Cheryl Brackett, Lead Work Package Engineer, Cianbro Constructors Eric Crivella, Plant Construction Executive, Bentley Systems, Inc.
• Create $10 million, state-of-the-art Eastern Manufacturing Facility. • Build and ship 54 prefabricated modules, totaling 9,000 tons of steel and 200,000 lineal feet of pipe. • The modules average 40-feet-by-40-feet in cross section, about 120-feet long, and weigh up to 700 tons each. • ConstructSim to visualize and interpret the module, plan construction, and generate parts lists and other information
Materials Management Feasibility Study
Priorities
Priorities
Construction Work Areas
Expedite Install Work to Ready a System for Testing
Work Packs
Turnover Systems Test Packs
Issued
Shop Fab
Track Spools Track Modules Work Complete Location
Work Pack Reports • Spool List • Field Matl Issue • Steel Hang List • Jobcards
Expediting Reports • Dwgs Not Released • Spools Not Fab • Field Mat’ls Not Onsite
System Reports Pressure Test Record Systems Completion
• • • • • • • • • • •
PDS 3D CAD Module definition & tracking Isometrics ISO transmittal database Line List Bentley Equipment list CIS/2 & piecemark Fabrication status iTrack on-site & progress Pipe unit rates IMS QA/QC and weld tracking
Jacobs
Cianbro
The VPM is distributed into a shared workgroup environment. User Machine #1
Uses
User Machine #2
A “Master Copy� of the VPM is archived on a server, with local copies resident on the user and data processing machines.
User Machine #3
• 3D Visualization, Interactive Planning & Construction Sequencing • WorkFace Planning – Steel and Pipe (fab, install & hydro) Work Packs
• • • • •
Material & Constraint Analysis Rapid Queries Status Tracking & Progressing Crane Logistics planning Quality Assurance
• Spool fabrication • Equipment installation • ISO release status • Pipe material availability • Work step tracking • Test pack status • QA/QC status • Work package constraints
• Top down management support and bottom up buy in from field supervision is key • Don’t underestimate the systems integration effort and the learning curve involved – Start as early in the project as possible
• VPM Admin role is critical – Always train a backup Admin
• Data validation is always a problem • Changing people & work processes is hard!
• Improved constructability analysis, interactive planning and coordination between engineering office and site office in using Virtual Plant Model • Visually plan optimal steel and pipe work crew packages • Streamline material, equipment & sequencing • Reduce rework / out-of sequence work • Speed time to start-up by systems tracking • Automated task estimates / automate data entry • Reduce time looking for information via visual monitoring the status of engineering, materials and construction execution progress
• Had direct comparison data because CIS/2 data was not available for 3 modules • Steel MTOs – substantially reduced time and human error (shin plates and bolts often get overlooked) • CSim steel work pack in 4 hours; to do same work pack manually would require 40+ hours • CSim saved a ton of time, effort and money on the structural steel • Bottom Line on the Business Case: • ConstructSim saved Cianbro ~$7M and helped ensure the project Key Performance Indicators of cost, schedule, safety and quality were met!!
If you would like more information contact: Cheryl Brackett
Eric Crivella
Lead Work Package Engineer
Plant Construction Executive
Cianbro Constructors
Bentley Systems
+ 1 207 907 7405
+1 713 249 4407
CBRACKETT@cianbro.com
Eric.crivella@Bentley.com