Catalogs >
Bentley Systems Europe B.V. >
Stopford Projects Uses ProSteel to Model Corrosion at Victorian-era Soda Ash Plant

Stopford Projects Uses ProSteel to Model Corrosion at Victorian-era Soda Ash Plant
2Pages

Catalog excerpts

Stopford Projects Uses ProSteel to Model Corrosion at Victorian-era Soda Ash Plant - 1

CASE STUDY Project Summary Organization: Stopford Projects Ltd. Solution: Buildings Location: Northwich, Cheshire, United Kingdom Project Objective: • Perform a structural inspection survey of Tata Chemicals’ 6,000-square-meter wet-side soda ash plant • Produce a color-coded inspection model indicating areas with no defects, minor defects, major defects, and severe defects • Deliver an intelligent 3D model for future asset management and maintenance Products used: ProSteel AutoPLANT Piping Bentley Navigator Fast Facts • A demonstration of ProSteel persuaded Tata Chemicals to choose an intelligent 3D model as the deliverable • The survey team inspected and documented approximately 5,750 individual structural elements • Stopford modeled more than 10,000 structural elements in ProSteel and 2,500 metric tons of iron pipe in AutoPLANT Piping ROI • Stopford’s bid on the Tata Chemicals project was one-third that of competitors, based on expected time savings • ProSteel’s model production speed helped Stopford to complete the project in just five months • Subsequent to the successful survey project, Stopford was awarded five follow-on projects using the intelligent 3D model Stopford Projects Uses ProSteel to Model Corrosion at Victorian-era Soda Ash Plant Leverages Century-old Pen-and-ink Drawings to Create Intelligent 3D Model of Structural Inspection Survey Results Full Structural Inspection Survey Performed Built by Brunner Mond & Company in 1873, the Winnington Works at Northwich, Cheshire, United Kingdom, was acquired in 2006 by Tata Chemicals Limited, the second largest producer of soda ash in the world. Tata Chemicals, based in Mumbai, India, commissioned Stopford Projects Ltd. to perform a full structural inspection survey of the 6,000-square-meter wet-side soda ash plant as part of an ongoing asset management and maintenance strategy. Within just five months time, Stopford delivered an intelligent 3D model created in Bentley’s ProSteel® to map corroded components throughout the plant. overall dimensions of 90 x 75 meters. The structure is comprised of a mix of 19th-century timber, early 20th-century columns, beams, and bracing, and 1950s-era steelwork. The supporting structure is now a structural steel shell clad in corrugated steel panels. Structural connections are mainly riveting, with sections riveted to form composite members. The building has remained virtually unchanged since its last major expansion in 1950. Over time, the constant wet, alkaline atmosphere has degraded the building materials. Stopford’s job was to perform the structural inspection as well as review the major equipment and pipework that impinges on the structure. The survey team had to inspect approximately 5,750 Stopford is a world-class During weekly client meetings, progress was monitored individual structural elements by reviewing the latest model using Bentley Navigator, an consultancy that provides and prepare comprehensive i-model, and progressive PDF views. multidisciplinary engineering documentation, with every design, project management, element photographed, assessed, numbered, and and construction services to both U.K. and international recorded on drawings. All secondary steelwork also had to be clients in a variety of industrial sectors. The firm started the inspected,including platforms, walkways, concrete floors, and $1.5 million Tata Chemicals project in April 2011, completed other load-bearing elements. the survey by September 2011, and was subsequently awarded follow-on remediation works. Using ProSteel, Bentley’s structural steel detailing and fabrication software, was critical to success because Stopford based its winning bid on completing the project quickly. Although Tata Chemicals did not initially specify an intelligent 3D model as the required deliverable, Stopford persuaded the client to reconsider by demonstrating ProSteel’s features – including model production speed, automatic updating, and model exporting to AutoCAD. Thousands of Components to Survey Given the go-ahead to use state-of-the-art modeling software, the survey team had to start from scratch at Winnington Works. The wet-side soda ash plant is a 10-story steel-framed building that occupies a T-shaped area with The results of the survey were to be evaluated for corrosion levels on individual components, so that Tata Chemicals could plan remediation works. From Archival Drawings to a 3D Model Stopford began building a basic model based on 671 archived drawings, including as-builts dating back to 1908. The earliest drawings reflected the British Standards of 1906. These original plans yielded enough data for 95 percent of the 3D model. The few 2D drawings of subsequent plant modifications comprised the remaining 5 percent. Also, a fairly recent model of a large vessel was incorporated. The first step was to create a custom library of obsolete steel and wood member sections in ProSteel, as well as a catalog of obsolete iron pipe standards in AutoPLANT® Piping™,

Open the catalog to page 1

Stopford Projects Uses ProSteel to Model Corrosion at Victorian-era Soda Ash Plant - 2

“Bentley software When remediation commenced, the 3D model was easily modified to reflect current as-built conditions. The color-coding facilitated prioritization of projects, with safety issues such as spurious loads, restricted access areas, and unsafe stairways getting prompt attention. provided the advantage of speed of modeling. Delivering Value for Maintenance and Safety Our price for the job was a third that of some other bidders. This was the main reason Stopford was awarded the project.” — David Coupe, piping department manager, Stopford Projects Find out about Bentley at:...

Open the catalog to page 2