BE Magazine - Volume 6, Issue 1 - (Page 27)

Best Practices – Factories solutions,” said PAC President Stephen Dudzik. “Using the software modeling tools and data-based capabilities permitted an agile and collaborative approach to the development of modular, repeatable design.” PAC specializes in providing engineering, design, and consulting services for capital projects in the process industry. A 3D design approach is at the core of the company’s strategy to work smarter and faster. In fact, Dudzik believes that using Bentley tools helps the company operate ﬁve times more efﬁciently than a traditional engineering ﬁrm. “One of our designers delivers the same amount of work as ﬁve designers in another company,” he said. “We have fewer people working on a project, producing better designs. That is a huge beneﬁt to the client.” instantaneously and automatically across all locations. This saved hours typically spent in data veriﬁcation. Construction cost constraints required substitution of acceptable but less costly materials. Additional cost savings were realized by allowing the structural steel fabricator to provide value engineering based on the steel layout. Reviewing the structural Virtual design reviews Four PAC engineers/designers worked with two Westfalia engineers to complete the design prototype for the 90 million-gallonper-year facility within the tight time frame dictated by the owner’s startup schedule. As the basis for the design, Westfalia provided plans for an existing facility with a production capacity of 30 million gallons per year. PAC team members not only had to convert process and instrumentation diagrams from German to ISA standards, but also had to scale up production to three times the capacity. Complete technical data for equipment such as vessel residence times, chemical dosing rates, and process ﬂuid properties were not immediately available, reducing the effective design time from 16 to 13 weeks. This put pressure on the team to submit initial P&IDs, process ﬂow diagrams, plant and equipment layouts, and other deliverables based on general design concepts. To meet these challenges, PAC initiated a nontraditional approach where all stakeholders were involved in reviewing designs in AutoPLANT. “We met daily using GotoMeeting.com with people in Germany, New Jersey, Michigan, Missouri, and Indiana all looking at the model and discussing improvements. Even vendors contributed,” Dudzik explained. “That daily work with the model, doing a lot of it online, allowed the stakeholders to get involved early in the project and get exactly what they wanted.” BE AWARD NOMINEE Nation’s Largest Biodiesel Plant Organization: Process Automation Concepts Ltd. Category: Innovation in Industrial Facilities The virtual design review process eliminated costly and timeconsuming travel to on-site meetings. Design modiﬁcations were made on the ﬂy as equipment data became available and speciﬁcations were ﬁnalized. Using Bentley software, the team was conﬁdent that changes made in one location were updated model in Bentley software, the designers instantly spotted and corrected interferences. This shortened construction time and eliminated errors. PAC estimates that the reduction in change orders reduced project costs by up to 20 percent. The Claypool plant was completed in about a year and a half, two months ahead of schedule. Within 48 hours of startup, it was running in a steady state—one of the advantages of Westfalia’s unique process. Louis Dreyfus Commodities is now building a second biodiesel plant in Lagos, Argentina, at a considerably lower cost using the Claypool prototype. PAC reused as much as 80 percent of the original engineering design work on this and subsequent projects. “With Bentley software and intelligent models, we were able to reissue the design for the new location with changes to compensate for the counterclockwise circulation in the vessels,” Dudzik said. “Our Bentley templates are so ﬁne-tuned now that we can roll into a new biodiesel project or other bioreﬁneries facilities much more quickly, completing the design and construction 20 percent faster and with total install cost savings of 20 percent.” For the residents of Claypool and vicinity, the plant has brought 70 steady jobs and a ready buyer for the region’s soybean crops. Although it is just one of 20 ethanol and biodiesel plants in the state, helping to make Indiana one of the top ﬁve biofuel producers in the country, it is possibly the most efﬁcient soybean processing plant in the world. Volume 6 Issue 1 | Be Magazine 27 http://www.bentley.com/en-US/Promo/AutoPLANT/AutoPLANT main page.htm http://www.GotoMeeting.com

Table of Contents Feed for the Digital Edition of BE Magazine - Volume 6, Issue 1

BE Magazine - Volume 6, Issue 1 Contents Anticipation’s Name Is V8i Be Awards of Excellence Kicks Off Competition Bentley Launches the Most Comprehensive SoftwarePortfolio for Infrastructure Ever Assembled in a Single Release MicroStation V8i Up Close & Personal Is Water the New Oil? How Does Intent Become Reality? Does Performance Create Sustainability? Renewing Confidence in Public Highway Infrastructure Enterprisewide System Manages International Airport Standardized CAD/GIS Platform Streamlines Infrastructure Engineering 3D Modeling Refines Reusable Design for Plant Prototype Lean Teams Deliver Automotive Assembly Plants Through Innovative Use of BIM Integrated 3DModels Enable Compact and Safe Plant Design Sustainable Development Supports Thriving Community Terminal Pumps Natural Gas Through Longest Subsea Pipeline Large UtilityWorks To Reduce SO2 Emissions Aging Power Station Boosts Engineering Productivity Hydropower Dam To Fuel Growing Economy Collaboration Tools Accelerate Chinese Railway Electrification System Design Rapid Rail Link To Meet Socio-Economic Development Goals High-CapacityWastewater Treatment Facility ReclaimsWater Resources City ExpandsWater SupplyWithout Deploying AdditionalWater Resources Private Calling Meets Public Service Learning Paths Map Skill Development for Infrastructure Professionals A Contemporary Approach to Site Design The Art of Visualization Special Feature: Be Communities Physical + Digital Investments = Intelligent Infrastructure

BE Magazine - Volume 6, Issue 1

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