Mahler AGS Saves Significant Labor Hours by Upgrading to Intergraph® CADWorx® Plant Professional & CAESAR II®

Mahler AGS, an international leader in designing and manufacturing hydrogen generation plants, built a new hydrogen generation plant in record time with Intergraph® CADWorx® Plant Professional and CAESAR II®.

The Challenge

Mahler AGS is an international leader in designing and manufacturing hydrogen generation plants, specializing in steam reforming and pressure swing absorption technology. With more than 60 years of experience in the business, the company provides tailored, turn-key solutions for clients across different chemical sectors.

Mahler AGS was employed to design and manufacture a modular hydrogen plant for a leading global company in the palm oil business. As part of the modular design principle, Mahler pre-assembled and delivered the plant as prefabricated units.

Mahler AGS was looking for both a new pipe stress analysis software as well as one to replace its existing design software (X-Plant) that also included a modern 3D planning solution. The new system needed to be compatible with the previous AutoCAD-based software, was easy-to-use, and was fast to implement so it could minimize project downtime and delay. Intergraph® CADWorx® Plant Professional and CAESAR II® were chosen due to their AutoCAD-based structure, scalability, and suitability for the project scope.

A tight time schedule and mixed existing ASME/DIN EN piping codes affected the design and manufacturing process of the new plant. Meeting the strict project deadlines was ensured by the efficiency and accuracy of CADWorx Plant Professional. As an AutoCAD-based solution, most of the users already had experience with a similar product and were able to get up-to-speed quickly.

The Solution

Even though this was the first of Mahler’s projects in which Intergraph solutions were executed, only a short adoption time was needed because training and design were performed in parallel. Due to the ease of use and quick implementation of both CADWorx Plant Professional and CAESAR II, the design for the new plant was completed within approximately five months from the project start date.

CADWorx Plant Professional was used to create an intelligent 3D plant model of the new plant, including intelligent 3D models of equipment, steel structures, and piping; 2D layout drawings, and civil guide drawings; isometric drawings; and bills of material for piping and steel.

CAESAR II was used for all piping stress calculations, data sheets, and piping specifications. As a default, CAESAR II creates bi-directional links between plant design and engineering analysis. This enabled Mahler to pass data between different departments without data loss.

Ultimately, by choosing CADWorx Plant Professional and CAESAR II, Mahler AGS reduced project man-hours by 10 to 15 percent, with an additional 25 to 30 percent reduction in time spent on stress calculations. The latter is attributed to the overarching compatibility between Intergraph solutions, requiring fewer model revisions throughout the design process, regardless of the amount of overall changes.