Burmeister & Wain Scandinavian Contractor A/ S ( BWSC) is one of the world's leading turnkey developers, suppliers and operators of medium- to large- scale power plants. The various types of power plants can be designed to burn a variety of fuels such as biogas, biomass, natural gas, heavy fuel oil and diesel fuels. One of the cornerstones in BWSC's success is the implementation of modular design concepts. To learn more about these concepts and the role that AVEVA Plant solutions play in BWSC's success, we visited the head office in Allerød, north of Copenhagen in Denmark. BWSC's successful modular design concept visualises power plant projects and speeds up delivery time ' BWSC is a turnkey power plant developer, supplier and operator, and delivers individual solutions tailored to our clients' needs,' says Erik Østergaard, Manager, Mechanical Department at BWSC. ' Our extensive track record, financial solidity, cultural know- how and, not least, our technical expertise have proven to be advantageous for our partners when bringing the power plant from concept to reality on time and within budget. To remain " Best in Class", we invest a lot of time in dialogue with our potential clients, which often develops into collaboration. In order for us to offer the clients exactly the required tailored solution, we listen carefully to their wishes and needs. ' For example, today our clients often demand shorter delivery times without compromising consistently high quality. To meet these requirements, we constantly have to develop ourselves, and concept development plays an essential role. One of the concepts we have implemented to speed up delivery time is our unique modular design concept. Basically, the concept consists of several " lego bricks" or modules which are put together based on PDMS 3D models. One of the advantages of the concept is that it meets the clients' expectations for shorter project delivery times,' Erik Østergaard continues. Unique modular design concept ' The complete plant is divided into smaller sections or modules. The modules are designed at our design office in Allerød. For the fabrication of the modules, we use acknowledged subcontractors all over the world. After fabrication, each specific module is tested individually before being shipped to the site for final assembly and commissioning. AVEVA Plant solutions support this concept right from the start of the project; from the creation of the first plant layout to all aspects of the layout and detailed design of the project, including layout arrangements, piping and steel work, right through to fabrication,' says Erik Østergaard. Specific project team ' A highly experienced project team is set up for every new project,' says Jane Eden Johansen, Group Manager, Layout & Piping at BWSC. ' The main project team is led by a Project Manager who has the overall responsibility for the project execution. Specialised coordinators, representing each engineering discipline within the specific project, work closely with the Project Manager as well as a group of engineers specially dedicated to the project. The team works together in one office, where PDMS enables them to control the physical project design.' Magnus Feldt Industry Marketing Manager, AVEVA ' Every power plant project is unique, but many of the components can be reused as 3D models with minor modifications, saving us considerable time and money...' From left, Jane Eden Johansen and Erik Østergaard. Page 10| AVEVA PIPELINE | 2010 Issue 2
Visualisation, synergies and reuse ' Cross- discipline reviews are continuously performed by the project team,' explains Jane Eden Johansen. ' The 3D PDMS models of the plant allow the engineers to walk through the whole plant virtually. One of the advantages is that it enables us to immediately detect potential design problems before the actual fabrication of the modules. ' 3D PDMS models are used for maintenance and equipment placing, for revamp planning, and in the training of new engineers and operators. The operation and maintenance staff can review their future workplace and verify that adequate space has been provided for maintenance procedures. Visualisation and familiarisation of the plant also lead to closer cooperation between the different departments in BWSC, which creates strong internal synergies. ' Another advantage is that several of the components are identical and can be reused for the design of a new project. Every power plant project is unique, but many of the components can be reused as 3D models with minor modifications, saving us considerable time and money,' Jane Eden Johansen continues. First project with AVEVA PDMS ' Applications from the AVEVA Plant portfolio, including PDMS, have been in use at BWSC since 2001,' says Erik Østergaard. ' The first use of PDMS was for the design of a diesel engine power plant in Panama. Since then, PDMS has been used in more than 30 BWSC power plant projects. One particularly interesting project is the Samawah power plant project in Iraq.' Significant increase in level of detail supports fabrication ' The use of PDMS has evolved since the first project,' says Jane Eden Johansen. ' The most significant advantage is that the level of details in the 3D plant model has expanded to support fast, smooth fabrication and installation. Together with PDMS, the AVEVA Multi- Discipline Supports application has made it possible to include all support details in the model. ' The high level of details facilitates the automatic extraction of production data such as isometric drawings, piping and equipment layouts, lists and reports, and Material Take Offs ( MTOs). The fabrication information is delivered to the subcontractors, making it possible to order exactly what is needed. AVEVA PIPELINE | 2010 Issue 2 | Page 11 Making the impossible possible The 60 MW Samawah power plant is a Japanese grant assistance project for the citizens of Iraq, part of the Japanese reconstruction of the country. The power plant was handed over to the client, the Iraqi Ministry of Electricity, in January 2009. BWSC has delivered design, engineering, equipment supply, transport, construction, installation, test and commissioning on a full turnkey basis. As the situation in Iraq was too risky, BWSC decided not to send the company's employees into war- torn Iraq. To solve this issue, an Inland Transportation and Security Contract was signed on 14 December 2007 to complement the original contract under a ' Remote Supervision Concept'. The scope included: . transportation of equipment, including the 320- ton engines and 250 containers, from Kuwait to Samawah, a journey of 350km, in 45 escorted convoys . provision of up to 175 security guards for round- the- clock site protection . training of 9 Iraqi engineers in the EU, Japan and the Azores . remote supervision of installation, test and commissioning. The Samawah diesel power plant was built, tested and commissioned entirely via remote supervision by BWSC in Denmark, without the presence of a single expatriate on site. The Remote Supervision Concept consists of: . establishment of a virtual site office at BWSC's head office in Denmark . establishment of a dedicated satellite connection for live audio/ video communication between the site in Iraq and the virtual site office in Denmark . establishment of live interface with the control system of the power plant . implementation of an extensive training program for Iraqi supervisors . establishment of shadow supervisors in Denmark as counterparts to the Iraqi supervisors . preparation of highly detailed installation manuals . establishment of an advanced IT system with easy access to all design documentation, mounting manuals, shipping lists, and so on . intensified quality control of all equipment sent to the site in Iraq . frequent meetings with supervisors and client representatives outside Iraq . appointment of a technically skilled Danish- Iraqi employee in Denmark. AVEVA PDMS model of the 60 MW Samawah power plant in Iraq. Image courtesy of BWSC. The 60 MW Samawah power plant in Iraq. Photograph courtesy of BWSC.