Wednesday, 17. August 2005

Improved Engineering Efficiency Through the Use of a Simple 3D Concept Model in Layout Planning

Bayer Technology Services (BTS) uses the “PLS Router” plant layout system to quickly generate 3D layout models and 2D arrangement plans. A three-dimensional layout plan can be generated quickly and easily using this tool. The system eliminates the manual drawing of 3D apparatus models previously required for arrangement planning and enhances the quality of the plant layout at low cost.

The PLS Router is best used after an initial, general layout has been drafted manually. Apparatus lists maintained in the Process and Engineering Warehouse (PEDW) database showing the primary dimensions of the apparatus and also the throughput and differential pressure for pumps can be read into PLS Router for maximum efficiency. The program uses these data to automatically generate the three-dimensional models of all apparatus and machinery, which an engineer can then place on the individual platforms.

PLS Router proved itself during a project for LANXESS. For this project, the basic engineering for the construction of a greenfield plant was performed by a fully integrated team of LANXESS and BTS employees under BTS project management.

Experts from the BTS Competence Center Plant Layout within Engineering placed the equipment in close cooperation with the project engineers. A high-quality, 3D model with more than 150 individual apparatus and machines was generated in less than two weeks. This enabled the planners to verify the assumed field size and grid dimensions.

The ability to visualize the planned arrangement of the apparatus and the routing of primary piping and cableways is an excellent foundation for the early review of process engineering requirements and for discussion with the customer. At this early stage, change requests can be easily integrated into the model. Changes in the apparatus list, such as apparatus size changes, are automatically transferred to the layout model thanks to the interface to the PEDW. This eliminates the manual comparison of the arrangement plans with the apparatus specifications.
The program also includes an option to automatically generate primary pipelines; the planned 3D model is therefore ideally suited as a basis for piping cost estimates.

The feedback from both the customer, LANXESS, and the project team on the use of the tool has been extremely positive: “The use of PLS Router in basic engineering means a genuine increase in efficiency,” said project manager Jens Hachtel. The short processing times and the lower costs compared to modeling in PDS are powerful arguments for the use of PLS Router.

In the last six months, BTS has successfully used PLS Router in eight projects, and will systematically use the tool in suitable projects in the future to take advantage of the cost and quality advantages it offers. PLS Router is currently being used for the layout planning of the MDI train in China.

The contact for the use of PLS Router at BTS is Dr. Peter Leuders, Head of the Competence Center Plant Layout.