Digital Transformation in Engineering: Integration of AVEVA Unified Engineering and AI for Multidisciplinary Projects
In this study, we explore how AVEVA Unified Engineering, combined with Artificial Intelligence, optimizes processes, reduces errors and automates decisions. From integrated use of 3D modeling, diagrams and engineering data to AI innovation for pipe support prediction, this project shows how technology is redefining efficiency in industry.
WHY AP CHOSE THE UNIFIED ENGINEERING SOLUTION:
AP decided to innovate by using the Unified Engineering environment with the AVEVA CONNECT environment to meet the needs of:
o Reduction in investment in powerful hardware and servers
o Availability of 24-hour technical support, ensuring operational continuity
o Ease of sharing information between the team and customers
o Secure environment for storing and accessing project data
o Use of 2D and 3D software within an online environment and always updated
o Remote Access and Efficient collaboration, reducing geographic and operational barriers
o Less dependence on IT
ADVANTAGES OF USING THE SOLUTION:
PCM ONLINE:
o 3D modeling on the point cloud in AVEVA E3D in the CONNECT environment with Solid Point Cloud and Hyperbubble resources.
o 53% Time Saved when converting E57 files using PCM Online compared to PCM Local
o With data stored in the cloud, team members can access and share information regardless of their location. This facilitates collaboration and quick decision-making.
o Cost reduction of approximately 56% in hardware for customers who access the 3D point cloud via the WEB without the need for powerful hardware, which increases transparency and trust in AP's work.
o Clients can view project progress in real time, monitoring work remotely and ensuring deadlines and specifications are met.
o Security of access to point cloud information via user login and password.
E3D IN THE CONNECT ENVIRONMENT:
o Reduction of approximately 34% in hardware costs due to system processing on servers, without the need for powerful computers for modeling and remote access licenses for employees.
o Use of online server space, with security and 24H technical support.
o Reduction of approximately 12% in rework due to power outages or loss of access to the server.
o Automatic and intelligent synchronization of information between disciplines, ensuring that all areas of the project work with integrated and updated data.
USING AVEVA SIMULATOR IN THE CONNECT ENVIRONMENT:
o Integration of simulator process information with AVEVA project automation tools.
o Gain of approximately 60% in time to prepare project documentation, in addition to reliability in reproducing information
o Reduction of approximately 20% in document correction rework activities.
o With data stored in the cloud, team members can access and share information regardless of their location. This facilitates collaboration and quick decision-making.
Integration and AVEVA Diagrams and AVEVA Engineering in AVEVA Unified Engineering
Using AVEVA Diagrams and AVEVA Engineering, all information generated in the initial phases of the project is reflected in the following stages, avoiding errors, rework and inconsistent decisions. Any attempted incorrect connection or conflict between disciplines is automatically identified, preventing incorrect modeling and ensuring that the project follows defined standards.
• Automatic and Intelligent Synchronization
o Guarantee that all disciplines [process, foreign, electrical, instrumentation and automation] work with integrated and updated data.
o Information generated in the initial phases of the project is automatically reflected in the following stages.
• Error Prevention and Rework
o Connections between equipment and piping can only be made in accordance with defined specifications.
o The system alerts and prevents incorrect modeling, ensuring compliance with project standards.
• Project information panel with 1D, 2D and 3D elements to facilitate project communication and visualization.
WORKFLOW UNIFIELD ENGINEERING
INTEGRATION OF ARTIFICIAL INTELLIGENCE [AI] INTO AVEVA UNIFIED ENGINEERING FOR OPTIMIZATION OF PIPE SUPPORTS
The application of Artificial Intelligence [AI] and Machine Learning in the AVEVA Unified Engineering environment brings new possibilities for multidisciplinary engineering, especially in the analysis, positioning and selection of pipe supports.
