SmartPlant Spoolgen Plus White Paper March 2012 PDF

WHITE PAPER
SmartPlant
Spoolgen Plus
Piping Productivity for Fabricators and Constructors
WHITE PAPER
SmartPlant Spoolgen Plus
Contents
1. Introduction ................................................................................................................. 1
2. Work Process Modernization ...................................................................................... 3
2.1. Piping Data Transfer from 3D Plant Design to Construction ........................................................... 4
3. SmartPlant Spoolgen Plus .......................................................................................... 6

3.1. Overview .......................................................................................................................................... 6
3.2. Goals ............................................................................................................................................... 7
3.3. Business Benefits ............................................................................................................................ 7
4. SmartPlant Spoolgen .................................................................................................. 9

4.1. Overview .......................................................................................................................................... 9
4.2. Work Process ................................................................................................................................ 10
4.3. Key Capabilities ............................................................................................................................. 13
4.3.1. Integrated Workflow Management ....................................................................................... 13
4.3.2. Automatic Deliverables ........................................................................................................ 13
4.3.3. Bills of Materials ................................................................................................................... 13
4.3.4. Piping Reports...................................................................................................................... 13
4.3.5. Replay .................................................................................................................................. 14
4.3.6. Repeatability ........................................................................................................................ 14
4.3.7. Integrated 3D Visualization .................................................................................................. 14
4.3.8. Cut and Paste ...................................................................................................................... 14
4.3.9. Elbow to Bend Conversion ................................................................................................... 14
4.3.10. Weld Gaps ......................................................................................................................... 15
4.3.11. Work Content Measurements ............................................................................................ 15
4.3.12. Flat Spools ......................................................................................................................... 15
4.4. Business Benefits .......................................................................................................................... 15
4.4.1. Productivity........................................................................................................................... 15
4.4.2. Efficiency .............................................................................................................................. 16
4.4.3. Accuracy .............................................................................................................................. 16
4.4.4. Consistency.......................................................................................................................... 16
4.4.5. Quality Assurance ................................................................................................................ 16
5. SmartPlant Isometrics ............................................................................................... 17

5.1. Overview ........................................................................................................................................ 17

6. Spoolgen-Piping ........................................................................................................ 20
6.1. Overview ........................................................................................................................................ 20
6.2. Work Process ................................................................................................................................ 21
6.3. Key Capabilities ............................................................................................................................. 22
6.3.1. Automatic Classification of Pipelines According to ASME/PED .......................................... 23
6.3.2. Weld Management ............................................................................................................... 26
6.3.3. Automatic Production of Final QA Documentation .............................................................. 28
7. Sample QA and Final Handover Documentation ....................................................... 30

8. Conclusion ................................................................................................................ 36
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1. Introduction
Figure 1: Engineering projects that include piping involve the main stages of Design, Fabrication, Construction (Erection), and
Operations to varying degrees.
Engineering projects that include piping involve the main stages of Design, Fabrication, Construction
(Erection), and Operations. But as Figure 1 shows, each project is different with more or less work
performed in the engineering office, the fabrication workshop, and the construction site. But all projects
face two major challenges:
Procure and assemble materials in time to efficiently fabricate piping spools in a workshop to the
required engineering and quality assurance standards
Deliver those spools, together with any erection items needed to complete the assembly, to the
site in a sensible sequence
These challenges are complicated by the fact that complex chains of primary and secondary contractors
and sub-contractors are involved.
To be successful in this task, various companies need to:
Effectively plan and prepare work packages (drawings and reports)
Efficiently utilize all available resources machinery, materials, and man-power
Make decisions that optimize spooling for efficient shop fabrication and safe field erection
Procure materials on time, and cost-effectively
Operate materials management proficiently in-house and at the site
Measure work progress and productivity to control costs and schedule
Monitor and control application of welding procedures and assess welder performance
Manage the impact of piping revisions on production
Reduce the potential for error and avoid unnecessary rework
Perform quality assurance (NDT) to relevant standards
Meet ever more demanding delivery deadlines set by the contract or client

There is an increasing demand within the process, power, and marine industries to work smarter, and not
just during the engineering and detail design project phases, but also during downstream procurement
and construction phases, and even extending into the operations and maintenance phase of the life cycle.
Competitive companies increasingly strive for shorter processing times and lower operating costs.
This has led many to adopt new methods that offer optimum quality and cost efficiency and therefore
maximum cost savings, without distracting them from their core business or being overly onerous to
operate and gain the resulting benefits.
Intergraph meets industry demands by offering an integrated piping solution SmartPlant Spoolgen
Plus that satisfies various order fulfillment scenarios in the scope of pipeline fabrication, construction,
and maintenance projects. With an emphasis on the drivers and financial demands of the business, but
aiming to deliver organizational performance improvements, piping contractors can realize productivity
gains and efficiency savings by replacing their outdated working methods with a continuous digital chain
that encompasses engineering, detail engineering, manufacturing, installation, and maintenance.
The key to success is a standard format for piping data that can be easily transferred between various
companies working on the digital chain. This standard format eventually delivers accurate and timely
information into overarching corporate systems, such as SmartPlant Construction and SmartPlant
Materials, that are used to manage the whole project.
2. Work Process Modernization

