PGESCo Digitizes Plant Information with Hexagon Solutions

The Challenge

PGESCo was contracted to build the South Helwan Power Plant in Egypt, a supercritical thermal power plant with three units containing; steam generators, steam turbine generators and steam condensers. Once ready, the plant would be generating 650MW of electricity from each unit.

For this project, PGESCo’s main goal was to meet the strict deadline of having the plant operational on schedule, while enhancing the quality of engineering deliverables and ensuring client satisfaction. PGESCo was contracted for the Front-End Engineering Design (FEED) phase of the plant, which had to be executed in accordance with the latest international codes and standards.

For this project, PGESCo worked as a Client Consultant for the owner of the plant. The scope of work was divided into six phases:

FEED (Front End Engineering Design) – preparing the conceptual design and issue tender documents for international bidding
Tendering & evaluation – preparing the tender document, collecting and evaluating offers and nominating the chosen bidder
Contracting – Contract negotiations with the bidder, reviewing the proposal, preparing and signing the contract
Design - Detailed and final engineering design for architectural, civil, geotechnical, mechanical, electrical, control system and communication systems services.
Construction management – reviewing the detailed design and fabrication of the components & the equipment, as well as managing the construction/installation activities performed by contractors. 
Commissioning & testing – monitoring the commissioning and testing activities to ensure smooth handover from the contractor to client, and starting of operations to transmit generated power to the national electricity grid.

The Solution

For the project, the company was searching for software solutions to help improve engineering productivity, as well as accelerate project schedules, enhance quality and accuracy of engineering design.

PGESCo chose Hexagon PPM solutions to meet the strict project deadline and enhance the quality of engineering deliverables. The key reasons for choosing Hexagon PPM, software included:

Unique rule-based architecture with the capability to automate engineering processes
Proactive and efficient support team
Proven technology with strong references across industries and countries

The rule-driven and data-centric nature of the Hexagon products helped PGESCo to improve the overall efficiency of the project delivery. While there were some issues between the integration of the electrical design and Smart 3D, the overall integration between different tools enabled smooth data transfer between different disciplines, supporting better revision control. This in turn allowed PGESCo to eliminate errors to improve the quality of the engineering deliverables.

Intergraph Smart® 3D and CAESAR II® were used for piping layout, piping support design and piping analysis to carry out the piping design activities and ensure that the detailed design by the contractors was correct. Intergraph Smart P&ID was used for system engineering to ensure correctness and generate the various engineering deliverables (valve, line and equipment lists, etc.). Intergraph Smart Electrical was used for cables design, routing and termination as well as generating electrical load list with breaker assignment.

For the structural design checks, Smart 3D was used for clash checking, and GT STRUDL® for analysis of the structural designs. In addition, the site engineers used Intergraph Smart Review continuously during the construction management phase for further clarifications and to ensure that what was designed in Smart 3D matches what was actually constructed at site.

The Hexagon PPM-based system also integrated data from external third-party systems, such as Tekla and ARCHICAD.

Structural design and architectural information could be easily exchanged between Smart 3D and the third-party systems easily to ensure fast clash checking.

Ahmed Nabil, Information & Systems Technology Manager at PGESCo, said, “Digitizing plant information with Hexagon tools helped us in eliminating human errors and data mismatches through automation and integration. We were able to use the information at the right time and place, with the latest data incorporated. Analyzing plant information was easy and could be done based on the business needs during each step of the project.”

Moving Forward

For this venture, PGESCo had a team of approximately 60 people working on the project, with 30 people having access to Hexagon tools; out of those, only 20 engineers have the ability to modify and delete data, and the rest have viewing rights.

PGESCo will continue to work with Hexagon tools in its current projects and expects similar benefits in the future.