The goal is to automate and optimize the definition of piping supports within AVEVA E3D, using machine learning to predict the ideal quantity, location and type of support based on technical and historical parameters from previous projects. This innovation will be integrated into AVEVA E3D's MDS [Mechanical Design System] module, enabling a smarter and more efficient workflow.
WORKFLOW IA SUPPORTS
ADVANTAGES OF USING THE SOLUTION:
o Reduced Modeling Time: AI eliminates the need for manual calculations and repetitive adjustments, significantly speeding up the design process by 20%.
o Greater Accuracy and Quality in Support Positioning: The use of machine learning ensures that support decisions are based on historical data and technical parameters, minimizing errors and rework.
o Cost and Material Reduction: Optimization of the number of supports used, avoiding both undersizing and unnecessary excess of supports.
o Improved Multidisciplinary Integration: Data generated by the AI model can be shared between piping, process and structural engineering teams, ensuring everyone works with consistent information.
o Automation and Efficiency: The process becomes more intelligent and autonomous, allowing the engineering team to focus on higher value-added tasks.
CASE STUDY – PROJECT INFORMATION
NEW AMAZONAS OUTLET POINT
AP Consultoria e Projetos is executing the new basic multidisciplinary project of a new gas outlet point in the Amazonas region, with the purpose of meeting two gas supply demands. The project, which already involves more than 1,200 engineering hours, aims to implement the new project to serve the new local thermoelectric plant, with a capacity of 825,000 m³/d and to meet the operational flexibility project of the local gas company, with a service capacity of 2,375,000 m³/d, to be consumed in contingency situations in Aparecida/AM.
The project began on 12/13/2023 and has a deadline of 7 months for completion, with a total of 226 documents issued.
This outlet point will have the purpose of filtering, heating, regulating pressure, measuring the flow of natural gas and limiting the flow, to be supplied to the Customer.
SCOPE OF SERVICE:
PROCESS:
§ FILTERING SYSTEM:
The filtration system will consist of 2 [two] sections sized for 100% of the maximum flow, with one section in operation and the other as reserve.
Main components of each section:
o 1 [one] cyclone filter and a cartridge filter combined in a single, vertical equipment, with quick-open closure and removal efficiency of 99.98% for 5 μm [β = 5000];
o 1 [one] differential pressure transmitter for alarm in case of high differential pressure;
o 2 [two] block valves with remote activation, XV-02A/B, at the inlet and 2 [two] manual block valves, ball type, at the outlet, for section isolation, VES-02A/B.
§ HEATING SYSTEM:
The heating system will consist of 2 [two] independent sections operating simultaneously, sized for 100% of the maximum flow.
Main components of each section:
o 2 [two] heaters [indirect liquid bath type - water in the hull and gas in the coil], each sized for 50% of the thermal capacity required by the system and 100% of the maximum flow required for the delivery point;
o 1 [one] three-way control valve [TV], divergent type, for each heating branch, controlled by a single pneumatic temperature controller [TIC], operating with natural gas, installed at the delivery point outlet;
o 1 [one] automatic gas intake blocking valve for the burner with local reset in case of interlock action in each branch;
o 2 [two] blocking valves with remote actuation at the input [XV-03A/B] and 2 [two] manual blocking valves at the output [VES-03A/B];
§ ADJUSTMENT AND PRESSURE SYSTEM:
The regulation system will consist of 4 [four] independent sections, grouped two by two: 2 for low-flow regulation at 3” and 2 for high-flow regulation at 10”, with one reserve in each section.
Main components of each section:
1 [one] shut-off valve with automatic closing by high pressure;
2 [two] pressure regulating valves, one operating as active [PV, control valve] and the other operating as monitor [PCV, self-operated valve];
1 digital controller [via PLC – preferred] and 1 pneumatic controller [in case of failure] for the PVs;
1 [one] pressure relief valve to prevent the automatic blocking valves from closing in the event of overpressure resulting from leaks in the regulating valves, when the section flow is zero.
1 [one] check valve at the outlet, upstream of the manual blocking valve.
