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Italteleco was founded in 1986, as a Software House specializedin industrial software solutions.
Since 1995 our core business is to provide integrated solutionsfor large-scale companies.
Since 2003 we are Business Partners ofIntergraph PP&M, the leading company in enterpriseengineering software for the design, construction, andoperation of plants, ships, and offshore facilities.
Our History
We firmly believe in continuous learning to develop the skills andknowledge of our personnel and in the application of newtechnologies as a tool to improve the processes in which we areinvolved.
Our Mission
Our Fields of Activity
Certifications
Existing documentation often unreliable and inconsistent with real fieldsituation.
Critical points:
Design based on unreliable data.
Additional EPC costs.
Leica HDS6100Range: 79 m.
Speed: 508.000 pt/s
Leica ScanStation C10Range: 300 m.
Speed: 50.000 pt/s
Z+F Imager 5010Range: 187.3 m.
Speed: 1.016.000 pt/s
Field Survey
Creation of a topographic controlnetwork,
Placement of the targets (at least 4visible from each scan)
Execution of the scanning from theselected scanning positions.
Acquisition of the targets coordinateswith a total station.
Field Survey
Single scans are executed fromdifferent positions so that all thevolume of interest is covered. Targetson each scan allow for precise pointcloud registration (roto translation to acommon coordinate system.)
Registration
Single scans are registered according to the coordinates of the targets oneach scan, surveyed with a total station: the final result is a point cloudrepresenting the entire plant, with correct plant coordinates.
3D Model
Modeling is performed by means of dedicate software(Cyclone/LFM/PDS/CadWorx): piping components are modelled accordingto applicable piping classes.
Isometric Drawing
Isometric Drawing
Piping Layout
Clash check allows for a precise identification of clashes between newpiping/equipment/structures (3D model) and existing plant (point cloud)
Issue of “Clash Check Isometrics” helps piping specialists to quickly identify andsolve every single clash.
Engineering
•Reliable as-builtdocumentation
•Accurate measurements
•Clash check
•Faster & Safer survey
•Constructability
Maintenance
•Minimize shut-down timewith accurate pipingsubstitution isometrics, critical lift simulations
•Identify in advance the best construction sequences
Operations
•Use 3D models for safeoperators training
•Integrate intelligent 3D model with RFIDtechnology for positive item identification, intelligentinspection&model markup
Scaffolding
• No need of scaffolding in most cases: survey costs are thus greatly reduced
Survey Time
• Minimize survey time: 2 operators with 1 scanner can survey an entire process plant(of average size) in about 15 days with an accuracy of 5 mm.
Shut-downTime/Construction
Time
• Shut-Down times are minimizedusing accurate and reliabledocumentation, critical lift simulations: no additional shut-down time costs, no additionaladjustment costs.
• Construction time are minimized using clash checktools, interactive 3D modelsconstruction sequencesimulations
Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person
2007
FCC - Regenerator - Phase
1
Laser scan, various
interference check testsSaras (Sarroch) 4000 50 Della Vedova R.
V1 Vacuum PlantLaser scan, 3D model and
critical lift simulationSaras (Sarroch) 3600 30 Cotza M.
RT1-RT2 PlantLaser scan, 3D model and
critical lift simulationSaras (Sarroch) 7500 40 Cotza M.
GPL UnitLaser scan, 3D model,
piping layouts extractionSaras (Sarroch) 2700 10 Cadeddu M.
IGCC UnitLaser scan, dimensional
checksSarlux (Sarroch) 4400 40 Puddu D.
Alkylation UnitLaser scan, plot plan
extractionSaras (Sarroch) 6000 30 Della Vedova R.
Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person
2008
FCC UnitLaser scan, shutdown
critical lifts simulationSaras (Sarroch) 24200 50 Cotza M.
Alkylation Unit
Laser scan, 3D
model,piping layouts
extraction
Saras (Sarroch) 6000 30 Della Vedova R.
