POWER May 2013 - 90

INSTRUMENTATION & CONTROL
procurement, and construction. The use of
3-D modeling techniques has been accepted
in plant design and construction because of
the need to increase the reliability and security
of the designs that will evolve into new
industrial installations. Process, electrical
power, oil, and gas plants are some examples
of facilities that have applied 3-D modeling
with excellent results in Mexico. For that
reason, a plant design and 3-D modeling
software system was used to design the plant
simulator, which allowed the project engineering
team to facilitate information flow
among engineers of all disciplines involved
in the design and construction.
The design and modeling software was deployed
in a client-server configuration, where
several users were able to retrieve, create, or
update the plant design concurrently. Access
to each plant area was carefully controlled by
granting appropriate privileges to each engineer
and designer.
All systems and components in the simulated
plant were represented and their attributes
stored in an external database linked to the items
within the 3-D model; all the documentation
and derived information is generated, retrieved,
and graphically managed via the 3-D model of
the simulated plant (Figure 1).
The 3-D plant design software was customized
to organize the information and
highlight the plant's key elements. The software
selected included the capability to automatically
generate from the 3-D model the
detailed engineering drawings and diagrams
required to proceed to the construction stage,
thus minimizing drafting time.
The 3-D model itself was utilized as a central
source of engineering information across all
disciplines involved in the design phase of the
project, thus delivering a unified and integrated
engineering solution to support engineers and
constructors throughout the project. This approach
delivered significant, compelling benefits
since it reduced time, costs, and personnel
effort by providing an easily accessible repository
of valuable plant design information and
up-to-date engineering documentation.
Additionally, the virtual model of the plant
currently provides support to training programs
and plant maintenance operations. The simulator
virtual model has been employed to identify and
evaluate problems that might have represented
risks to personnel or equipment in the real site,
such as plant layouts that would prevent fast reaction/runaway
in case of an emergency evacuation.
The model can be exploited, among other
uses, to simulate and visualize critical operations
on a real-scale, virtual site.
Model Integration
As mentioned above, 3-D modeling solutions,
such as that used to create the simulator, facilitate
efficient engineering design, data storage,
and revision of information. This applies
whether the data are produced via handover
from engineering projects executed by thirdparty
contractors, during construction or plant
walkdown exercises, through concurrent engineering
of small on-plant projects, or by legacy
data integration from previous engineering
records. However, integration and model validation
is a very important phase that cannot
be overlooked in a project of any magnitude,
2. Reproduce reality. The simulator contains a reproduction of several elements of the
plant control components and associated instrumentation. Courtesy: IIE
as it leads to enhanced engineering data and
design integrity. In effect, model integration
allows better coordination and decision-taking
among all players and disciplines involved in
the design and construction of any industrial
plant, from engineering to commissioning,
and from design to test and operations.
Plant design information is dynamic, because
it often changes, especially during the
detailed engineering revision stages when several
final design decisions are taken. Besides, it
is well known that plant design data is highly
interdependent-the actions or decisions made
in one plant discipline can affect many others,
and this can be a serious problem when it is not
properly managed. Therefore, adequate coordination
and teamwork throughout the complex
maze of partners, suppliers, and internal departments
involved in the project is required.
Leading companies have recognized this and
have tried to manage it through the use of moreinclusive
practices like formal review/approval
workflows, but this practice has proven to have
limitations, as it only deals with clear, highly
visible interdependency problems.
Adequate management of the frequently
changing engineering design basis throughout
the different stages of a project is a key reason
why model integration and design validation is
an imperative step preceding construction; to facilitate
this task, plant design management software
systems deliver advantages for designers,
plant owners, and operators.
Therefore, in order to act in accordance
with best practices, and to avoid design
change management problems, once all core
elements of the plant's virtual model were settled,
the next step was to integrate all of them
in a version for reviewing and validation. This
integration and validation was carried out with
the same software application used to model
the elements for the plant simulator, but auxiliary
third-party validation tools can also be
employed to assist the review, validation, and
construction of the facilities.
Construction
The Plant Process Simulator includes a
physical reproduction of a section of the
real nuclear power plant, which includes a
pair of vessels, electric pumps, pipelines,
control loops including valves, and associated
instrumentation such as manometers,
thermocouples, level gauges, flow indicators,
transmitters, and limit switches (Figure 2).
This section of the simulator includes
a motor control center with a cabinet designed
to store the AC and DC distribution
circuitry, the electric interrupters, breakers
and all the mechanical and electrical protections
found in a real plant. Both an air dryer
and a compressor were included in order to
supply instrumentation air to all pneumatic
90
www.powermag.com
POWER | May 2013
http://www.powermag.com

POWER May 2013

Table of Contents for the Digital Edition of POWER May 2013

Contents
POWER May 2013 - Cover1
POWER May 2013 - Cover2
POWER May 2013 - Contents
POWER May 2013 - 2
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