D2M Solutions is Unique

IN THE MIDDLE EAST REGION IN OFFERING END-TO-END DESIGN TO MANUFACTURING SOLUTIONS

INTRODUCTION

ENERGY, PROCESS/UTILITIES, OIL&GAS
D2M Solutions can offer solutions for the rapid and efficient design and manufacture of plant, equipment, and parts and components to the Oil & Gas sector. PLM (Product Lifecycle Management) systems are the only technology to manage all the data related to plant construction, the operations, maintenance and processes and provide enterprise wide and partner collaboration. Dassault Systemes has developed advanced PLM solutions to cope with the specific needs of the Oil, Gas and Energy sectors; whether companies are involved with EPC, plant owners and operators, equipment and services suppliers and MRO companies for oilfield and offshore.
On-time construction and efficiency in operations are standard requirements in the Oil and Gas sectors, whereby delays, down-times and errors can prove costly and create financial and other exposure to risk. Companies are under particular pressure to take into account environmental factors, compliancy with health and safety and industry standards, maintain 24/7 operations, and effectively manage their operations. The complexity of plant and offshore installations creates huge amounts of data, processes and people that have to be managed in order to achieve the abovementioned goals. The best way to deal with the vast requirements is to utilize the power of PLM systems under one integrated platform which provides unprecedented access to the enterprise real time data for informed business decisions. Leading companies in this sector such as Technip, Alstom Power, Preem Petroleum AB, ITER and Hydro-Quebec are using Dassault Systemes world-class PLM enterprise solutions for their successful operation.
oilandgas

The role of 3D scanning in Plant planning, redesign, reconstruction and maintenance.

Z+F 3D laser scanners can be used to very rapidly survey existing plant in accurate 3D detail. The survey data can then be used to effectively create plant extensions, new building constructions, reconstruction / redesign and retrofits. Spatial coordinates are accurate to a millimetre, from which 2D construction plans can be drawn with confidence. Complete CAD models can be generated from the 3D scan data of the factory or plant. There is no other means of obtaining such accurate information related to the plant and therefore 3D scanning can provide essential data when any new alterations to existing plant have to be made. It is also valuable when maintenance teams need to plan access to areas for in situ repair work, and when plant is relocated and rebuilt. Additionally one of the main concerns of contractors involved in plant modifications is clashes and collisions with existing parts and machinery, which can be eliminated when the 3D plant data is already available. Companies in the Oil and Gas sectors can create an updated 3D data base that will serve them for future requirements of reconstruction, maintenance and decommissioning.

The potential cost reductions using 3D scanning for new building and modification work are so significant in this sector due to the complexity of plant, high values and expense related to down-time, that it is becoming a vital part of the product development process.

Virtual reality and 3D visualization for oil & gas sectors

A virtual reality environment and 3D visualization of plant can be used for improved understanding of plant at all stages of design, construction, assembly and maintenance. It can be especially useful in developing maintenance and training manuals whereby complex plant and equipment are involved and each installation has its unique layout. Health and safety requirements can be applied with safety procedures easily explained in a 3D virtual life-like environment.

Rapid production of oilfield parts components and equipment

In addition to implementing PLM for successful product development and product lifecycle management, companies can now use a range of advanced technologies for rapid and accurate production of parts and equipment. 3D scanning can be used to Reverse Engineer (rapidly capture the geometry of parts or their housings), to obtain a CAD file that can be used for new product development. 3D scanning is particularly useful when original CAD data is not available and parts are required quickly. The 3D scan data can be used for further processing to create a rapid prototype part. The part can be used in two ways, firstly directly as a master model for sandcasting of metal parts. Secondly with vacuum casting the rapid prototype model is used to produce a silicon mold. The silicon mold creates a wax master model to be used in rapid production of investment casting shells. This patented technology can rapidly produce metal parts in hours instead of days and can be a very cost effective way to produce customized and low volume metal parts.

Solutions for: Oil and Gas plant construction and operation, Offshore platforms, EPC, MRO, Maintenance, Plant relocation, modification, equipment and industrial machinery, spare parts and components

CUSTOM SOLUTIONS

ON DEMAND SPARE PARTS - ENERGY, PROCESS/UTILITIES, OIL&GAS
THE NEEDS OF THE INDUSTRY

The EPU (Energy, Process and Utility) industry faces the difficult challenge of maintaining production facilities and assets so as to minimize downtime to the bare minimum. The factors that can affect the downtime can be summarized below:

  • Long lead time for certain parts, leading to the need to stock components to satisfy long term demand.
  • Obsolete components, which can either, be impossible, or very costly/difficult to source, sometimes leading to the decommissioning of an asset.
  • Inability of local manufacturing industry to reproduce parts to the necessary standards, or at the necessary speed to satisfy demand.
  • Lack of digital data for components, leading to the inability to produce locally, or errors during the reverse engineering stage, which can lead to parts which are not fit for purpose.

THE SOLUTION

Parallel Kinematics CNC machining

Parallel Kinematics machining is a combination of capabilities of high end robotics and multi axis machining, which results in an extremely fast system that can be used to do all the finishing on the casted parts.


CAD/CAM/CAE and PLM Solution

By using the latest 3D design and simulation tools, designers can reduce the time needed to redesign components and deliver larger volumes of work in a more effective way. At the same time, all the IP that is created during the designing or digitization of parts is saved in the PLM layer in an organized fashion for reuse whenever required.

The PLM platform shall also be used to manage projects and the people involved in these projects through the extensive capabilities of the platform. By connecting the design capabilities to all other aspects of the organization, errors and problems can be identified sooner and changed earlier leading to plenty of optimizations and cost reductions.


CT Scanning for reverse engineering and quality control

CT Scanners have the added benefit of being able to scan “hidden” features of components, since the x-rays penetrate the entire part. Quality control on the castings can also be performed to make sure that no air bubbles or cracks are present in the final part.


Rapid Investment Casting

Investment casting can be used to produce castings which require better accuracy than sand casting. Complete lines can be set up which are capable of producing low volume runs of parts, allowing end users stock only the number of parts they require.


3D printing of complex sand cores

3D printed sand cores can drastically reduce the time needed to produce a fully functional sand mold for the casting of metals. By using this method of additive manufacturing, extremely complex designs can be produced effortlessly. The cores can be delivered to the foundries for casting on a just-in-time basis, reducing the need for keeping large numbers of stock components.


3D printing of components for low volume manufacturing of plastic parts or test parts.

3D printing in the EPU industry can be used for either printing low volume end-use plastic components, or it can be used to produce test parts for validation, before an investment is made in permanent tooling or metal components. Production systems can also be used to produce a variety of manufacturing tools (such as sheet metal tooling) to allow the end user to produce a further amount of parts by using the 3D printed tooling, adding to the capabilities of local manufacturing.


3D Scanner for the quick acquisition of the 3D geometry of parts.

By utilizing the latest in handheld 3D scanning technology, ground crews can quickly and easily capture the complete geometry of interior components. This can later be sent to engineering departments for modeling in CAD software, alterations or developments of the original design.


THE BENEFITS OF THE SOLUTION

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