Eng1.neen.

ng Praet'ice

Engineering & Construction (E&C): Modeling

lntegration Enables Optimized Execution
As E&C companies strive to develop Building lnformation Modeling (BIM) 60 models
for the owners and operators of CPIfacilities,strong efficiency gains benefit all parties
Stephen Wyss
BechtelCorp.

T
uly transformational change
s upon the engineering and
construction (E&C) indus-
try, and sorne consider the
trends that are occurring today to be
enabling the most significant evolu-
tion in history. Cumbersome doc-
ument-based project execution is
transitioning to robust, data-centric
execution, as innovators seize op-
portunities in emerging technologies
and ongoing expansion in cloud-
based environments. E&C contrac-
tors that embrace, define and drive
change will flourish, while those that
dawdle will find themselves in the
undesirable position of reacting to
change. Several contemporary stud-
ies (1] document how E&C industry
productiv ity has lagged over recent
FIGURE 1. Great etticiencies arise when construction statt can access materials- and project-related
decades relative to other industries, informalionviaa modelviewer
and identify the catalysts that are
driving this change. Collaboration is tools (devices and platforms) and advanced capabilities to rede-
a dominan! theme in the path to in- from cloud-based data sources, to fine the traditional relationships
creased productivity. facilitate operation and maintenance and responsibilities that exist be-
Opportunities for productivity-en- ot the facility. tween engineering, procurement ,
hancing collaboration are presenting This article distinguishes the regu- construction and commissioning
themselves inmanyspheres - reg- latory, organizational and contractual functions
ulatory, organizational and contrac- aspects of project management and • Contractual collaboration entails
tual. Of these, one of the contractual the trends that are driving the path parties altering execution and re-
paths stands out - the path to BIM to 60, and offers recommendations lationships to facilitate information
60 (For more on BIM 60 models, for how E&Cs can use this path to exchange and share risk so as to
see the sidebar on p. 59). implement paradigm-shifting work minimize information-sharing bar-
Once E&Cs evolve their processes process changes that can signifi- riers and to be more nimble in
as part of this data-centric paradigm cantly enhance productivity. implementing executionalvariation
shift, they will be able to deliver a • Regulatory collaboration entails
BIM 60 model to the owner upon proactive public and private part- The drive toward a 60 model
construction completion, populated nerships (P3), with parties working Approximately two decades ago,
with relevant building componen!in- together to create and facilitate owner and operators throughout the
format ion, such as product data and conducive environments chemical process industries (CPI)
details, maintenance and operation • Organizational cotlaboratíon in- began requiring a 30 model as a
manuals, cut-sheet specifications, volves E&C entities seizing inter- deliverable from E&Cs whenever a
photos, warranty data, web links to na! productivity-enhancing op- capital project was handed over for
product onllne sources, manufac- portunlties relatlng to lnnovative operatlon. In the near future, E&C
turer information and contacts, and software tools and cloud-based contractors can expect to find own-
more. Data will be accessible via environments, and using these ers and operators requiring delivery

56 CHEMICAL ENGIN EERING WWW.CHEMENGONLI NE.COM DECEMBER 2018

of a 60 model as the key deliverable
with the facility at handover. Why is
that?
While a 30 model has historically
enabled owner/operator personnel
to maintain and update a centralized
engineering database of the facility,
the delivered facility still carne with
volumes of documents and manu-
als produced from a document -
centric execution process, and ali
of those support materials needed
to be managed through a central-
ized control and storage organiza-
tion. Owner/operator maintenance
and operations personnel needed
to access key plant information from
within this document storage andor-
ganizationsystem, whether via hard-
copy documents and manuals, or
via an electronic data management FIGURE 2. With greater centralization and integration ot all project-related data and information, con-
system (EOMS) - a cumbersome struct on personnelcan easily check the most up-to-date material test reports from a tablet
process in either case.
By contras!,a 60 model produced or a list of parts for an instrument, sophisticated design-authoring soft-
using a data-centric execution pro- a 60 model with fully developed at- ware tools. These allow the model
cess centralizas and streamlines tributes at the object level - the to evolve as E&Cs design the facil-
information access for ali stakehold- operator's pump or the technician's ity. Parties not involved in the design
ers, because it is object-centered, instrument - enables that individual process, but who have an interest
not document -centered.Whereas in to visualize the object (a pump or in monitoring the design evolution
a document-centric environment. an instrument. in the example above. (such as the procurement staff. con-
operator or technician might need to or any other object) via a model struction staff and others), are able
chain through multiple documents to viewer, and directly access linked to monitor this evolution vía the use
find the information sought, whether information from the object through of model viewers (Figure 1).1
it was a maintenance log of a pump associated attributes. Model viewers display the 30
1. Examples of model víewers include ln- model much the same as the de-
tergraph's Smart Pfant Review, Autodesk's Model viewers sign-authoring software, but do so
Navísworks, and CAXperts Universal Plant Ouring the design phase of a facil- from a static file that is created on a
Viewer ity,30 models are constructed using regular basis (generally daily,with the

