed safely, on budget, and on schedule. He holds an MBA and bachelor's degree in industrial engineering and has received extensive training in project management, ISO standards, and manufacturing techniques internationally.
Falkonry provides a predictive operations platform called Falkonry LRS that allows operations teams to discover patterns, explain behaviors, and predict outcomes from their existing operational data without requiring data scientists. The platform uses machine learning techniques to analyze time series data and provide insights like detection of abnormal behaviors, classification of conditions, and prediction of future outcomes. It aims to help companies improve key metrics like throughput, quality, safety and yield. Falkonry customers across various industries have reported achieving 5-10x return on investment.
- Nitin Agrawal has nearly 8 years of experience as a mechanical engineer working on plant layouts for power plants. He has worked on projects in India, Portugal, Vietnam, Germany, Saudi Arabia, and South Korea.
- His responsibilities include designing building layouts, coordinating project teams, developing maintenance concepts, and troubleshooting issues.
- He currently works as a senior mechanical lead engineer at Siemens, where he has taken on roles such as project lead and software conversion team head.
Data Center Optimization with Avocent MergePoint Infrastructure Explorer (AMIE)42U Data Center Solutions
In this presentation 42U and Avocent show how the Avocent AMIE infrastructure software solution can help you optimize your data center.
To view the recorded webinar, which includes a live demo of the software, visit http://www.42u.com/webinars/Avocent-AMIE-Webinar/playback.htm
Summary: Avocent MergePoint Infrastructure Explorer (AMIE) software presents a fresh alternative to familiar tools such as spreadsheets and VISIO diagrams. With real-time visibility, users can model, plan for, and schedule changes to their data center. Coupled with asset management and capacity planning, AMIE takes the guesswork out of data center projects.
The power of the industrial internet has trasformed the use of equipment and given a boost to technology. In the case of paralell flow regenerative technolgy used in lime production, it has enabled lime producers to improve efficiency, reduce power demand and yeld significant cost benefits.
The power of the industrial internet has trasformed the use of equipment and given a boost to technology. In the case of paralell flow regenerative technolgy used in lime production, it has enabled lime producers to improve efficiency, reduce power demand and yeld significant cost benefits.
PJBUMI Heavy Engineering & Services Sdn. Bhd. is an engineering company with divisions in property development, digital solutions, energy, and telecommunications. The intern's objectives were to adapt to the working environment, apply classroom knowledge, and learn new skills. During the internship, the intern assisted with tender proposals, project work, and administrative tasks like setting up meetings and editing company documents. The intern concluded that the experience provided valuable practical training and insights into engineering applications in industry.
IRJET-To Implement Cloud Computing by using Agile Methodology in Indian E-Gov...IRJET Journal
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Abstract
Many developed countries in the world, uses Information and communication technology to deliver public services in a more efficient & easy way. The benefits of the Electronic Governance are huge and day by day increasing from one to many public services. But implementation of the governance is constrained due to 1) high costs of investment 2) shortage of domain experts 3) diverse and irreconcilable systems and 4) Security and privacy issues. With the Invent & rise of Cloud computing, i am looking various aspects of use of cloud computing in e-governance is emerged. Cloud computing can solve many of the above mentioned hurdles and provide better way to e-gov expansion, but it has some risks also. Agile development treats optimize the chance provided by cloud computing by doing software relinquishes iteratively and getting end user feedback more frequently and quickly.
Khubaib Khan is an instrumentation engineer with over 10 years of experience working in fertilizer and power plants. He has expertise in DCS/PLC systems including Yokogawa Centum CS 3000 and GE Fanuc Rx3i PLC. Khan is currently an instrumentation area engineer responsible for maintenance, troubleshooting, and projects involving gas turbines, HRSGs, nitric acid plants, and CDM projects. He has received awards for his maintenance excellence and safety initiatives.
The document provides a resume for Khalil Ahmed Khalil Awwad, outlining his 22 years of experience in project management, site management, field service operations, and maintenance for various power and electricity companies in Egypt and Saudi Arabia. It details his roles and responsibilities in these areas, as well as his educational background and professional training. The resume highlights notable projects he has contributed to and aims to showcase his skills and qualifications for career opportunities in related fields.
Meramat Anak Tajak has over 25 years of experience in instrumentation engineering working for Shell Malaysia. She has led projects involving real-time pipeline modeling, smart field technology, and enhanced oil recovery. Her career highlights include implementing computer-assisted operations and contributing to production gains through neural network modeling. She is now seeking new challenges to match the needs of companies in 2016.
