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Comprehensive 3D Digital Design Solution Saves RMB 158 Million on Alumina Refinery Project

Comprehensive 3D Digital Design Solution Saves RMB 158 Million on Alumina Refinery Project
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Comprehensive 3D Digital Design Solution Saves RMB 158 Million on Alumina Refinery Project - 1

CASE STUDY Advancing Infrastructure ill lint? Project Summary Organization: Shenyang Aluminum and Magnesium Engineering & Research Institute Co., Ltd. Solution: Manufacturing Location: Bukit Batu, West Kalimantan, Indonesia Project Objectives: • Establish a collaborative digital design platform to develop an aluminum refinery in Indonesia. • Optimize the design scheme through intelligent modeling and standardized digital workflows. • Extend the application of 2D and 3D digital models for lifecycle management in the aluminum industry. Project Playbook: OpenBuildings Designer, AutoPIPE®, Bentley Raceway and Cable Management, Bentley Substation, LumenRT, MicroStation®, Navigator, OpenPlant, OpenRoads, ProjectWise® Comprehensive 3D Digital Design Solution Saves RMB 158 Million on Alumina Refinery Project Using Bentley BIM Technology Reduces Resource Hours and Facilitates Accessibility to Digital Models for Lifecycle Management Fast Facts • SAMI used Bentley technology to establish China' s first industry-specific, 3D digital design platform. • The team used OpenPlant applications to create specific coding specifications and perform collaborative plant engineering. • ProjectWise optimized efficiency by managing more than 30,000 documents and 1,000 directories. ROI • Bentley's integrated applications enabled 3D intelligent modeling among 120 staff members, saving more than 5,000 resource hours. • OpenPlant increased drawing and report accuracy by 2 percent. • Bentley software facilitated the development of mobile applications, providing access to digital models for complete lifecycle management. Committed to Digitalizing Design Processes As part of China's One Belt, One Road initiative, the country's largest primary aluminum producer, Aluminum Corporation of China, entered into a joint venture with two Indonesian firms to deliver Indonesia's first smelter-grade alumina plant. Located in West Kalimantan, the plant has an annual production capability of 1 million tons. The facility spans approximately 136 acres and includes aluminum, thermal power, gas house, and water treatment zones, with 68 independent workshops in the whole factory. Shenyang Aluminum and Magnesium Engineering & Research Institute (SAMI) was retained to provide engineering consulting and 3D digital design services for the RMB 4.3 billion aluminum manufacturing project. As its largest overseas engineering project, SAMI faced numerous management and design coordination challenges. With more than 30,000 documents and a 120-person staff among more than 15 departments, the company needed to reconstruct its design workflows and create a digital engineering database and process management system to optimize the design scheme. "Because SAMI has many different departments that need to work together, we need many different software applications," stated Fangbo Liu, director of digital engineering project operations (BIM) center. The organization committed to Bentleys integrated 3D BIM technology solution to streamline and digitalize workflows and deliver a multidiscipline, full-site digital information model accessible to the client and all stakeholders. a wide range of equipment, devices, and design workflows. Integrating OpenBuildings™ Designer (formerly AECOsim Building Designer) facilitated efficient 3D design coordination among the multiple engineering disciplines to optimize modeling processes. More specifically, SAMI established more than 5 million engineering datasets and defined standard coding rules using OpenPlant Modeler. OpenPlant PID provided the intelligent platform and unique operation interface to manage piping and instrumentation diagrams, 3D models, and drawing standards for accurate reporting, minimizing rework during construction. The interoperability of Bentley's OpenPlant applications with ProjectWise ensured all standards were highly integrated to accelerate information mobility and optimize design reviews and project team coordination. Working in a connected data environment with Bentley's BIM technology, SAMI developed a unique engineering database and 3D collaborative design management system to efficiently manage multidiscipline design and build a precise 3D digital information model. Interoperability Drives ROI and Innovation Using Bentley's integrated 2D/3D technology within a connected data environment, design workflows were streamlined and efficiency improved, saving SAMI more than 5,000 resource hours compared to traditional, manual design methods. OpenPlant's intelligent P&ID modeling features optimized design, reducing total project investment costs by 1.8 percent to save RMB 78 million. The interoperable applications enabled SAMI to create digital models and Establishing a Collaborative Digital Management Platform With no industry-specific systemic digital precedent in China, SAMI needed to establish a digital design platform, including an engineering database and new standard coding, for the aluminum industry. The company built a project management database using ProjectWise, standardizing document identification and organization, establishing more than 1,000 work catalogs, and facilitating collaboration through real-time accessibility to all participating staff. The company configured OpenPlant™ to develop industry-exclusive specifications for generate more than 1,000 drawings and more than 500 reports. Drawing and report accuracy also improved by 2 percent using digital processes, saving approximately RMB 80 million in rework costs. Integrating reality modeling with LumenRT and MicroStation to create animated visualizations optimized the design process and enhanced stakeholder understanding of the design scheme. This transparency resulted in a more compact layout of the entire site, reducing civil engineering costs. The comprehensive, integrated modeling capabilities of Bentley applications allowed SAMI to verify all aspects of the

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