EnBW Takes Control of Plant Documentation with CADWorx® E&I powered by Sigraph.CAE

EnBW Energie Baden-Württemberg AG, the third largest utility company in Germany, implemented CADWorx® E&I from Intergraph® to homogenize processes and, by having a uniform documentation management system in place, to gain the ability to provide staff with up-to-date documents at all times.

The Challenge

EnBW operates two combined cycle heat and power plants in Stuttgart, which are used by the Stuttgart-Münster operating control center to process both hard coal and waste. In all, the Stuttgart-Münster facility offers an electrical output of 164 MW and a thermal output of 450 MW. 

The power plant has been regularly adapted to meet increasing environmental protection requirements.  EnBW’s rich history is a wonderful asset, but it also presents the company’s main challenge when it comes to documentation. An industrial plant that started operation more than 100 years ago has continued to grow over the years. The facility has been modified, retrofitted, and modernized so much that documentation without any burden from the past is practically unimaginable.

Hence, EnBW needed to develop a comprehensive solution that focused on the entire suite of documentation.

Uwe Worms, certified electrician in charge at Stuttgarter Heizkraftwerke, recalls, “CADWorx E&I was the only system that was able to link together schematic diagrams distributed over several project levels and files, and completely describe individual structural elements in the form of objects. A fuse in CADWorx E&I is not just a symbol, but also includes features such as size or breaking capacity.”

In 2008, an introductory project was launched to transfer all of the documentation for an existing waste-fired boiler to CADWorx E&I. This project was specifically chosen because it posed the most obstacles for a successful implementation.

Kerstin Müller from Technical Documentation compiled the metadata and documents and then transferred them to CADWorx E&I. Müller had to also simultaneously draw up the necessary guidelines, symbols, and all other objects required as a basis. The first boiler represented a major task, which in turn benefited the operators when it came to documenting the next systems, since the preparatory work had already been completed.

The objective was to prepare consistent and coherent documentation, and then make the resulting documents available to colleagues, such as electricians or system engineers. Although these employees do not have CADWorx E&I, the system does include a web-based interface that can be used to find individual components and subassemblies, by entering an inventory number for example.

The Solution

While talking about his experiences, Worms said, “With CADWorx E&I, we were able to eliminate any inconsistencies that previously existed in our documentation. Now all information is available in a central database, all plans are interconnected, and the system constantly monitors all entries to point out any inconsistencies. For instance, it is no longer possible to assign a terminal twice, since the system recognizes such errors.” 

While importing existing documentation, Müller and her colleagues found many errors thanks to CADWorx E&I and were able to correct them. CADWorx E&I pointed out wherever it noted any loophole or inaccuracies in the documentation. “In the past, with manually prepared documentation, a cable could easily be routed to the wrong terminal, for example,” said Müller. “That just does not happen with CADWorx E&I.”

In the past, five people were responsible for a system. Today, one person supports three systems. This is why EnBW continues to glean the knowledge of its employees, incorporate that knowledge into the documentation database, and gain the advantages of data accuracy and data quality. 

“Quality must be much better and the data must be accessible, even for non-CADWorx users. And we have managed to do this with CADWorx E&I,” said Worms. “Today we have a very good solution that is closely linked with our SAP system, which optimally supports us with our complex tasks.”

Read the whole case study here.