Shandong Iron and Steel Group wanted to optimize their blast furnace kinetic energy conversion system, aligned with the state’s commitment to improve efficiencies of traditional energies. The project required building two new 3,800-cubic-meter blast furnaces in Jinan to reduce iron smelting energy consumption. Shandong Province Metallurgical Engineering won the bid but faced several challenges when designing the plant’s 27 subsystems. They previously used third-party plant design software but encountered modeling inadequacies that made them realize they needed a more robust, collaborative modeling solution.

Shandong Province Metallurgical Engineering selected MicroStation, OpenBuildings, and OpenPlant for structural, architectural, and pipeline design, and ProjectWise to coordinate modeling among the 14 disciplines. By performing collision detection, they identified and resolved over 60 equipment errors to save more than CNY 3 million. They used the applications to improve digital management of more than 3,000 equipment models and enabled delivery of the first blast furnace 20 days ahead of schedule, saving over CNY 1.2 million. 

Project Playbook: AutoPIPE, MicroStation, OpenBuildings, OpenPlant, OpenRoads Designer, ProjectWise, LumenRT

The design of a JPY 2 billion chemical plant required proper placement of supports to avoid damage to the pipes and equipment. Typically, performing pipe stress analysis during conceptual design requires manual calculations and model input to generate options for the optimal design. On this project, Nippoh Engineering knew that they would need a pipe modeling and analysis application to automate the process.

After considering their options, they selected AutoPIPE to create algorithms and mathematically derive appropriate placement of supports to alleviate loads on process piping. Using the software’s support optimization feature, they were able to quickly create multiple design proposals, reducing the number of resource hours needed for design. By designing and analyzing efficient support points, they reduced unnecessary parts, optimizing the design and making it suitable for the environment. 

Project Playbook: AutoPIPE

M/Y Aurelia 29 is a 39.23-meter-long yacht with a waterline length of 38.23 meters, featuring a steel and aluminum displacement hull and three decks. Pad Project was hired to perform 3D design engineering of the furnishings but faced an unconventional industrial architectural style where modernity meets vintage, uncommon in the nautical field. The boat’s interior required them to design approximately 46,000 components and manage over more than 300 square meters of furniture surface to be engineered. To accommodate the unique architectural guidelines, numerous modifications, and a large number of files, they needed flexible 3D modeling technology.

They selected MicroStation to integrate 3D point clouds and create a cross-referenced information flow with third-party software, managing thousands of files without slowing design. MicroStation enabled the team to work simultaneously in a single environment in real time and modify the architectural elements timely and cost effectively. The digital solution decreased production times and reduced modifications by the on-board fitters by 50%. 

Project Playbook: MicroStation

An RUB 15.5 million project involved installing new equipment and integrating new workflows at a Russian manufacturing plant built in 1966. However, most of the pipeline drawings were difficult to find or unavailable, making it impossible to generate an actual 3D model of the entire facility. To avoid costly problems and rework, they needed an integrated technology solution to simulate the factory’s future workflow.

They used a scanner to capture a 3D point cloud of the assembly shop and imported the point cloud into MicroStation to generate 3D models of the newly integrated equipment within the existing facility. The models helped identify potential clashes prior to installation, avoiding RUB 2 million in costs. Working in a digital environment eliminated the need  to search, convert, or restore factory plans and layouts, estimated to save RUB 5 million annually. Overall, MicroStation enabled seamless installation and integration, estimated to save the plant at least RUB 7 million per year. 

Project Playbook: MicroStation