Sondus Ahmed has over 7 years of experience as a project engineer working on control system projects in Kuwait and Egypt. Her roles have included I/O assignment, wiring diagrams, function design specifications, and database management. She has a bachelor's degree in chemical engineering and certifications in Six Sigma, Experion PKS, and HSE trainings. Her skills include AutoCAD, Microsoft Office, and working collaboratively under pressure as part of a team.
The document outlines an agenda for a workshop on digital twin technology from a manufacturing quality perspective. The workshop will discuss using CAE simulation and artificial intelligence to create digital twins for closed-loop in-process quality improvement. Speakers will discuss applications in automotive and aerospace manufacturing and how digital twin technology can shorten lead times and ramp-up times by improving quality.
Industry 4.0: Merging Internet and FactoriesFabernovel
Industrial IoT and connected objects for factories are part of our research at FABERNOVEL OBJET, our activity dedicated to IoT.
The future of industry is at the crossroads of internet and factories. Some call it INDUSTRY 4.0 or FACTORY 4.0 in reference to the upcoming fourth industrial revolution. Governments and private companies in Germany, UK and the USA have acknowledged the importance of industrial IoT and its central role in future industrial transformation.
The adoption of Industrial Internet has both near-term and long-term impacts and will be characterized by the emergence of new models such as the “Outcome Economy” and the “Autonomous, Pull Economy”.
We believe that INDUSTRY 4.0 is a growth opportunity for industrial companies, and have decrypted this very phenomenon in the following presentation.
The document discusses 7 engineering design projects completed by the author. It provides brief descriptions of each project including the client, objectives, design challenges, solutions developed, and project deliverables such as 3D models, drawings, and reports. The projects cover a range of industries including automotive, communications, construction equipment, and more.
George Booras, EPRI - Power plant capture case studies - IntroductionGlobal CCS Institute
This document summarizes a presentation on cost estimates for carbon capture and storage (CCS) applications in power plants. It discusses challenges in estimating costs for retrofitting CCS to existing power plants. It also emphasizes that research and development are critical to driving down costs and enabling the learning-by-doing necessary for CCS technologies to be deployed at large scale. Sharing lessons learned from early CCS projects is important for the long-term success of carbon capture.
Energy-Efficient Task Scheduling in Cloud EnvironmentIRJET Journal
1. The document discusses developing an energy-efficient task scheduling approach for cloud data centers using deep reinforcement learning.
2. It aims to minimize computational costs and cooling costs by optimizing task assignment to servers based on factors like temperature, CPU, and memory.
3. The proposed approach uses a greedy algorithm to schedule tasks to servers maintaining the lowest temperature, thus reducing energy consumption and improving data center performance.
COMPARATIVE STUDY OF ACTUAL AND CRASHED SCHEDULE OF BUILDING USING MSPIRJET Journal
This document compares the actual and crashed schedules of a building construction project using Microsoft Project (MSP) software. It discusses crashing the schedule by using overtime, slack time optimization, and alternative building materials and techniques to reduce the project duration from 228 days to 198 days. Crashing activities involves adding additional resources and crews to speed up durations but at increased costs. The case study examines crashing the schedule of a residential project in Bangalore, India from 8 months to a shorter duration desired by the client, analyzing time and cost optimizations possible through alternative techniques like rat trap bonding, precast plank and joist roofing system, and using polycarbonate glass.
Najmul Saqib Maniar is a project manager with over 15 years of experience managing large scale projects for Dawlance Group of Companies in Karachi, Pakistan. He has managed projects ranging from USD $1.8 million to USD $6 million related to facility development, equipment installation, and environmental compliance. His experience includes managing teams of up to 195 direct and 556 indirect workers while ensuring projects are completed safely, on budget, and on schedule. He holds an MBA and bachelor's degree in industrial engineering and has received extensive training in project management, ISO standards, and manufacturing techniques internationally.
Falkonry provides a predictive operations platform called Falkonry LRS that allows operations teams to discover patterns, explain behaviors, and predict outcomes from their existing operational data without requiring data scientists. The platform uses machine learning techniques to analyze time series data and provide insights like detection of abnormal behaviors, classification of conditions, and prediction of future outcomes. It aims to help companies improve key metrics like throughput, quality, safety and yield. Falkonry customers across various industries have reported achieving 5-10x return on investment.
- Nitin Agrawal has nearly 8 years of experience as a mechanical engineer working on plant layouts for power plants. He has worked on projects in India, Portugal, Vietnam, Germany, Saudi Arabia, and South Korea.
