Rob de Leeuw

1
Experiences with Database Driven 2D and 3D
Schematics

• Rob de Leeuw
• Sr. Manufacturing IT Analyst
• Lyondell Chemical Company

2
Agenda

• Introduction to Lyondell
• 3D 2D experience
• Background
• Why maintain 3D model after construction
• Impressions
• Benefits
• Challenges Difficulties
• Future within Lyondell
• Questions

3
Introduction to Lyondell - Fast facts

• One of the worlds 10 largest chemical companies
• Operations on five continents
• Approximately 10,000 employees
• 18.6 billion in consolidated 2005 revenues
• Including 100 of LCR, combined revenues would
  have been 24 billion
• Leading capacity positions in all major products
• A Fortune 500 company
• NYSE LYO

4
Introduction to Lyondell Reportable Segments

• Lyondell intermediate chemicals and derivatives

Propylene oxide and related products
Ethylene, co-products and derivatives
Equistar
(Acetyls)
Inorganic chemicals
Millennium
(TiO2)
(Flavors Fragrances)
Other
LCR
Refining
Not a reportable segment
5
3D 2D experience - Background

• Recent Capital Projects
• Botlek BDO-2 plant
• Plant startup in 2001
• 3D engineered using Aveva PDMS
• Lyondell experience minimal
• No specs / requirements defined by Lyondell
• Engineering contractor specs/requirements
• 2D done without database oriented system
  (AutoCAD)

6
3D 2D experience - Background

• Recent Capital Projects (2)
• Maasvlakte PO-11 plant (50 owned by Bayer)
• Plant startup in 2003
• 3D engineered using Aveva PDMS
• Learned from BDO-2 results to define specs
• 2D engineered with multiple systems
• End result delivered in Intergraph Smartplant
  PID
• Converted to CEA Plant4D PID

7
3D 2D experience - Background

• What is contained in the 3D models / databases?
• Piping
• /- 18.000 Isometrics for the PO-11 plant
• /- 17.000 Isometrics for the BDO-2 plant
• Equipment Static and Rotating
• Instrumentation and control valves
• Cable trays
• Structural Steel
• Buildings
• What is contained in 2D schematics / database
• /- 450 PIDs for the PO-11 plant
• Equipment, Line, Instrumentation and Valve data

8
3D 2D experience Why maintain after
construction?

• 3D models database
• Cost for maintaining As Built 3D model slightly
  higher
• Expected pay back
• Major projects / revamps
• Turn around preparations
• 2D schematics database
• Data validation with SAP and Intergraph INTools
• Using AutoCAD as database front-end
• Unlimited undo and improved reliability

9
3D 2D Experience Impressions 1
10
3D 2D Experience Impressions 2
11
3D 2D Experience Impressions 3
12
3D 2D Experience Impressions 4
13
3D 2D Experience - Benefits

• 3D Models
• Turn around / revamp preparations
• Locating Relief Valves by querying database
• Assigning wall thickness measurement points on
  18.000 isometrics was a matter of hours not
  months
• Data consistency Line List 3D model
• Snapshots for Construction Work Packages
• Backgrounds for 2D CAD drawings (plot plan and
  XRefs)

14
3D 2D Experience - Benefits

• 2D schematics in Plant4D
• Improved data consistency (line list, equipment
  list etc)
• Navigating through components on a PID
• Reporting
• Unlimited undo for AutoCAD interface

15
3D experience Challenges Difficulties

• No version control
• As Built / To Built complicated to manage
• Managing Publication in DMS done in batches
  instead of triggered
• It takes a different level of draftsmen and
  engineers
• 3D tool mainly used in internal
  project/engineering office, not (yet) for
  maintenance and reliability departments
• Niche applications, small market acceptance
  compared to AutoCAD (for example)
• Finding qualified contractors to operate the
  systems

16
3D 2D Future within Lyondell

• As Built / To Built / project support for Plant4D
  PID system
• Further integration with SAP and Documentum DMS
• Engineering Data Warehouse
• Extending the usage outside the internal
  project/engineering office
• Web based access tools
• Will it be recognized as Strategic Direction?
• New plants?
• Existing plants?

17
What about you?

• Are you willing to bet that your Process Safety
  Critical Information is accurate today?

18
Questions