Process facilities are some of the most complex built environments in existence and therefore gain significant benefits from Digital Facility representations. Process facilities change and evolve with continuous maintenance projects, scheduled unit turnarounds, capital projects to create new process units, debottlenecking activities, and a host of compliance and integrity monitoring functions. Each of these activities either modifies the existing facility or requires accurate knowledge of the current facility. The largest portion of wasted capital as it pertains to these types of activities can be directly traced to the dimensional uncertainty caused by incomplete or inaccurate facility documentation.
Quantapoint has proven that adoption of a Digital Facility and associated work processes can substantially improve capital efficiency across all portions of the facility lifecycle and we offer services including data collection and delivery, consulting, and software to help owner/operators achieve these efficiencies in each of the following areas:
Front End Planning and Design
Using a Digital Facility early in the project planning stage enables more efficient process optimization, plot plan development, and improved efficiency for engineering tasks. Having a digital model of an existing unit can provide guidance for reusing the unit in new facility designs or can provide background information to guide revamp or debottlenecking efforts in most CAD environments.
Capital Revamp Projects
Capital projects tend to introduce a large amount of new equipment and piping into the existing plant, so accurately locating connection points and performing clash detection of new items against the current facility provide the largest efficiency drivers. Engineering designs can be executed with sufficient certainty to eliminate field fit up welds from the normal design process.
Fabrication and Construction
The Digital Facility and associated work processes can provide fabrication and construction activities with tools and information to reduce rework, improve communications, and cut schedules.
Fabrication verification services using the Digital Facility routinely improve construction schedules and reduce wasted capital by finding errors in spool and vessel fabrication long before construction begins.
Construction planning benefits through precise location of cut lines, visualization of spool sequencing and lift planning, scaffold planning, and assembly simulations.
Turnarounds typically involve a number of small maintenance projects executing alongside larger capital projects in an atmosphere of managed chaos involving large crews of craft workers all trying to meet aggressive startup schedules. The success of these efforts frequently hinge on the quality of the information used to generate turnaround planning documents, replacement in kind construction drawings, and new capital project engineering. Adoption of a Digital Facility work process has been proven to enable achievement of less than 1% rework while meeting or exceeding schedule expectations. In addition, the Digital Facility enables discovery items to be handled as they occur without need for additional documentation or schedule slip.
Maintenance and Operations
Maintenance comprises a continuous and necessary expenditure of capital without corresponding increases in plant revenue. The Digital Facility and associated work processes have been proven in process facilities to enable a maintenance efficiency increase of at least 35% as compared to traditional methods.
Inspection and Compliance
Process facilities maintain large compliance and plant integrity departments who are improving the efficiency of their daily tasks through the use of the Digital Facility. Quantapoint has developed work flows and software that enable a host of previously disconnected asset inspection activities (from piping equipment strategies to car seal tag programs) to be integrated and managed through the Digital Facility; bypassing the traditional methods of inspection isometrics and separate spreadsheets. These methods can link legacy facility engineering data and enterprise asset management software to dramatically impact the efficiency of integrity and compliance activities.