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CHEMICAL ENGINEERING WWVV.CHEMENGO NLINE.COM DECEMBER 2018

 using computer modeling of facili-
ties tor more than tour decades, al-
though the first models were not
created using software that mim·
icked a design process, but instead
consisted of data input from scaled
plastic models. The primary benefits
trom 30 models have historically
been the ability to both produce
drawings from the model and per-
torm clash-checks.
As a result, the 30 model scope
has historically been limited to inclu-
sion of only !hose disciplines and
objects where the time involved to
input model data and associated
value was outweighed by detriments
FIGURE 3. The BIM 60 approach leverages a data centric paradigm shift that allows engineers to move associated with manual drawings,
from reliance on disconnected documents,software and databases,toward an approach based on cen- specifically the inability to identify
tralized objects, tools and data.These engineers check design speciticalions trom a centrallocal.ion
clashing attributes and extrae! data.
file compiled overnight). Modelview- this information via numerated links Electrical bulk materials are a good
ers are also able to display object, or in the model viewer without the need example. Most E&Cs will model me-
componen!, and attribute informa- to exit the model viewer and access dium- and high-voltage cable and
lion associated with that object, to the EOMS system. associated raceway, but leave low-
the extent that attributes are defined Conversely, it the model viewer voltage wire and cable and small-di-
and data are associated. can be accessed via a cloud-linked ameter conduit out of the model. In
Model viewers allow remole table! (Figure 2),this enables the op- this scenario, the E&Cs will generally
staff to view the objects in the fa- erator or technician to access the install the low-voltage wiring in the
cility and dril! down to the object same information standing directly in field, and document it using as-built
sought - say. the pump or instru- front of the obiect - the pump or drawings. There are similarities inin-
ment above - in much the same instrument - and to troubleshoot strumentation,although most piping
way they would do so physically. on the spot, pulling up necessary and civil/structural materials do end
lf they know the gener ic descrip- information, such as inspection re- up getting modeled.
tion of the item, say "deminer- cords, materials certifications and The trend is toward modeling
alized water storage pump," or so on, without having to run back to more, not less, but until such time
"hydrogen gas bulk-feed pressure a centralizad work station, or worse as owner and operators require the
regulator," or have an identifier of yet, to a document-control office. vast majority of objects in the model,
the item, such as "WO-MT-001" Aside from the reduced time needed E&Cs will still define model scope
or "PG-PCV-001," then using the to access the information, the im· based on executional value obtained
model viewer query functionality, proved timeliness associated with from modeling objects that are di-
they can drill down to and visualiza making a decision to take an object rectly related to construction execu-
the object virtually in the model in off line or out of service, particularly tion. The E&C firm uses the model
its adjoining environment, without when shutdown or satety consider- primarily tor engineering personnel
actually being required to do a site ations are involved, allows for better- to communicate to construction per-
inspection. Alternately, if they know intormed decisionmaking. sonnel about how to build the facility,
the area of the facility but are not and to document the physical facility,
certain of the item sought, they can 60 model rectifies E&C issues inclusive of materials. lf theconstruc-
open the model viewer, drill down Today's modeling tools provide a tion craft knows what to do without
to the area sought, and then navi- strong plalform for E&C compa- having it articulated in the model, for
gate in the model to find the item nies who successfully transilion to example, how to route minar wiring,
sought, just as if they had to do the a data-centric execution process to or how frequently wiring may need
same physically in the facility. deliver a 60 model. But there are cable ties, then there is no value to
lt the object has a fully developed two huge challenges these contrac- the E&C to expend resources to in-
set of attributes - such as specifi- tors tace: (1) model scope, and (2) clude such detail in the model. lf the
cations, design data, manufacturar model integration. The greater the owner/operator states a leve! of de-
name, manufacturer part number, challenge, the greater to opportunity tail to be in the model that exceeds
manufacturar inspection records, - and in both ot these challenges lie what the E&C sees as value-added,
constructor installation records, opportunities that present E&Cs with then the E&C will add it. But not un-
maintenance records - with direct the opportunity to lead and define less required to do so.
links into an EOMS system that con- change, instead of being left in the While it is unlikely 60 models will
tains associated records, the opera- dust to react to it. ever oontain actual modeling of
tor or technician can directly access Model scope. E&Cs have been every minute object in the tacility -

