Italteleco Laser Scanning Engineering RFID Applications

 Italteleco was founded in 1986, as a Software House specialized
in industrial software solutions.
 Since 1995 our core business is to provide integrated solutions
for large-scale companies.
 Since 2003 we are Business Partners of
Intergraph PP&M, the leading company in enterprise
engineering software for the design, construction, and
operation of plants, ships, and offshore facilities.
Our History

We firmly believe in continuous learning to develop the skills and
knowledge of our personnel and in the application of new
technologies as a tool to improve the processes in which we are
involved.
Our Mission

 Existing documentation often unreliable and inconsistent with real field
situation.
 Critical points:
 Design based on unreliable data.
 Additional EPC costs.

Leica HDS6100
Range: 79 m.
Speed: 508.000 pt/s
Leica ScanStation C10
Range: 300 m.
Speed: 50.000 pt/s
Z+F Imager 5010
Range: 187.3 m.
Speed: 1.016.000 pt/s

 Field Survey
 Creation of a topographic control
network,
 Placement of the targets (at least 4
visible from each scan)
 Execution of the scanning from the
selected scanning positions.
 Acquisition of the targets coordinates
with a total station.

 Field Survey
 Single scans are executed from
different positions so that all the
volume of interest is covered. Targets
on each scan allow for precise point
cloud registration (roto translation to a
common coordinate system.)

 Registration
 Single scans are registered according to the coordinates of the targets on
each scan, surveyed with a total station: the final result is a point cloud
representing 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 according
to applicable piping classes.

 Clash check allows for a precise identification of clashes between new
piping/equipment/structures (3D model) and existing plant (point cloud)
 Issue of “Clash Check Isometrics” helps piping specialists to quickly identify and
solve every single clash.

Engineering
•Reliable as-built
documentation
•Accurate measurements
•Clash check
•Faster & Safer survey
•Constructability
Maintenance
•Minimize shut-down time
with accurate piping
substitution isometrics,
critical lift simulations
•Identify in advance the best
construction sequences
Operations
•Use 3D models for safe
operators training
•Integrate intelligent 3D
model with RFID
technology for positive item
identification, intelligent
inspection&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-down
Time/Construction
Time
• Shut-Down times are minimized
using accurate and reliable
documentation, critical lift
simulations: no additional shut-
down time costs, no additional
adjustment costs.
• Construction time are
minimized using clash check
tools, interactive 3D models
construction sequence
simulations

Date/Plant Description Customer/Plant Area [m2] Elevation [m] Contact Person
2007
FCC - Regenerator - Phase
1
Laser scan, various
interference check tests
Saras (Sarroch) 4000 50 Della Vedova R.
V1 Vacuum Plant
Laser scan, 3D model and
critical lift simulation
Saras (Sarroch) 3600 30 Cotza M.
RT1-RT2 Plant
critical lift simulation
GPL Unit
Laser scan, 3D model,
piping layouts extraction
Saras (Sarroch) 2700 10 Cadeddu M.
IGCC Unit
Laser scan, dimensional
checks
Sarlux (Sarroch) 4400 40 Puddu D.
Alkylation Unit
Laser scan, plot plan
extraction

2008
FCC Unit
Laser scan, shutdown
critical lifts simulation
Alkylation Unit
Laser scan, 3D
model,piping layouts
extraction
2009
Mild Hydrocracking Unit
Laser scan, reactor lifting
simulation
Saras (Sarroch) 13000 40 Caredda R.
FCC Unit
check nozzle K1R2-K1E58
Biomass Power Plant
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 Plant
existing structures
Sicet (Ospitale di Cadore) 18000 20 Vascellari M.
U400 Desolphoration Unit
isometric extraction for
piping replacement Saras (Sarroch)
2400 40 Pili A.
CCR Unit
checks on CCRD19 Saras (Sarroch)
9000 40 Cotza M.
Visbreaking Unit
Laser scan, battery limits
cross section extraction Saras (Sarroch)
4200 30 Spanu U.