- His responsibilities include designing building layouts, coordinating project teams, developing maintenance concepts, and troubleshooting issues.
- He currently works as a senior mechanical lead engineer at Siemens, where he has taken on roles such as project lead and software conversion team head.
Data Center Optimization with Avocent MergePoint Infrastructure Explorer (AMIE)42U Data Center Solutions
In this presentation 42U and Avocent show how the Avocent AMIE infrastructure software solution can help you optimize your data center.
To view the recorded webinar, which includes a live demo of the software, visit http://www.42u.com/webinars/Avocent-AMIE-Webinar/playback.htm
Summary: Avocent MergePoint Infrastructure Explorer (AMIE) software presents a fresh alternative to familiar tools such as spreadsheets and VISIO diagrams. With real-time visibility, users can model, plan for, and schedule changes to their data center. Coupled with asset management and capacity planning, AMIE takes the guesswork out of data center projects.
The power of the industrial internet has trasformed the use of equipment and given a boost to technology. In the case of paralell flow regenerative technolgy used in lime production, it has enabled lime producers to improve efficiency, reduce power demand and yeld significant cost benefits.
The power of the industrial internet has trasformed the use of equipment and given a boost to technology. In the case of paralell flow regenerative technolgy used in lime production, it has enabled lime producers to improve efficiency, reduce power demand and yeld significant cost benefits.
PJBUMI Heavy Engineering & Services Sdn. Bhd. is an engineering company with divisions in property development, digital solutions, energy, and telecommunications. The intern's objectives were to adapt to the working environment, apply classroom knowledge, and learn new skills. During the internship, the intern assisted with tender proposals, project work, and administrative tasks like setting up meetings and editing company documents. The intern concluded that the experience provided valuable practical training and insights into engineering applications in industry.
IRJET-To Implement Cloud Computing by using Agile Methodology in Indian E-Gov...IRJET Journal
P.V.S.S.Gangadhar, A.K.Shrivastava, Ragini Shukla "To Implement Cloud Computing by using Agile Methodology in Indian E-Governance ",International Research Journal of Engineering and Technology (IRJET), Volume2,issue-01 April 2015.e-ISSN:2395-0056, p-ISSN:2395-0072. www.irjet.net .published by Fast Track Publications
Abstract
Many developed countries in the world, uses Information and communication technology to deliver public services in a more efficient & easy way. The benefits of the Electronic Governance are huge and day by day increasing from one to many public services. But implementation of the governance is constrained due to 1) high costs of investment 2) shortage of domain experts 3) diverse and irreconcilable systems and 4) Security and privacy issues. With the Invent & rise of Cloud computing, i am looking various aspects of use of cloud computing in e-governance is emerged. Cloud computing can solve many of the above mentioned hurdles and provide better way to e-gov expansion, but it has some risks also. Agile development treats optimize the chance provided by cloud computing by doing software relinquishes iteratively and getting end user feedback more frequently and quickly.
Khubaib Khan is an instrumentation engineer with over 10 years of experience working in fertilizer and power plants. He has expertise in DCS/PLC systems including Yokogawa Centum CS 3000 and GE Fanuc Rx3i PLC. Khan is currently an instrumentation area engineer responsible for maintenance, troubleshooting, and projects involving gas turbines, HRSGs, nitric acid plants, and CDM projects. He has received awards for his maintenance excellence and safety initiatives.
1. Kusile Power Station Project
South Africa
InnovationinPowerGeneration
Leveraging the plant MicroStation 3D CADD models and information content in
visualisation and simulation technology .
Creating truly integrated project execution capability and to maximising the ROI3
for Eskom as the Owner-Operator.
Delivering an intelligent integrated information asset of highest value across the
entire plant lifecycle.
2. Organisation: Eskom Holdings (Pty) Ltd
Project Name: Kusile Power Station
Category: Innovation in Power Generation
Bentley Software Used: Bentley MicroStation, Bentley InRoads, Bentley
Structural, Bentley Navigator, Bentley STAAD
Other Software Used: 3D-Pact and Flownex Simulation Software
Project Phase: Under Construction
Completion Date: 2018/19
Project Location: Witbank, Mpumalanga, South Africa
Capital Cost of Kusile Project: $14,000,000,000.00
Cost of 3D Visualisation & Simulation Innovation Project: $1,454,000.00
3. Kusile: The Project
South Africa is currently facing electricity generation capacity constraints - in response, Eskom
Holdings is in the process of building three major power station plants - Medupi and Kusile (Coal
Fired) and Ingula (Pumped Storage).
