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Materials Handling Projects in the 3D world

Barry Woodin

Product Owner SP3D Materials Handling Edition (MHE)

11/16/2010

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SP3D Materials Handling Edition

History

Technology Partnering Memoranda Jan 2008

Sinclair Knight Merz, United Group Limited Resources and Intergraph

POC Completed July 2008 Perth WA

Requirements Defined August 2008 Perth WA

MHE development Sept 2008 Perth WA

SCRUM Team Established March 2009 India/Australia

First SCRUM Sprint August 2009 India/Australia

MHE BETA Version on SP3D MHE Nov 2009 India/Australia

SP3D MHE 2009.1 HF 6 Official launch Perth Western Australia 30th

September 2010

2010 Intergraph Corporation. All

Rights Reserved! 2

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Materials Handling Industry

Business Challenges/Opportunities

Demand for mining of resource

material driven by China and Indiainfrastructure expansion

Mining production output, limited by

timeframe to bring new projects

online.

Currently materials handling project

deliverer is driven by outdated

document centric technology.

Availability of highly experienced

engineering and designprofessionals will become more of a

resource issue over the next 5 to 10

years as the Baby Boomers retire.

2010 Intergraph Corporation. All

Rights Reserved! 3

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Global Metals Demand Forecast

11/16/2010 SP3D Materials Handling Edition 4

Order of Magnitude Impact:

Iron Ore One Pilbara production everyfive years [approx. 200 MT / Annum]

Aluminum One Saguenay productionevery nine months [approx 1.4 M tons ofalumina / annum]

Copper One Escondida productionevery year [approx 1.0 M MT of copper]

Source: Rio Tinto Macquarie Global Metals & Mining

Conference Nov 2009

What is driving the forecast?

Source: Reuters Ecowin, Consensus Economics

India is right behind in demand

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Steel Demand in Developing Nations

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Materials Handling Solution

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Faster and safer

commissioning andramp-up due to

integrated engineering

design supported by

3D model

Commissioning

Minimize construction errors

and rework

Real time response to field

demands

Construction Decision-making on multidisciplinary issues 3D model real time access and usage by site contractors

EDMS on-line access by suppliers and field contractors

Engineering systems fully integrated to Alunortes ERP

(purchasing, materials control)

Integration

Operations training

Total project life cycle support

Integrated operation, maintenance

and EHS design review

Operation & Maintenance

Detailed design documentation automatically

generated from 3D database

Consistency and reliability of 3D database

Digitalized document transmittal and

processing (paperless engineering design)

Technology

3D Model Benefits in Mining & Metals Projects

Correctness of engineering design

Accuracy of materials take-offs

Quality

Shortened project

implementation

Optimized engineering

effort and resources

Schedule

3D modelling increased job

site safety due to anticipated

review and validation of

construction methods and

safety issues

Safety

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Functionality Breakdown

SmartPlant 3D

SmartMarineSmartPlant 3D for

plant layout

structural, piping,mechanical, Hvac and

electrical design

SmartMarine 3D

plate work

functionality for

designing the

conveyor chute

SmartPlant Materials

HandlingEdition for conveyor

and chute design

functionality

SmartPlantMHE

8SP3D Materials Handling Edition

11/16/2010

http://localhost/var/www/apps/conversion/tmp/scratch_4/Marketing/SmartPlant%20Materials%20Handling%20POC.m2v

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Conveyor Layout

Conveyor belt line

layout is managed

easier in the 2D

environment, similar to

how Plant projects use

P&ID

The industry Profile and

Data sheet, is one of

the major deliverable

for conveyor layout

projects .

The Profile and Data

Sheets contains

geometrical data that is

used . to drive the 3D

model design

2010 Intergraph Corporation. All

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Chute Design

Chute Design

Typical Conveyor Head Chute with Transfer

Chute.

Chute Wizard would be used for starting

point for parametric driven Designs.

Chutes can be detailed to manufacturingstandards.

Chute outputs, are manufacturing drawings

and output to CNC machines.

Chute Linear plate can be exported to

detailing package via CIS/2 interface

2010 Intergraph Corporation. All

Rights Reserved! 10

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MHE Workflow Truss Placement Example

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Layout is made easy in theSmart 2D environment

The 2D TRUSS Placementlayout is populated to the 3D

Model

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SmartSketch

SmartSketch is a premium tool

for 2D drawing generation.

SmartSketch's underlying

technology and user interface

make it easy to use and integrate

with data-centric products

SmartSketch provides powerfulfeatures such as parametric and

relationships that enable

execution of design changes

quickly and efficiently. These

changes are then populated to the

S3D Model.

2010 Intergraph Corporation. All

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http://localhost/var/www/apps/conversion/tmp/scratch_4/SmartSketch.avi

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Conveyor Design in Mining

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Bulk Materials Handling

In Plant Design

Vertical Radius Conveyors

Incline

Decline

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Concept / Workflow

11/16/2010 SP3D Materials Handling Edition 14

Concept

2D Drives 3D Placement

User can re-visit 2D design

Workflow (Standard 3D Project)

Plan high level Plant system breakdown

Plan and create initial coordinate systems (CS)

Plan initial work assignments

Establishment of Site Plan

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Workflow (MHE Specific)

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Import major equipment

Define major conveyor systems

Create Coordinate System for Conveyor

Create Belt

Copy the Coordinate information to SmartSketch

Create trusses via truss wizard Use SmartSketch to place conveyor equipment

Complete Project as per standard SmartPlant 3D

http://localhost/var/www/apps/conversion/tmp/scratch_4/Belt%20layout.avi

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Workflow (MHE Specific)

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Truss/Gantry 2D Layout

Populated to 3D

http://localhost/var/www/apps/conversion/tmp/scratch_4/Truss%20Placement.avi

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Workflow (MHE Specific)

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Use SmartSketch to place conveyor associated equipment

Complete Project as per standard SmartPlant 3D

http://localhost/var/www/apps/conversion/tmp/scratch_4/Idler%20Placement%20and%20update.avi

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Examples of SP3D MHE Automation Wizards

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Truss/Gantry Wizard

Chute Wizard

http://localhost/var/www/apps/conversion/tmp/scratch_4/Chute%20Detail%20and%20Parametric.avihttp://localhost/var/www/apps/conversion/tmp/scratch_4/Truss%20Gantry%20avi.avi

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SP3D MHE Deliverables

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SP3D Standard Deliverables

PLUS MHE Specific Deliverables

Chute Plate Standard MHE

Industry Drawing Templates

Linear Chute Plate export via

CIS/2 to detailing

applications.

Chute Plate work output to

CNC fabrication machines

Profile and Data Template to

enable BOM embedded

reports

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Benefits and Enablers Summary

Benefits

Access to Smart 3D Technology

Gives the ability to Front End Load (FEL) data to enable estimation of

Preliminary Equipment Design , Layout , Schedule and Estimate

Drive Standardisation and Modulation

Reduce manufacturing costs

Leverage off each project for future projects ( Build organisation catalog database)

Reduce onsite construction cost

Drawing Generation

Reduced costs of drawing generation

Enabled through

Smart 3D technology

Rules and relationship based architecture

Automation and re-use approach

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SmartPlant 3D Materials Handling

Summary

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Global demand for MHE

projects

Current technology is not

keeping up with demand

Simple 2D to 3D workflow

Conveyor layout

Chute Plate Design

Deliverables

MHE based on proven S3D

technology