InfraServ Gendorf Technik (ISGT) is a subsidiary of chemical park operator InfraServ Gendorf. The company is fully committed to plant services and maintenance. This project had two aims: to improve further prefabrication of piping isometrics and to streamline the generic plant construction projects from prefabrication to assembly. The key goal for the company was to reduce the administrative burden by automating and digitizing piping prefabrication work processes.
When prefabricating piping isometrics, even minor deviations can quickly lead to delays throughout the project. ISGT had already noticed that the traditional, manual approach to pipeline construction was slow and prone to errors. With the manual approach, all the existing data from the customer had to be manually entered into the system to be able to control the bending machines and production. This often resulted in a number of incorrect entries, and the throughput times were often prolonged. It made overall project execution and management difficult and time-consuming.
With this in mind, ISGT decided to look for a way to enable the company to save time, improve efficiency, and lower costs. A solution was to be developed that would enable a digital and intelligent data flow between management of pipe components in the certified pipe classes and the 3D design model, without having to re-enter the data manually into the system.
Intergraph® SmartPlant® solutions were chosen for the task mainly due to their integration and automation capabilities, which would in turn reduce data errors. As a longtime Intergraph customer, ISGT was familiar with the integrated, digital data management solutions provided by the company, and believed that both time and cost savings could be reached by further use of Intergraph solutions.
The implemented solution included several Intergraph products: PICODA, Intergraph Smart Reference Data, Smart Isometrics, Smart Spoolgen®, and INCOP-R. This piping fabrication solution helped ISGT to close the gap between the planning and plant maintenance with digitized data. With a digital approach, ISGT could get rid of the error-prone manual work processes: the data from the planning software is now transferred via an interface to the control system software of the bending machines.
In addition, the piping fabrication solution automatically checks the data for the production of pipes for plausibility and completeness. The data management solution provided by Intergraph is used throughout the project life cycle from detailed engineering and work scheduling to isometric, bills of material, working papers and pipe classes creation. The software also enables digital data exchange from planning to production to assembly, enhancing the overall project quality.
The new piping fabrications solution has provided InfraServ Gendorf Technik with:
- 20-30% time savings in work preparation and scheduling.
- 10-20% time savings for documentation.
- Up to 30-40% time savings in project evaluation, depending on project scope, complexity and customer.
Werner Bayerl, head of order management at ISGT, commented on the company's decision to digitize piping fabrication: “We often face problems with the documentation during our plant reconstruction projects. Although our customer might have the original data about the existing pipelines available, certain updates and changes are always done during the maintenance and operations that are not always shown in the original documentation.
"This often leads into surprises arising later on when reusing data. With the software from Intergraph, we can now provide constantly updated data in both directions: from original planning to the bending machines, as well as from the actual manufactured isometric of the pipes back to our client. This way, the actual 3D model of the plant is always up-to-date and the effort to control and update documentation is considerably reduced.”
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