Owner operators will normally specify the use of, and small-to-medium engineering design contractors
and large EPCs will typically use, a variety of process engineering and 3D plant design tools to execute
projects. Its unrealistic, and simply far too expensive, for any piping contractor to have all of these
systems in-house, so the piping contractor will usually default to working in the lowest common
denominator with paper and Microsoft Excel being commonly employed.
Figure 2: A common, paper-based work process involves all projects and service activities in parallel.
A key benefit of SmartPlant Spoolgen Plus is its ability to work electronically with piping design data
produced by all of the leading and most popular process engineering and 3D plant design systems.
Figure 3 shows how SmartPlant Spoolgen Plus replaces an outdated, inefficient paper and Excel-based
work process with an automated, efficient digital-based work process that enables the piping contractor
to work with many different clients using many different design systems.
Figure 3: A modern, efficient, digital-based work process supports piping information and data received from many different systems
and clients.

Piping contractors who choose SmartPlant Spoolgen Plus to modernize their work processes can expect
to benefit from:
Faster work preparation
More efficient resource utilization
Improved internal and external communications
Shortened production hold-ups due to effective change management
Elimination of islands of duplicated information
More accurate materials procurement
Improved materials delivery schedules
Better materials management
Reduced errors and rework
Increased accuracy and quality
Lower operating costs
Shortened project schedules
Meeting of tight delivery schedules
Fewer construction delays
Enhanced business reputation
Satisfied clients leading to repeat business
Further efficiencies are also possible through the integration of other business processes and other
third-party vendor systems used in the organization.
2.1. Piping Data Transfer from 3D Plant Design to Construction
As Figure 4 shows, most of the worlds 3D plant design systems use Intergraph ISOGEN to
automatically create piping design isometrics. ISOGEN receives a data file containing a description
of the pipeline to be documented. The software then automatically lays out the drawing and creates
the material takeoff based on the information in this file. The exact form the drawing takes the style
of dimensioning or the units of coordinates, for example is determined by a set of controls.
ISOGEN creates a piping isometric drawing using the selected CAD format AutoCAD , MicroStation,
or Intergraph SmartSketch but the information used to create that drawing is contained in the IDF/
PCF data file created by the plant design system.
Figure 4: ISOGEN is widely used by all leading plant design solutions.

This file is one of two types:
ISOGEN Data File (IDF) is used by traditional systems, such as Intergraph PDS
and AVEVA PDMS
Piping Component File (PCF) is used by all recent systems, such as Intergraph
SmartPlant 3D and CADWorx Plant Professional
IDFs/PCFs are the primary input to SmartPlant Spoolgen Plus, and are usually transmitted
electronically to the fabricator. This ensures a seamless handover of design data with no loss
or corruption of design information.
Figure 5: Electronic data transfer supports the efficient and accurate exchange of information with procurement and construction
management solutions.
3. SmartPlant Spoolgen Plus

3.1. Overview
SmartPlant Spoolgen Plus provides maximum flexibility and unparalleled ease of use for the efficient
management and intelligent reuse of process engineering and physical piping data, whether used for:
Major CAPEX projects Where the project scope covers hundreds or even thousands of pipe
spools produced either for a single project or for multiple projects over the course of the business
year
Projects requiring fewer numbers of pipe spools For example, those needed for the rapid
execution of time-critical, small-scale brownfield piping modification projects, where plant
downtime needs to kept to an absolute minimum
SmartPlant Spoolgen Plus is bundled into three distinct parts:
Figure 6: SmartPlant Spoolgen Plus boosts productivity for pipe construction and maintenance projects.
SmartPlant Spoolgen Plus supports the typical scope of common pipe construction and maintenance
projects, such as:
Greenfield
Brownfield
New plant constructions
Revamps and retrofits
Plant expansions and extensions
Maintenance and repairs
Modifications and debottlenecking
Turnarounds and shutdowns
Inspection
3.2. Goals
The solution meets a variety of goals, such as the abilities to:
Offer openness and interoperability with client design systems
Benefit from ease of use and operation
Enable productivity and efficiency gains
Support project schedule reduction
Deliver project cost reduction
Enhance and assure attainment of quality
Enable a digital data handover to the client
Help the business win repeat orders
3.3. Business Benefits

The business benefits provided by SmartPlant Spoolgen Plus are extensive and include:
Improved workflows
Flexible toolset supports both greenfield construction and brownfield maintenance projects
Solution accommodates both paper and electronic data input
Project execution is improved thanks to enhanced communication between QA/QC and

welding department, and shop and field personnel, supported by a user-friendly, easily
understood graphical user interface
Productivity and efficiency grow due to toolset ease of use and electronic data exchange
Integration with accounting, procurement, and other business systems reduces the need for
duplicate data entry into disparate systems
Configurable shop, field, sub-contractor, and QA documentation is produced automatically
Performance monitoring of welder effectiveness identifies sub-standard welders
Electronic handling of material and welder certificates avoids moving paper certificates
between sites
Impact of piping revisions on production is more easily managed and efficiently dealt with due
to change management (standard functionality)
On-demand reporting of progress and status information, required by management and other
stakeholders, is easily produced
Higher data quality and standards compliance
Automated, configurable, rule-driven work process supports adherence to engineering and

