The need for perfect execution in the engineering, procurement and construction (EPC) business is magnified even more when an entire plant is shut down to allow for modifications.
SETAL Construções of Brazil faced this challenge after winning a US$150 million turnkey project from Companhia Siderurgica Nacional to perform the detailed engineering, procurement and construction to replace a 25-year-old blast furnace at its iron production facility in Volta Redonda, Brazil. SETAL's consortium partner, Voest Alpine Industrieanlagenbau (VAI), handled the basic design.
Once the furnace was blown out, SETAL had only 93 days to remove the aged furnace and replace it with a new one so that the Volta Redonda site would begin producing iron again. There was no room for error.
SETAL needed an edge, and turned to a familiar technology provider: Intergraph Process, Power & Marine for more than a decade. The solution is SETAL's main detailed engineering tool. But 70 percent of SETAL's work is with the petrochemical and chemical industries, and it had never used PDS® during a siderurgy project. In fact, SETAL had never heard of any EPC company in the world using PDS for this type of project.
All of SETAL's existing and temporary structures were modeled. All tubing, flexible hoses, lighting fixtures, electrical trays and conduits were included. By the time the 3D model was completed nine months later, it contained more than 3,000 lines.
PDS provided its natural benefits of clash detection and easy drawing production. SETAL promotes its PDS expertise as one of its competitive advantages. By allowing the EPC company to save time and costs, reduce errors, improve designs, increase productivity and minimize material surplus, PDS helps SETAL execute projects faster and better.
Intergraph visualization tool DesignReview® was extensively used to simulate construction operations. Numerous simulations using the 3D model were performed, allowing SETAL to forecast how time-consuming construction operations would be and to avoid extra work during actual construction. SETAL also used the visualization tool for construction control and planning, and for layout analysis, design review, visual clash checking and simulations.
Since completion of the blast furnace, SETAL has moved to the next-generation visualization tool from Intergraph: SmartPlant® Review. SETAL is excited about the new SmartPlant Review collision detection features and the software's ability to make simulations even more effective.