To promote economic growth, meet increasing electricity demand and stimulate South Africa’s
economy, it is crucial to complete these projects in the fastest time possible. With the current
electricity capacity shortage, Kusile Power Station construction has been fast tracked, reducing its
construction schedule from 10 to 8 years.
In 2009, Group Technology (Engineering) partnered with the Kusile Project to prototype 3D
visualisation and simulation technologies to leverage the engineering and design base information
and MicroStation 3D CAD model content to create truly integrated engineering, project execution
optimisation and enhanced O&M capabilities.
Once complete, Kusile Power Station will exist of 6 x 800MW power generation units – making it one
of the largest coal-fired power stations in the world. The first unit is planned for commercial
operation in 2014, after which the other units will be commissioned at 9 month intervals with full
commercial operation by 2018.
Each super-critical boiler is 115 metres high, chimneys are 220 metres high and approximately
500,000 m³ of concrete and 42,000 tonnes of reinforcement steel will be used to execute the project.
Kusile Power Station will be the first Eskom plant to implement FGD (Flue Gas Desulpherisation)
technology. FGD is the current state-of-the art technology used to remove oxides of sulphur (SOx),
from the exhaust flue gases in power plants that burn coal or oil. This technology is fitted as an
atmospheric emission abatement technology, in line with current international practice, to ensure
compliance with air quality standards, especially since Kusile power station is located in a priority air
shed.
The Goal
Project Data
4. Project Challenges
TIMELINE TO CONSTRUCT
The initial normal 10-year construction timeline for this type and size of plant was reduced to 8 years
for Kusile due to electricity supply constraints.
DESIGN AND CONSTRUCTION INTEGRATION COMPLEXITY
With a multi-contractor EPC project design and execution strategy there are significant design and
construction integration challenges, with complex lay-out/arrangement design requirements.
NEW TECHNOLOGY
Kusile Power Station will be the first Eskom project to implement FGD technology. It is a very complex
plant process to control, requiring a very good understanding of the physical plant, process behaviour
and control to ensure optimal flue gas emissions control.
INTEROPERABILITY & 3D MODEL CAD FILE SIZES
The multi-contractor EPC approach has resulted in 3D model submissions in various formats. Merging
these very different and large file sizes for design, plant and construction integration checking into one
consolidated model became a major challenge.
TRAINING & SKILLS DEVELOPMENT
A new generation of engineers, operators and plant maintainers need to be trained on very complex
plant, new technology and processes (Medupi and Kusile will also have the first super-critical boilers
installed in the Eskom fleet).
SAFETY (ZERO HARM)
Plant and staff safety is non-negotiable for Eskom. Decreased construction timelines and the amount of
staff involved with construction activities demands increased focus on safety, the use of correct PPE
and safe working practices. Training of operating staff on the actual plant, while phased construction is
still happening, also posed a major safety risk.
OPERATIONAL READINESS
Reduced construction timelines requires earlier operational readiness - confirmation of operability and
maintainability is required in the design phase. Faster, more efficient commissioning of plant is critical -
the integrated nature of plant systems demands correct, sequential start-up of plant systems.
5. Benefits
By leveraging the MicroStation platform, 2D/3D CAD content delivered on the Kusile project; and
teaming this up with 3D visualisation and simulation capability, a significant return on innovation has
been delivered for Eskom - not only on these projects, but also future projects:
• Earlier and improved plant commissioning planning, preparation and execution capabilities.
• Faster, safer “virtual” pre-commissioning, operator & maintenance training and inspection route
development very early on in construction, reducing plant hand-over lead times.
• Reduced risk of operability & maintainability design issues in construction/commissioning phases.
O&M staff could evaluate the virtual 3D plant before construction begins. ($1:$10:$100 cost
saving principle)
• Operator regulatory competency and capability testing can be done safely in a virtual plant that
closely mimics the real plant asset.
• Pre-commissioning training possible on typical plant disturbances/upsets – preparing operators for
abnormal/emergency situations, improving plant commissioning efficiencies and resulting in
better operator response in emergencies reducing the impact of actual plant damage caused by
such occurrences.
• Enhanced plant commissioning and operating – changing plant conditions and operating
parameters can be simulated in a 3D virtual environment.
• Pro-active training on new plant technology to reduce the risk of “learning curve” failures during
commissioning and operations.