2009
Mild Hydrocracking UnitLaser scan, reactor lifting
simulationSaras (Sarroch) 13000 40 Caredda R.
FCC UnitLaser scan, dimensional
check nozzle K1R2-K1E58Saras (Sarroch) 900 40 Cotza M.
Biomass Power Plant
Laser scan, 3D model and
critical lift simulation for
boiler substitution
Sicet (Ospitale di Cadore) 18000 20 Vascellari M.
U400 Desolphoration Unit
Laser scan, isometric
extraction for piping
replacement
Saras (Sarroch) 2400 40 Pili A.
Biomass Power PlantLaser scan, 3D model,
existing structuresSicet (Ospitale di Cadore) 18000 20 Vascellari M.
U400 Desolphoration Unit
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
2400 40 Pili A.
CCR UnitLaser scan, dimensional
checks on CCRD19 Saras (Sarroch)9000 40 Cotza M.
Visbreaking UnitLaser scan, battery limits
cross section extraction Saras (Sarroch)4200 30 Spanu U.
Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person
2010
Topping 1 UnitLaser scan, battery limits
cross section extraction Saras (Sarroch) 4200 30 Spanu U.
Main Stack
Laser scan, dimensional
check for elevator
installation Saras (Sarroch)
400 80 Aymerich S.
Z3 UnitLaser scan, stack vibrations
monitoring Saras (Sarroch)- 130 Cozza R.
2011
Topping 2 Unit
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
9000 40 Corvetto F.
CCR Unit
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
9000 40 Corvetto F.
CCR Unit
Laser scan, 3D model,
design of overhead
travelling crane
modifications
Saras (Sarroch) 2000 25 Cotza M.
Centro Olio Val d'Agri
Laser scan, 3D model,
virtual as-built survey on
P&IDs Saipem (Viggiano)
62500 15 Sirignano A.
Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person
2012
Alcoa
Laser scan, dimensional
checks
Alcoa Trasformazioni s.r.l.
(Portovesme)2500 15 G. Meloni
RT2 Unit
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
3000 30 Cocco W.
Vacuum 1 Unit
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
4500 45 Cocco W.
2013
SG10 Area
Laser scan, 3D model,
isometric and piping
layout extraction Isab (Priolo)
45000 10 Giuliano G.
CR27 -FCC UnitLaser scan, dimensional
check Isab (Priolo)400 40 Giuliano G.
LPG Storage Plant (LPG
spheres and bullets)
Laser scan, 3D model,
isometric extraction virtual
as-built survey on P&IDs Saras (Sarroch)
28000 15 Di Monte D.
Products StorageTanks
Laser scan, 3D model,
isometric extraction virtual
as-built survey on P&IDs Saras (Sarroch)
200000 15 Di Monte D.
FCC unit/Expander
Laser scan, .LFD dataset
generation (LFM Server)
Saras/Foster Wheeler
Italiana (Sarroch)
10000 30 Stefanini L.
FCC unit
Laser scan, .LFD dataset
generation (LFM Server)
Foster Wheeler Italiana
(Ploiesti, Romania)45000 65 De Angeli P.
Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person
FCC unit
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
15000 60 Garau L.
Topping 1
Laser scan, 3D model,
isometric extraction for
piping replacement Saras (Sarroch)
12000 50 Vargiu M.
MHC UnitLaser scan, 3D model,
clash check Saras/IDI (Sarroch)500 15 Pagani W.
2014
Biogen Idec PlantLaser scan, .LFD dataset
generation (LFM Server)Foster Wheeler Italiana
(Hillerod, Denmark)
50000 5 Mencarelli A.
Furnace Exhaust Duct
Laser scan, Dimension
Check
Topping Units, Sarlux
/Kirchner, (Sarroch)- 20 Donzelli C.