58 CHEMICAL ENGINEERING WWW.CHEMENGONLINE .COM OECEMBER 2018

down to the last screw and washer
- we can expect that 60 models
UNDERSTANDING BIM
uildinginformation modeling (BIM) is a processinvolving the generation and manage-

B
will eventually model most objects,
and when it comes to items such ment of digital representations of physical and functional characteristics of places.
BIM files often (but not always) involve proprietary formats and data, and they are typi-
as minor hardware, to have those
cally used to support decisionmaking regarding a building or other built asset.
items still fully detailed in reference
BIM "dimensions" are defined generically as:
data in the model. This includes a • 30.This virtual modelof the facility uses a variety of authoring tools and contains a graphi·
list of installation parts that goes with caluser interface with data-capturing techniques
a minor component such as a • 40.This is a 30 model that has beenintegrated with a t me element - specifically the
conduit fitting. project schedule. This lets users view the model over t me as the facility will be erected,
Model integration. Model integra- and helps to identify conflicts inwork areas
tion creates the biggest challenge, • 50.This is a 40 model thatisintegrated with cost or resource (quantity) data, enabling
and the greatest opportunity for E&C users to monitor cash flow, staffing requirements and other material-related requirements
productivity enhancement awaits • 60.This model contains all of the information needed fer commissioning, startup,hando-
ver,operat on, maintenance and management of the facility
there. Even where an E&C provides
• 70.This model's objects are identified according to risk level, including risk assessments,
the engineering tor the entire facility,
HAZID/HAZOP,startup. operat on and more
every facility employs a significant • no. This model incorporates and defines supplemental dimensions, as needed; ferin-
amount of complex equipment con- stance, inadversa climates objects can be associated with weather-related elements •
tracted from speciatized suppliers.
Many of these components and sys-
tems experience a comprehensive ties - inctuding materials suppli- tion - force the design process to
design evolution with a free-standing ers, service suppliers, joint venture be iterative, with the core design
30 model of their own.These mod- partners and more - that facilitate constantly being impacted by up-
els will need to be compatible with integration ot externa!data, includ- dated supplier data as the equip-
the model that is produced by the ing model data where applicable, ment design evolves in parallel
E&C, and eventually integrated into so as to deliver a consolidated 60 much the same as the facility design
a final 60 modet for detivery to the model evolves. As noted above, such major
owner/operator. This may sound quite daunting. equipment includes fired heaters,
Such equipment includes fired The first issue above - model ca- large compressors, pumps, turbines
heaters. heat-recovery steam gen- pacity - will be resolved via ongo- and more.
erators (HRSGs), complex compres- ing advances in technological pro- In a document-centric design pro-
sors, turbines and more.Meanwhite, cessors. The second issue - the cess, these suppliers communicate
when the E&C subcontracts a por- legalstatus of data - needs time, to with the E&C via document submit-
tian of the design to a subcontractor, allow the legal community to catch tals. lnformation is exchanged at key
or the project is structured as a joint up with technotogy; in the meantime, project milestones, at which point
venture, models developed by the E&Cs should consult legal counsel the supplier's designs and draw-
different contractual parties will need to carefully protect themselves in ings achieve a certain leve!of design
to be compatible and integrated with this relatively uncharted area. The maturity, and communicate a large
the prevailing 60 model, as well. third issue - improved collaboration amount of information in a block,
between contractual parties - is despite the fact that much of the in-
lntegration-related challenges where the potential exists for E&Cs formation may have matured sorne
When it comes to integrating models to transform the stodgy, histor ical, time ago.These submittals often re-
