Conversion of PDS Catalogs and Specifications to

SmartPlant 3D

Toshio Hayashi
Project IT Group Manager
Toyo Engineering Corp.
Oct , 2009
 Global Toyo – EPC Offices
3D + Marian
Toyo Korea 300 3D
Toyo EU (Seoul) Marian

(Luxembourg) TOYO JAPAN

Toyo India Toyo China 2800 Toyo USA

(Mumbai) (Shanghai) (Houston)
1500
All Global Toyo  5800
Toyo Malaysia
(Kuala Lumpur) Toyo Thai
(Bangkok) Toyo Brazil
(Rio de Janeiro)
Toyo EU Toyo China Toyo Korea Toyo India Toyo Malaysia Toyo Thai Toyo USA Toyo Brazil
Toyo’s Business Segment History

Industrial
Facilities & Systems
Environment

Number of
project Gas &
Energy Solution Petroleum

Petrochemical
Chemical
Fertilizer

1961 2010
Toyo-Japan 3D-CAD History
1980 1990 2000 2009

1983 1987 1998

CAPES
- Toyo Own Developed 3D-CAD
- 30 Projects completed
- Working with Host Computer 1993 1995
Intergraph PDS
- 50 Projects completed
- Toyo Own Customization
for QC Tools / Dwg Issue Control / Physical Piping Support Library
- Interface to SPMaterial
R&D phase 2005
Actual Project Intergraph SmartPlant 3D
Ready to apply to Actual Project NOW !!
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Introduction
 Background - Why Toyo chose Conversion in 2007
 Development stage of SP3D @Toyo
 Manpower limitations
 Cost Evaluation (Remodel / RDB only / Full Conversion)

 Conversion Project (for Reference)

 Petrochemical Process Plant
 350 Equipment, 4000 Piping lines, 8000 sheets of Piping Iso.
 Full PDS Modeling including U/G system

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Outline of PDS  SP3D Conversion Work
 Task-1 PDS RDB -> SP3D RDB Translation Catalog DB preparation
 By Intergraph Conversion Center
 3 months for Piping / Structure / Raceway RDB
 Task-2 PDS model -> SP3D model Migration Model DB migration
 By Intergraph Conversion Center
 8 months for all PDS models migration
 Manual Touch up and Confirmation for Converted SP3D model
 By TOYO SP3D Finalization
 4 months for manual touch up
 2 months for all Piping Iso extraction

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Schedule of Conversion Work
Dec.2007 Feb.2008 Sep.2008 Mar.2009

PDS V7.2
As-Built
Task-1 : 3 months
Upgrade
PDS V7.2  8.0 PDS Spec
Confirmation
Translation
Task-2 : 8 months
Deliverable
PDS Model
- Excel file for Bulkload Confirmation
Migration
Deliverable
Work By TOYO - Plant Backup file (.bcf)
SP3D Model
Work By Intergraph Touch up & Confirmation
4 + 2 months
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RDB Translation (Task-1) - Outline
 Piping Specifications
 35 Piping Specifications translated with PDS Datatranslator.exe
 2500 Piping Specialty and Instrument items creation
 Symbol mapping + 30 custom EDEN (User symbols) creation
 Structure Sections
 2700 Structure sections translation with assistance of DCC tools
 40 Custom sections creation
 EE Raceway Specifications
 242 Specification creation with assistance of DCC tools
 PDS/SP3D Code List creation
 Additional Toyo specific PDS code creation
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Model Migration (Task-2) - Outline
 Piping Models
 130 Piping models migration
 Creating connectivity and tapping manually about 3000 points
 Equipment Models
 95 Equipment models migration (Import as G-Types + Manual
remodeling)
 Structure Models
 73 Structure models migration + General Solid Import as G-Types
 EE Raceway Models
 12 EE Raceway models
 ( HVAC Models  No HVAC model available )
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Manual Touch up and Quality Confirmation
@ Converted SP3D model
 Incorporated additional field change (as built conditions)
 500 Field Revision incl. all discipline
 Physical Piping support modeling
 Only critical items available on PDS (before conversion)
 PDS Civil General Solid model  SP3D G-type
 PDS FrameWorks Solid  PDS Equipment  SP3D G-Type shape
 Manual selection by each item wise
 Confirmation for Quality of Converted SP3D Model
 Extraction of all Piping Isometric Drawing (8000 sheets)

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Model Migration - Limitations
 Piping Models
 Model migration by PDS model basis  Piping line connection
through PDS models created manually for Piping Iso creation by line
wise
 Equipment Models
 Connection between equipment shapes are not maintained.
 Ladders, stairs and handrails are migrated as individual columns and
beams.
 Structure Models
 Migrated Structure models don’t have connectivity between structure
members.
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Summary
 RESULTS and FEED BACK
 For RDB Translation
▪ Successful use of semi-automated tools for Piping
▪ Successful manual effort for other RDB data (steel, tray, etc)
▪ Translated specifications provide a basis of Toyo standard RDB in
SP3D
 For Model Migration
▪ Results not identical to native SP3D due to known limitations
▪ ~70 % of PDS data migrated by tools, ~30% manual rework
▪ Quality assurance issue, How to validate??

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For more detail on legacy data conversions and Intergraph
tools and capabilities contact you local Intergraph office or
Richard Smykay
Richard.smykay@intergraph.com

Thank you !!