• Correct and validated construction, maintenance and operating sequences can be developed and
implemented. Technology already deployed at Medupi and Kusile Operating Departments.
• A major ROI has been the successful prototyping of this capability for use on brownfield plants as
well. Existing 3D laser scans were successfully migrated into MicroStation and 3D solid models
created. With MicroStation being the most efficient preparatory platform, the same 3D
visualisation technology capabilities could be enabled.
Return on Innovation
6. Benefits
Time Savings
Money Saved
• Kusile Power Station is currently on track to deliver the units on the accelerated construction time
line. This means a saving on project execution (and associated resource cost) of 24 months.
• Notable Commissioning and hand-over time savings are anticipated due to pro-active operating
staff training; and commissioning and start-up procedures being developed and validated early in
construction.
• The 3D visualisation and partial simulator is already deployed at both the Medupi and Kusile
Power Station Operating Departments, where staff has been trained in the use of the technology;
and they are using this platform to develop the required operating procedures, training sequences
and commissioning information packs.
With Kusile Power Station on track to be commissioned 2 years faster than originally planned, there
is significant benefit from Eskom in that income can be generated from this power station 2 years
faster than planned (estimated profit at $1,098.80M for 4800MW capacity at 82% load factor).
The table below indicates the typical anticipated benefit that can be obtained leveraging the 3D
visualisation and simulation capability in an engineering, operating and maintenance environment:
Typical Cost Impact Cost
Project Stand Time $4,750,000/day/unit
Lost production (Delayed Commissioning) $ 300,000/day/unit
Plant load loss risk (incorrect plant operations)
Load Loss, 800MW Unit/day
Unit Trip, 800 MW Unit, return in 4 hours
$ 300,000/day
$45,000/incident
Improved Plant & Worker Safety
Prevention of 1 disabling injury
Prevention of 1 fatality
$16,000/incident
$225,000/incident
Reduced Commissioning Time (Pre-commissioning Operator
Training)
$ 300,000/day
Alarm/abnormal condition training (Reduced load losses & trips) $4,750,000/day
Large Equipment Failure prevent (e.g. Generator failure) $10,500,000/incident
7. Value Add of Using Bentley Products
• All lay-out/arrangement design and changes on the coal fired projects are made using the Bentley
MicroStation platform and associated Bentley Civil Products. The capabilities offered by
MicroStation makes management of such a complex plant design much easier to control and
manage.
• The MicroStation 3D capability also enabled fast and efficient checking of “plant problem areas” for
design or construction interferences. MicroStation’s interoperability capability made it possible to
bring together multi-EPC 3D model submissions in various formats fast and effectively.
• The ability to extract additional design information and content from the .DGN files also supported
faster and more accurate creation of virtual 3D plants in 3D-Pact.
• MicroStation was found to be the most efficient and capable tool to integrate all the different and
size-able 3D model submissions from the various contractors; and was the primary platform used to
develop, integrate and prepare the 3D visualisation model used for simulation.
8. How this Project created a Competitive Edge
• The extent to which the 3D CADD models can be used for maximum ROI3 benefit for Eskom in all
stages of the plant asset and lifecycle.
• The extent to which design base information and 3D CAD model content have been leveraged for
use in construction, operations and maintenance activities.
• The value add that has been extracted from the 3D CADD model submissions.
• The 3D virtual and interactive platform that has been created on a very large and complex plant,
without negative performance to the 3D virtual environment performance and user experience.
• The creation of a platform that can readily receive and exchange information with other Eskom
business systems like the SAP ERP system.
The Project Differentiators
Meeting the Engineering Challenges
The Unique Competitive Edge
• 3D CADD models are no longer just a design deliverable, but a key business information asset and
project deliverable.
• A virtual, interactive 3D O&M training and plant information environment at the user
desktop/laptop.
• Leveraging 3D CADD Models and PC gaming technology to create a unique and highly valuable
information asset usable to all plant staff.
• The numerous applications for the 3D virtual environment capability within construction,
commissioning, training, operational readiness and skills development, which significantly
enhances Eskom’s business operations and safety programs.
• Being able to effectively deal with the complexity and size of the project – and to be able to create
a fully immersive 3D, virtual and interactive platform with visibility to all stakeholders and role
players.
• Leveraging the 3D Model content as a critical plant information asset over the entire plant
lifecycle, including O&M.
• Being able to merge and manipulate Multi-EPC 3D model submissions of large size and different
file types in Bentley MicroStation.
