Process, Power and Marine Division

ANIMP INFORMATION and COMMUNICATION TECHNOLOGY SECTION

CONFERENCE MAY 2010

Using SmartPlant 3D on the

Suncor Firebag Project

(A Client Perspective)

© 2008 Intergraph Corporation. All Rights Reserved.

Using SmartPlant 3D on the

Suncor Firebag Project

Who is Suncor?

What is the Firebag Project?

Review Suncor Firebag Teams Accomplishments

Review Issues, Benefits and Risks

Discuss Future Steps

Presentation Objectives

Plant Images courtesy of Suncor Energy

Who is ?

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Suncor’s Integrated Strategy

© 2008 Intergraph Corporation. All Rights Reserved.

What is the Firebag Project ?

© 2008 Intergraph Corporation. All Rights Reserved.

Current Situation

© 2008 Intergraph Corporation. All Rights Reserved.

•SmartPlant

•Four basic modules in use:

• SmartPlant 3D,

• SmartPlant P&ID,

• SmartPlant Review, and

• SmartPlant Instrumentation

• SmartPlant 3D – CADD Modeling Tool

• SmartPlant P&ID – Intelligent P&ID database / drawing tool

• SmartPlant Review – Model Review, Visualization and Collaboration tool

• SmartPlant Instrumentation – Instrument database and design tool

Why SmartPlant 3D ?

© 2008 Intergraph Corporation. All Rights Reserved.

Firebag Accomplishments

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SmartPlant Interactive

User Documentation

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Firebag Accomplishments cont’d

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Firebag Accomplishments cont’d

Discipline Drawings Count

Comp/Total

Status / Issues / Concerns

Process P&IDs 510 / 510 Conversion from PIW to SPPID,

exceeded expectations

Piping GA’s

Iso’s

800 / 922

14,600 /

17,500~

Generation using drawing automation

Isogen used directly from model

Civil Piling

Concrete

Steel

400 / 428

400 / 450

2200 / 2237

working in SP3D drawing production tool

Electrical Layouts

Sections &

Details

500 / 655

50 / 63

Stage 3 production moving forward

under simplified workflow which will

provide consistent and stable results

using lessons learned from civil drawing

experience

© 2008 Intergraph Corporation. All Rights Reserved.

© 2008 Intergraph Corporation. All Rights Reserved.

Suncor’s Firebag- Project

(Collaboration Map)

Jacobs

Mumbai

Jacobs

Edmonton

Suncor

Host

Jacobs

Charleston

Colt

Calgary

Current SmartPlant 3D Implementation:

– ~ 300 - 350 Concurrent Users

– 5 Workshare Sites

– Single Replicated Model

Jacobs

Calgary

© 2008 Intergraph Corporation. All Rights Reserved.

Firebag Stage 3DSU

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SmartPlant 3D Screen Image courtesy of Suncor Energy

Suncor Energy

Firebag Stage 3 DSU Project

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Suncor – Firebag Stage 3

Firebag Stage 1 thru 6

(Stage 3 shown modeled)

© 2008 Intergraph Corporation. All Rights Reserved.

Project Issues

Area Criticality /

Performance

Comments

Modeling M/M Majority of key modeling issues resolved, minor ones

being addressed

Copy/Paste/Mirror functionality improved to meet

Stage 4+ requirements

Specs M/M Spec database complete

Mapping to material masters complete

Drawings H/M Drawing generation for Piping disciplines good, being

enhanced for Civil discipline

Workshare H/H Stable and good performance

Performance M/M Generally stable with little impact on project production

Installation of upgrades completed smoothly

SP Review M/M Adequate performance

Support M/H High level of support from Intergraph at all levels to

address outstanding issues

© 2008 Intergraph Corporation. All Rights Reserved.

Assessment of Key

Performance Indicators

KRA Assessment

(1-5)

Comments

Workshare 4 Meets expectations

Productivity 4 Medium drawing production in civil discipline

Piping iso production above standard milestone

Data Ownership 4 Meets expectations

Vendor Support 4 High level of support, both locally as well as

remotely

Data Reuse 4 Model reuse potential is good, currently being

evaluated and improved

General 4 General overall user buy-in to new system

Good collaboration between all parties on resolving

gaps between functionality and requirements

© 2008 Intergraph Corporation. All Rights Reserved.

Immediate Benefits derived

© 2008 Intergraph Corporation. All Rights Reserved.

• Mobilization of low cost engineering centre

~ 25,000 manhours at $75.00 cost

Difference = ~$1.5M

• Flexibility of workshare – $200k

• Single configuration database ~$200k

• Cost avoidance for multi-model management

~10% *100,000 mhrs- 10,000 hrs ~ $1.0M

Future Benefits

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Future Benefits

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Firebag 3D Model Data Reuse

Stage 4…Stage 5

22

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Firebag 3D Model Data Reuse

Process Area (Copy Rotate)

23

© 2008. Intergraph Corporation. All Rights Reserved.

2000-person capacity Quarry Park office

Full service EPC office

– In-situ heavy oil recovery

– Power and cogeneration

– Sulphur recovery

– Gas processing

– Refining and upgrading

JACOBS Calgary Operations

80 Specs

300 Process modules

500 Pipe Rack modules

27 Building modules

1,650 Tagged equipment

20,000 Lines

45,000 Isos

55,000 Spools

43,000 Valves

13,000 Instruments

40,000 Tons of steel

JACOBS Firebag Project Facts

4 Years in design

5 Workshare locations (3 countries, 2 continents)

340 Designers (120 + 60 + 15 + 65 + 80)

15 Admins ( 8 + 3 + 1 + 1 + 2)

4,700,000 Objects

80+ GB Database Size

JACOBSFirebag Project Facts

Process, Power and Marine Division

Integrating the

Engineering

Enterprise…

GWC Technology

SQL Server / Oracle

SQL Server Oracle