RFID-BasedPlant Data Collection&Management Systems
Blind Flanges Management
SmartPlant P&ID Mobile
Inspections&Maintenance
RFID-BasedPlant Data Collection&Management Systems
Software Requirements
All the applications will be used in petrochemical plants duringconstruction, operation and maintenance, they must therefore comply with the following
requirements:
1) It must be possible to install the applications on mobile devices2) It must be possible to use the applications in explosion risk areas3) Items identification must be univocal4) It must be possible to write information on the RFID tags5) Applications must be interfaceable with other DB-based applications6) It must be possible to access data from Intranet/Internet
RFID-BasedPlant Data Collection&Management Systems
Chosen Technology
Development Environment: Microsoft .NET Compact Framework
Palm Sized PC (PPC) characteristics :
Operating System: Windows Mobile RFID Scanner: 125 kHz ATEX Certification
RFID-BasedPlant Data Collection&Management Systems
RFID TAG characteristics (Other TAG types can be used on Customer’s request):
Operating Frequency: 125 kHz Chip: HITAG S 2048 (read/write) ATEX Certification Easily identifiable (yellow colour)
Low operating frequency and RFID scanner’s characteristics require physical contact between RFIDscanner and tag in order to complete any operation:It is therefore impossible either to operate on the wrong tag or to record wrong information.
About 2000 blind flanges are involved in the shutdown of a medium-sized plant. Flanges are inserted and then removed in about 40 days.
This process must be correctly managed and controlled, in order to ensure high safety levelsand avoid problems that could lead to unwanted accidents and/or delays.
It is therefore necessary:
To verify the status (inserted/removed) of every blind flange.
To verify the status of every interference blind flange (common to several blinding plans)
To verify the completion status of every blinding plan
To easily identify any potential problem
Blind Flanges Management
Blind Flanges Management
Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of eachequipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
Blind Flanges Management
Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of eachequipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
Blind Flanges Management
Blind flanges positions are identified with a univocal code on the P&ID and on the blinding plan of eachequipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
Blind Flanges Management
Information concerning blinding plans and blind flanges positions are loaded into the DataBase (in this case: Intergraph AIM-Directa): Relations are created between objects.
Database is synchronized daily with data from the field.
Blind Flanges Management
Properties shown in the figure are associated to every blind flange (fully customizable on request)
Blind Flanges Management
For every blind flange position, an RFID tag is initialized with the blind identification code and initial status: initial status is set to “To be identified”, meaning the blind flange position has to be identified on the field.
Initialized tags are then mounted on a metallic support which is then placed in the correspondent blindflange position.
User registers, with the PPC, the correct placement : status is set to “Identified”
During the shutdown operations, users , using the PPC, register insertion/removal of blind flanges: Status is set to “Inserted”/”Removed”
Removal of interference blinds can be registered on the system only when all the operations concerning the blinding plans on which the interference blind flange appears have been completed. Users are constantlyreminded that they are working on interference blind flanges.
Blind Flanges Management
Application login (using an RFID tag) Main Menu
Blind Flanges Management
Blinding plans list Blinding plan: checking general status
Blind Flanges Management
RFID Tag Reading Setting status to “Identified”
Blind Flanges Management
Setting Status to “Inserted” Setting Status to “Removed”
Blind Flanges Management
Interference Blind Flanges: setting status to “Inserted” and registering start of activities
Blind Flanges Management
Data from the field is synchronized daily (or at every shift change) with the main DB: users can accessinformation via the document management system (in this case: Intergraph AIM/Directa)
Icons are coloured according to the blind status.
SmartPlant P&ID Mobile
SmartPlant P&ID Mobile has been developed to allow plant operators, construction and maintenance personnel, to access, view and modify SmartPlant P&ID information using a Palm Sized PC (PPC) Using RFID tags to identify equipments, instruments, piperuns, piping components, etc. queries on the system are automatically performed.