2 [two] manual block valves, ball type, one at the inlet and one at the outlet, to isolate the section, the one at the inlet must be remotely actuated.
§ MEASUREMENT AND FLOW SYSTEM
The High Flow Measurement System will consist of 2 [two] independent 10” sections, sized for 100% of the maximum flow [170 to 3,200 10³m³/d], with one section in operation and the other as reserve.
The Low Flow Measurement System will be composed of 2 [two] independent 3” sections, sized for 100% of the minimum flow range [18.5 to 185 10³m³/d], with one section in operation and the other as reserve. This skid is intended only for the plant start-up scenario.
Main components of each section:
o 1 [one] primary measuring element [orifice plate type meter in low flow sections and ultrasonic type meter in high flow sections];
o 1 [one] flow computer [to calculate the corrected flow depending on pressure, temperature and compressibility factor], to be installed in the panel shelter;
o 2 [two] manual block valves, ball type, one at the inlet [VES-08A/B] and one at the outlet [VES-09A/B], to isolate the section, in the case of the high-flow skid;
o 2 [two] manual block valves, ball type, one at the inlet [VES-10A/B] and one at the outlet [VES-11A/B], to isolate the section, in the case of low flow skid;
o Orifice plate type meters with straight sections and unidirectional flow.
ELECTRICAL:
§ Execution of the Shelter equipment and grounding arrangement project
§ SPDA Project
§ Carrying out a lighting technical study in the new PS
INSTRUMENTATION/ AUTOMATION:
§ Specification of all instrumentation and valves
§ Flow computer
§ Chromatograph
§ PLC [Programmable Logic Controller] Specification
Process automation involves PLC [Programmable Logic Controller] equipment with all its solutions/configurations, meeting all Automation and Cybersecurity standards and requirements
Through the PLC, all PS field instrumentation [including control, command and monitoring] are supervised by the local SCADA CONTROL CENTER.
§ Telecom system
o The Telecom system includes the installation of two VSAT antennas that work redundantly to guarantee data acquisition.
MECHANICS:
§ Modular Skids
o Reduction of field assembly labor;
o Carrying out tests before Boarding;
o Changes within a controlled environment;
o Shipping with all hydraulics, electrical and instruments ready, only for connection in the field;
o Dimensions for Transport;
o Early possibility for Lay-out study;
CIVIL:
§ Carrying out topography services, studying the natural or artificial characteristics present on the surface of a location.
§ Survey: Geotechnical investigation, with the purpose of evaluating the presence of water in the subsoil and the resistance of the soil, among other geological and geotechnical characteristics of the site.
§ Adequacy of the existing Shelter
§ Paving, drainage and earthworks plan
3D SCANNING:
§ Capture the reality of the Existing ERP, ensuring the interconnection of the new Exit Point facilities to the point cloud.
§ Possibility of querying the point cloud via PCM in Connect
SMS:
§ Support with a security technician to monitor the execution of topography and surveying activities
CONCLUSION:
The case study clearly shows how using AVEVA CONNECT and Unified Engineering delivered cost savings, increased efficiency and improved collaboration in the design of the new gas outlet in Amazonas. The use of 3D modeling, process simulation and integration with automation ensured greater reliability and agility in execution.
The integration of AVEVA Unified Engineering with Artificial Intelligence marks a significant advancement in multidisciplinary engineering, bringing greater efficiency, precision and automation to industrial projects. The connected approach between diagrams, 3D modeling and engineering data reduced errors, optimized collaboration between teams and ensured consistency at all stages of the project.
Additionally, implementing AI for pipe support prediction demonstrated how the use of machine learning can transform processes, reducing modeling time and ensuring smarter, more reliable design. With this innovation, the engineering sector is moving closer and closer to an automated, integrated and data-driven approach, where decisions are based on predictive analysis and not just manual experience.
This project not only validates the effectiveness of these technologies, but also paves the way for new applications of AI and AVEVA Unified Engineering in engineering.