2010
Topping 1 Unit
Laser scan, battery limits
cross section extraction Saras (Sarroch)
4200 30 Spanu U.
Main Stack
check for elevator
installation Saras (Sarroch)
400 80 Aymerich S.
Z3 Unit
Laser scan, stack vibrations
monitoring Saras (Sarroch)
- 130 Cozza R.
2011
Topping 2 Unit
9000 40 Corvetto F.
CCR Unit
9000 40 Corvetto F.
CCR Unit
design of overhead
travelling crane
modifications
Centro Olio Val d'Agri
virtual as-built survey on
P&IDs Saipem (Viggiano)
62500 15 Sirignano A.

2012
Alcoa
checks
Alcoa Trasformazioni s.r.l.
(Portovesme)
2500 15 G. Meloni
RT2 Unit
3000 30 Cocco W.
Vacuum 1 Unit
4500 45 Cocco W.
2013
SG10 Area
isometric and piping
layout extraction Isab (Priolo)
45000 10 Giuliano G.
CR27 -FCC Unit
check Isab (Priolo)
400 40 Giuliano G.
LPG Storage Plant (LPG
spheres and bullets)
isometric extraction virtual
as-built survey on P&IDs Saras (Sarroch)
28000 15 Di Monte D.
Products StorageTanks
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
Foster Wheeler Italiana
(Ploiesti, Romania)
45000 65 De Angeli P.

FCC unit
15000 60 Garau L.
Topping 1
12000 50 Vargiu M.
MHC Unit
clash check Saras/IDI (Sarroch)
500 15 Pagani W.
2014
Biogen Idec Plant
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-Based
Plant Data Collection&Management Systems
Blind Flanges Management
SmartPlant P&ID Mobile
Inspections&Maintenance

RFID-Based
Software Requirements
All the applications will be used in petrochemical plants during
construction, operation and maintenance, they must therefore comply with the following
requirements:
1) It must be possible to install the applications on mobile devices
2) It must be possible to use the applications in explosion risk areas
3) Items identification must be univocal
4) It must be possible to write information on the RFID tags
5) Applications must be interfaceable with other DB-based applications
6) It must be possible to access data from Intranet/Internet

RFID-Based
Chosen Technology
 Development Environment: Microsoft .NET Compact Framework
Palm Sized PC (PPC) characteristics :
 Operating System: Windows Mobile
 RFID Scanner: 125 kHz
 ATEX Certification


RFID-Based
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 RFID
scanner 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 levels
and 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 positions are identified with a univocal code on the P&ID and on the blinding plan of each
equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.

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.

Properties shown in the figure are associated to every blind flange (fully customizable on request)

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 blind
flange 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 constantly
reminded that they are working on interference blind flanges.

Application login (using an RFID tag) Main Menu

Blinding plans list Blinding plan: checking general status

RFID Tag Reading Setting status to “Identified”

Setting Status to “Inserted” Setting Status to “Removed”

Interference Blind Flanges: setting status to “Inserted” and registering start of activities

Data from the field is synchronized daily (or at every shift change) with the main DB: users can access
information via the document management system (in this case: Intergraph AIM/Directa)
Icons are coloured according to the blind status.

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 manages the following
SmartPlant P&ID objects:
Equipments
Equipment Components
Instruments
Instrument Loops
Nozzles
Piperuns
Piping Components
Graphic P&ID can be visualized on the PPC:
an intelligent zoom is performed on the
selected object (not working, in this version, on piperuns)

A desktop application uses “Llama” libraries (Logical Model Automation) and SmartSketch
libraries to connect to SPPID database and performs the following operations:
Reads properties values of the various objects
Generates a mobile DB, which is transferred on the PPC
Converts graphic P&IDs from .pid to .dwg format
When properties are modified on the PPC, updates SmartPlant P&ID’s DB

Unit Selection Queries can be performed manually or using an RFID TAG

Query Results Object visualizaton on the P&ID

Properties are categorized like on SPPID Modification of a property on a piperun

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”

Data from DB
Item Name
Item Picture from DB
Physical contact between RFID scanner and RFID TAG ensures positive identification of the item: item
data, work orders, inspection check-lists are shown on the handeld device screen.

Work Orders Management: Work Orders for the item are shown on the handheld device and managed
on the field by maintenance operators.

ASSET DATA VISUALIZATION

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 in
a working group of international caliber in the petrochemical industry. The
aim was to optimize the management of physical and virtual warehouse
stocks. 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 a
significant 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) for
every 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 with
PED 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, horton
tanks, 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 tapping
solutions 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.

Italteleco Laser Scanning Engineering RFID Applications

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