Materials Handling Projects in the 3D world

Barry Woodin Product Owner SP3D Materials Handling Edition (MHE)

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SP3D Materials Handling Edition History

Technology Partnering Memoranda Jan 2008

Sinclair Knight Merz, United Group Limited Resources and Intergraph

POC Completed Requirements Defined MHE development

July 2008 August 2008 Sept 2008

Perth WA Perth WA Perth WA

SCRUM Team Established

First SCRUM Sprint MHE BETA Version on SP3D MHE

March 2009
August 2009 Nov 2009

India/Australia
India/Australia India/Australia

SP3D MHE 2009.1 HF 6 Official launch Perth Western Australia 30th September 2010
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2010 Intergraph Corporation. All Rights Reserved!

Materials Handling Industry Business Challenges/Opportunities

Demand for mining of resource material driven by China and India infrastructure expansion
Mining production output, limited by timeframe to bring new projects online. Currently materials handling project deliverer is driven by outdated document centric technology. Availability of highly experienced engineering and design professionals will become more of a resource issue over the next 5 to 10 years as the Baby Boomers retire.
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2010 Intergraph Corporation. All Rights Reserved!

Global Metals Demand Forecast

Order of Magnitude Impact: Iron Ore One Pilbara production every five years [approx. 200 MT / Annum]
Aluminum One Saguenay production every nine months [approx 1.4 M tons of alumina / annum] Copper One Escondida production every year [approx 1.0 M MT of copper] What is driving the forecast?

India is right behind in demand

Source: Rio Tinto Macquarie Global Metals & Mining Conference Nov 2009
Source: Reuters Ecowin, Consensus Economics

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Steel Demand in Developing Nations

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Materials Handling Solution

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3D Model Benefits in Mining & Metals Projects

Commissioning Construction
Minimize construction errors and rework Real time response to field demands
Faster and safer commissioning and ramp-up due to integrated engineering design supported by 3D model

Integration
Decision-making on multidisciplinary issues 3D model real time access and usage by site contractors EDMS on-line access by suppliers and field contractors Engineering systems fully integrated to Alunortes ERP (purchasing, materials control)

Safety
3D modelling increased job site safety due to anticipated review and validation of construction methods and safety issues

Quality
Correctness of engineering design Accuracy of materials take-offs

Technology
Detailed design documentation automatically generated from 3D database Consistency and reliability of 3D database Digitalized document transmittal and processing (paperless engineering design)

Operation & Maintenance Schedule

Shortened project implementation Optimized engineering effort and resources Operations training Total project life cycle support Integrated operation, maintenance and EHS design review

Functionality Breakdown
SmartPlant Materials Handling Edition for conveyor and chute design functionality

SmartMarine 3D plate work functionality for designing the conveyor chute

SmartPlant MHE SmartMarine SmartPlant 3D SmartPlant 3D for plant layout structural, piping, mechanical, Hvac and electrical design

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Conveyor Layout
Conveyor belt line layout is managed easier in the 2D environment, similar to how Plant projects use P&ID

The industry Profile and Data sheet, is one of the major deliverable for conveyor layout projects .
The Profile and Data Sheets contains geometrical data that is used . to drive the 3D model design
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2010 Intergraph Corporation. All Rights Reserved!

Chute Design

Chute Design
Typical Conveyor Head Chute with Transfer Chute. Chute Wizard would be used for starting point for parametric driven Designs. Chutes can be detailed to manufacturing standards.

Chute outputs, are manufacturing drawings and output to CNC machines.

Chute Linear plate can be exported to detailing package via CIS/2 interface

2010 Intergraph Corporation. All Rights Reserved!

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MHE Workflow Truss Placement Example

Layout is made easy in the Smart 2D environment

The 2D TRUSS Placement layout is populated to the 3D Model

2010 Intergraph Corporation. All Rights Reserved!

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SmartSketch
SmartSketch is a premium tool for 2D drawing generation.
SmartSketch's underlying technology and user interface make it easy to use and integrate with data-centric products SmartSketch provides powerful features such as parametric and relationships that enable execution of design changes quickly and efficiently. These changes are then populated to the S3D Model.

2010 Intergraph Corporation. All Rights Reserved!

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Conveyor Design in Mining

Bulk Materials Handling In Plant Design Vertical Radius Conveyors Incline Decline

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Concept / Workflow
Concept
2D Drives 3D Placement User can re-visit 2D design Workflow (Standard 3D Project) Plan high level Plant system breakdown Plan and create initial coordinate systems (CS) Plan initial work assignments Establishment of Site Plan

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Workflow (MHE Specific)

Import major equipment
Define major conveyor systems Create Coordinate System for Conveyor Create Belt Copy the Coordinate information to SmartSketch Create trusses via truss wizard Use SmartSketch to place conveyor equipment

Complete Project as per standard SmartPlant 3D

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Workflow (MHE Specific)

Truss/Gantry 2D Layout
Populated to 3D

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Workflow (MHE Specific)

Use SmartSketch to place conveyor associated equipment
Complete Project as per standard SmartPlant 3D

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Examples of SP3D MHE Automation Wizards

Truss/Gantry Wizard

Chute Wizard

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SP3D MHE Deliverables

SP3D Standard Deliverables
PLUS MHE Specific Deliverables Chute Plate Standard MHE Industry Drawing Templates

Linear Chute Plate export via CIS/2 to detailing applications.

Chute Plate work output to CNC fabrication machines Profile and Data Template to enable BOM embedded reports

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Benefits and Enablers Summary

Benefits
Access to Smart 3D Technology Gives the ability to Front End Load (FEL) data to enable estimation of Preliminary Equipment Design , Layout , Schedule and Estimate

Drive Standardisation and Modulation

Reduce manufacturing costs Leverage off each project for future projects ( Build organisation catalog database) Reduce onsite construction cost Reduced costs of drawing generation

Drawing Generation

Enabled through

Smart 3D technology
Rules and relationship based architecture Automation and re-use approach

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SmartPlant 3D Materials Handling Summary Global demand for MHE projects

Current technology is not keeping up with demand Simple 2D to 3D workflow Conveyor layout Chute Plate Design Deliverables MHE based on proven S3D technology

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