trom disparate sources, E&Cs tace iterative design process into a more quire the E&C to adjust the design
the following three challenges: robust, accelerated design process. upon receipt of the supplier draw-
• The 60 data infrastructure must E&Cs that are able to establish ings, and possibly add comments
be capabte of addressing, storing, collaborative design processes with tor the supplier on certain unaccept-
and linking all of the requisite data their suppliers, subcontractors, able aspects of the design.
at the object tevel, without loading and jo int-venture partners will be Not only does this cumbersome
up the compiled model with data able to significantly reduce de- document -submittal process delay
that are beyond the reasonable sign-related costs and shorten the finalization of the E&C design,but
ability ot the modeting software to project schedules. if the submittal results in comments
process and display back to the supplier, then the sup-
• All parties need to estabtish pro- Reduce iterative model design plier's design experiences a similar
cesses and protocols retated to Oesign authoring 30 model software iterative impact, which may further
archiv ing of data to protect them- allows E&C disciplines such as civil, impact the core E&C design. Most
selves from the curren!undefined structural, architectural,piping, elec- iterative design changes are small -
legal status of data until such time trical and instrumentation systems but they can significantly impact the
as thelegal community catches up to evolve the design simultaneously. final piping, design drawings, and
with related emerging technology However, current-state document- have cascading impacts on struc-
and the law becomes settled centric processes relating to pivota! tural steel and even civil engineering
• E&Cs need to establish collabora- equipment - primarily mechanical requirements, sometimes causing
tive processes with externa! par- equipment and sorne instrumenta- fouodatioo sh;lts, whOh m;gh
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM DECEMBER 2018
 impact related underground electri-
cal and piping facilities.
As E&Cs transition to data-centric
execution, a more-streamlined pro-
cess whereby the contractual parties
- the E&C and its major equipment
suppliers - exchange information
vía regular model exchanges will ac-
celerate information exchange. This
newer approach offers the potential
to completely eliminate the cumber-
some document-submittal process,
and supports the delivery of a 60
model (Figure 3).
Affected parties have done what
they can to optimize the existing,
cumbersome document-submittal
process - identifying drawings and
data to be submitted, and attempt-
ing to break up submittals in logical
groups of information. But for large,
complex equipment, the number of
drawings and documents can reach
into the hundreds, and there can be
dozens of individual submittals of
groups of drawings, each of which
has the potential to necessitate re-
petitive submittal.
And these document-submittal
processes have required E&Cs to
create entire bureaucracies (for in-
stance, dedicated document-contro l
organizations) that manage these
submittals. Oocument control teams
receive supplier documents into the
document-control systems, whether
this is an EOMS or a hardcopy sys-
tem. For instance, documents are
issued out to the responsible engi-
neers, with routing around to ali im-
pacted parties, and then received
back for incorporation of comments
and transmittal back to the supplier
- a laborious, error-prone and time-
consuming process.
Envision a more streamlined pro-
cess where the equipment supplier
exchanges model updates with the
E&C company on a regular basis
- at least once each week - and
the E&C integrates each model up-
date into the E&C model. The sup-
plier's model objects are assigned
attributes for submittal references
(inclusive of required submittal
dates), supplier design maturity,
and E&C approval status, and the
supplier re-integrales data from
the E&C back into its core model,
including acceptance status and
critica! design comments affect-
ing the supplier design. Ali of this
60
happens efficiently each time an
exchange and update occurs. In
such a process, the E&C can iden-
tify issues with the evolving sup-
plier design early, and communi-
cate issues back to the supplier vía