9. Competitive Edge – Examples
Operational Inspection Training,
including training on selecting
and wearing the right PPE for the
operating/maintenance task at
hand.
MicroStation 3D Model and
design base information
integrated with plant process
simulator to provide insight into
plant behaviour when process
parameters changes (used for
operational training).
Maintenance dismantling/
assembly sequence development
(used for maintenance training
and as an aid to maintenance
work orders in SAP ERP PM
module).
10. Competitive Edge – Examples
Plant and component
dynamics enabled to
simulate actual plant
behaviour (in this case a
steam leak incident on
high pressure pipework).
Construction planning and
sequence simulation – in this
case a comparison between an
old and new project plan
submitted to indicate changes
(new activities added, activities
removed, late & early
construction and supply).
Plant process visual
simulation used for
operator training on end-
to-end power generation
processes.
11. Environmental & Community Impact
FGD is current state-of-the art, best practice technology used to remove oxides of sulphur (SOx)
from the exhaust flue gases in power plants that burn coal or oil. The Kusile FGD Plant will have a
minimum of 90% removal efficiency, significantly reducing the emissions impact.
Bag-filter technology will be used for the control of particulate matter, while “Low NOx” burners
will be used for the control of NOx emissions.
The 3D visualisation and simulation enabled on top of the MicroStation 3D CAD models of Kusile
has enabled Eskom to gain a thorough understanding of the plant design, process, operational and
maintenance requirements of FGD technology.
Efficient use of the FGD technology and having staff that can optimally operate the plant, will
enable Eskom and South Africa to meet their commitments towards emissions reductions as part
of the United Nations Global Compact.
The Environment
The Community
All 49 million South Africans are dependent on a stable, reliable and sufficient supply of electricity
– delivering our new generation capacity in the fastest and most reliable manner is in the best
interest of the country as a whole.
The 3D visualisation and simulation capability was exclusively developed in partnership with a local
South African company, supporting Eskom’s corporate strategy to focus on local supplier and
engineering capability development.
FGD produces gypsum as a by-product. Gypsum is used in the manufacture of dry walls and
ceilings, which opens up numerous economic opportunities for the community.
Eskom is actively engaged with engineering skills development – the technology capabilities
developed not only enables the world of engineering design and construction, but also show how
3D CAD models, visualisation and simulation technology is used to create smarter, optimised and
highly efficient power generation infrastructure.
12. Collaboration Technology Used
The Black & Veatch POWRTRAK integrated system environment is used for Project Collaboration
with all contractors and staff on the Project expected to submit design documentation, drawings
and 3D Models into the system.
The 3D-Pact platform is the primary O&M collaboration technology, leveraging 3D models and
design base content from other systems and sources to bring it together in one seamless,
integrated environment for O&M staff.
"3D PACT and 3D plant information platform provides unimaginable value to familiarise trainees with the plant layout,
equipment internals and equipment locations. 3D PACT provides an easy, safe virtual environment for trainees to explore
the full plant in real time and learn not only the plant/system layouts and view equipment internals, but it also provides an
efficient platform to prepare trainees for unit commissioning tasks and operations. Even after construction of the plants
are completed, I believe 3D PACT will provide a time-efficient platform for new learners... It will further allow for planning,
training and testing of employees on dangerous operating tasks before they execute such tasks on the plant, thereby
reducing the risk of injury to people and damage to equipment.”
Gert Geyser, Medupi Operating Training Group
13. Acknowledgements
Flownex Flue Gas Desulpherisation
Design Module Development, Flownex-
3D Pact Integration Development and
Eskom Engineer Training on technology
Flownex 3D-Pact Library, Medupi and
Kusile 3D operator and maintenance
simulator development & deployment
Plant Process design best practice
optimisation, configuration, intelligent
P&ID’s, 3D simulation software and
CADD system enhancements.
Specialist consulting and advisory
services.
Kusile Data Provision & Migration
assistance, CADD 3D Model provision,
best practice advisory on engineering
practices, data transfer quality
management & mapping
Kusile Data Migration mapping, system
configuration testing, Plant
Codification Reviews & Document to
KKS Mapping
Group Technology -
Engineering
Jackie Herndler
Waleed Moses
Pumza Damba
Siphamandla Mnyani
Johannes van Tonder
Raymond Nchabeleng
Albert Mogapi
Group Capital
Johann Harmse
Evelyn Monesa (Kusile)
Generation
Phindile Mooketse
Deborah Maune
Gert Geyser
Kevin Brink
Medupi Operating & Training
Departments
Project Partners Eskom Team Members