SmartPlant P&ID Mobile
SmartPlant P&ID mobile manages the followingSmartPlant P&ID objects:
EquipmentsEquipment ComponentsInstrumentsInstrument LoopsNozzlesPiperunsPiping Components
Graphic P&ID can be visualized on the PPC:an intelligent zoom is performed on theselected object (not working, in this version, on piperuns)
SmartPlant P&ID Mobile
A desktop application uses “Llama” libraries (Logical Model Automation) and SmartSketchlibraries to connect to SPPID database and performs the following operations:
Reads properties values of the various objectsGenerates a mobile DB, which is transferred on the PPCConverts graphic P&IDs from .pid to .dwg formatWhen properties are modified on the PPC, updates SmartPlant P&ID’s DB
SmartPlant P&ID Mobile
Unit Selection Queries can be performed manually or using an RFID TAG
SmartPlant P&ID Mobile
Query Results Object visualizaton on the P&ID
SmartPlant P&ID Mobile
Properties are categorized like on SPPID Modification of a property on a piperun
SmartPlant P&ID Mobile
Adding appropriate values of “Construction Status” allows a simple work progress monitoring: In the above figure, piperuns with hydrotest completed are highlighted in blue (data registered with PPC). Every construction status can be traced from prefabrication to “Ready for Start-Up”
Inspections&Maintenance
Data from DB
Item Name
Item Picture from DB
Physical contact between RFID scanner and RFID TAG ensures positive identification of the item: itemdata, work orders, inspection check-lists are shown on the handeld device screen.
Inspections&Maintenance
Work Orders Management: Work Orders for the item are shown on the handheld device and managedon the field by maintenance operators.
Inspections&Maintenance
ASSET DATA VISUALIZATION
Inspections&Maintenance
ASSET DOCUMENTATION VISUALIZATION
Benefit of RFID-Based Plant Data Management Systems
Process management improvement Process monitoring is easier with consistent, verified data Problems are easily identified and managed Identification errors are not possible
Easy and fast transition to the new system Applications are designed to be as similar as possibile to the traditional working procedures (applications are fully customizable according to the Customer’s specifications Training time for a low-skilled user: 2 hours.
We started our engineering&design activities in 2001 with participation ina working group of international caliber in the petrochemical industry. Theaim was to optimize the management of physical and virtual warehousestocks. This project was to be applied to Petrochemical and Refining plants(standard materials coding, supplier agreements, purchase requisitions,automatic generation of purchase orders) with the goal of achieving asignificant reduction in operating costs.
Engineering&Design
Since 2002 we developed additional skills and we can now provide the following services:
Updating and management of piping material catalogs (according to ENI standards)
Design of piping material classes
Modification/updating of existing piping material classes (ASME/EN) forevery kind of material (carbon steel, low-alloy steel, stainless steel, duplex, monel etc.) and for every rating.
Design of pressure vessels and pressure systems in compliance withPED directive.
Engineering activities for the purchase of spare parts in compliance with D.M. 329/04 and subsequent circulars.
Engineering&Design
We can manage every stage of the project:
◦ Material requisitions
◦ Technical analysis of tenders
◦ Supplier follow-up
◦ Technical documentation review
◦ Pre-commissioning
Engineering&Design
Engineering&Design
Design of PED equipment (ASME/EN) including spherical tanks, hortontanks, fixed and floating roof tanks (API 650, API 620, API 653).
Other Activities
Engineering&Design
Fitness for service analysis - API 579
Design of repair systems (armouring) and evaluation of hot tappingsolutions for piping and equipment (API 2201, API 570, ASME PCC-2)
Finite elements analysis of pressure systems and structures
Design of piping material classes in compliance with ASME B31.3 / B31.1/ EN13480
Manufacturer of pressure equipment (in compliance with PED)
Commissioning reports for pressure systems in compliance with DM329
Inspection and testing of piping and pressure equipment.
Engineering&Design
Stress analysis (ASME B31.3)
Engineering&Design
Verification of mechanical stability for pressure equipment and structures.
Software
Puma5
www.italteleco.it