model-attached comments.
Not only does this significantly
reduce document-related iteration,
but it transforms the design reviews
from a cumbersome, milestone-
based document-review process
to an accelerated data-review pro-
cess, as the object design matures.
In such a scenario, the responsible
E&C procurement personnel are
charged with monitoring and expe-
diting supplier progress, and they
can query the model for a set of
data defined as a single submittal,
and ascertain if the supplier de-
sign is progressing to support the
schedule dates.
Similarly, E&C engineering staff
can simply execute a similar query
once a set of supplier objects has
achieved a level of design maturity
such that approval is required, and
can query the status of the objects
in the model. with the status being
communicated back to the supplier
vía the next model exchange. Such a
seamless model-exchange process
accelerates!he exchange of critica!
information, and completely elimi-
nates the burdensome document-
submittal process. Engineering
hours are significantly reduced, the
schedule is accelerated, the docu-
ment-control hours are significantly
reduced, and the infrastructure for a
60 model is enabled.
Further benefits of a 60 model
This article discusses the benefits of
a 60 model to the owner and opera-
tor of a capital-intensive CPIproject.
The same benefits accrue to non-
design E&C personnel as they ex-
ecute their duties, to the extent the
information is available in the model
at any given time. Procurement spe-
cialists, expeditors, quality-related
personnel, logistics experts and
warehousing personnel can access
the model viewer and query individ-
ual objects or groups of objects to
seek information or status updates,
and such information can be easily
accessed by purchase order num-
ber, work package or any attribute
group assigned .
CHEMICAL ENG
IN EERING WWW.CHEMENGONLINE.COM DECEMBER 2018
Similarly, using this newer ap-
proach, construction personnel will
have increased access to data and
delivery information to plan work,
create work packages and confirm
construction readiness. Commis-
sioning and startup teams probably
benefit the most, in that documents
that they would otherwise need to
compile into hand-over packages
are ali available at the object level,
facilitating system startup
and handover.
Closing thoughts
The discussion above has focused
on the benefits of model integration
- enabling improved collaboration
- between E&Cs and their major
equipment suppliers, not only as a
path to BIM 60, but to significantly
increase boththe design productivity
of the E&C and its major equipment
suppliers. There will be similar ben-
efits with minor suppliers that have
submittal requirements. And experi-
ence gained in integraling models
will facilitate model integration from
subcontractors and jo int-venture
partners. leading to the delivery of
a 60 model to owner/operators.
Clearly, in addition to delivering a 60
model to the owner/operator, E&Cs
have the opportunity to realize signif-
ican!productivity enhancements as
they improve their work processes to
deliver a BIM 60 model. •
Edited by Suzanne Shelley
References
1.World Ecooomoc Forum, Sliapingthe Future of Conslruc·
lion: A Breakthrough in Mindset and Tecmology, May
2016; McKuisey GI0001 lrntia!Ml.Re•weong Conslruc
tion:A Roole to Higher l'roductivíl)I.February 2017.
Author
r-: ¡¡¡;;;JI Stephen Wyss is a materials
manager with Bechtel Corp.
(12011 Sunsel Hills Road.Reston,
Virginia, 20190; Email: sewyss@
bechtel.com). He has more than
40 years of experience working
with engineering, p<ocurement
al\d construction oontractors,in·
cfuding tenures at Black & Vealch,
Pritchard, CF Braun, and lnter·
graph.His curren!duties entail COOfdinating materials·
related aspects of engineering, p<ocurement, suppliers,
and construction, for both bulk mate(ials and major
equipment oo large industrialcapital projectsinctuding
process plants, power plants, mining facilities, and rail
facilities .His proiect experience has generally bee11 in
emerging economies with logistical challengesincfud·
ing me Middle East, India. Africa,and South Amelica .A
registered mechanical engineerin Texas and California,
he holds a J.O. degree trom Loyola Law School {los
Angeles) and an A.B.degree in architecture from Ule
University ot Californiaat Belkeley.