QA standards
Reduced manual data entry leads to fewer data errors, omissions, and mistakes
Accurate, high quality, electronic design data means less rework
Comprehensive weld management, including weld traceability, ensures welding procedures

and protocols are observed
Data validation prevents duplicated and unqualified data from entering the work process,
avoiding confusion in the shop or at the field
Time and cost savings
Solution offers greater than 50 percent time savings in work preparation effort, equating to
an average time saved between two to four hours per pipeline manufactured
Project schedules are shortened due to fast work preparation supported by drawing and
report automation
Project costs are reduced thanks to eliminating CAD drafting from the work process
High-quality deliverables are produced in minutes, not hours, thanks to industry-standard

ISOGEN drawing automation
Bulk MTOs are produced in minutes, not days, due to the elimination of manual counting
Enhanced client relations
High quality, as-built isometric deliverables are produced quickly and easily for handover to
clients
Quality handover deliverables enhance business reputation and client relationships
Cost and schedule savings provide a competitive advantage when bidding for projects
Solution offers the opportunity to broaden your customer base
Solution supports business expansion and growth along with participation in larger fabrication
projects, at home or abroad
Client satisfaction increases due to pipe spools being delivered on schedule or sooner,
enabling facilities to be brought online quicker
Clients receive added value through electronic handover of high-quality, highly accurate
electronic piping isometrics that can be reused in operations and maintenance activities
for example, to produce isometrics for inspection
Automation presents an opportunity to re-evaluate how projects are priced, enabling more
attractive bids to be submitted for future tenders
4. SmartPlant Spoolgen
4.1. Overview
SmartPlant Spoolgen is a proven, industrial-strength application that enables the automatic creation
of piping isometric drawings for fabrication and erection from the design created during the detail
design phase of a process, power, or marine engineering project. The technology is based on
ISOGEN, the industry-standard software for automated piping isometric generation, and has been
deployed successfully on all sizes of plant engineering projects in every region of the world. Today,
more than 370 companies worldwide use SmartPlant Spoolgen to automate their pipe fabrication
and erection work process.
Figure 7: SmartPlant Spoolgen offers an easy-to-use interface.
SmartPlant Spoolgen is fast and accurate because it eliminates the need to redraw isometrics and
manually re-create material take-offs, dramatically shortening the work preparation lead-time in terms
of drawing production and bulk material calculations.
SmartPlant Spoolgen boosts productivity because no CAD skills are needed to produce deliverables.
It employs ISOGEN to create high-quality pipe spool drawings in many different formats automatically
and without CAD drafting. AutoCAD, MicroStation, and Intergraph SmartSketch outputs are supported.
If spool drawings are not utilized by the shop, SmartPlant Spoolgen can instead be used to produce full
pipeline isometrics containing all required manufacturing and test information, configured in accordance
with company standards and working practices.
SmartPlant Spoolgen is not a design system. Changes to the source (IDF/PCF) data that it processes are
strictly controlled to maintain the original design integrity. This helps to eliminate transcription errors and
ensures that the design intent is faithfully preserved throughout the fabrication and erection phases.
4.2. Work Process

SmartPlant Spoolgen can work with data (IDF/PCF) from almost any plant design system Intergraph
SmartPlant 3D, PDS, and CADWorx; AVEVA PDMS; and Bentley AutoPLANT and PlantSpace are all
supported.
Take advantage of a variety of powerful configuration and customization options that ensure the solution
will fit smoothly into any existing piping construction or piping maintenance work process.
Individuals who understand the work processes employed and capabilities of the fabrication workshop
environment are empowered to make the right decisions concerning how a pipeline should be spooled
for efficient fabrication and transportation, and later, safe erection.
Without altering the original pipe design, and without the need for redrafting or re-entry of material data,
SmartPlant Spoolgen provides a workflow environment for fabrication and erection information to be
added to piping designs by the appropriate people at the appropriate time. This enables the creation
of new drawings containing all required information to fabricate and erect a pipeline to be produced.
Figure 8: SmartPlant Spoolgen fits smoothly into your work process.
The software includes an integrated workflow database that prevents users from working on the same
pipeline and keeps a record of every pipeline received in to the project. This record enables the software
to detect piping revisions when they are received from the engineering design contractor. The replay of
edits made to the previous version of the pipeline is automatically added to the latest revision, eliminating
duplication of effort and saving time and cost.
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After import, pipelines are checked out for work to be performed on them. Thanks to simple editing
functionality, users interact with the pipeline on-screen to add all required fabrication and erection
detailing.
Additional information is easily and quickly added using familiar Microsoft Windows -type point-and-click
and drag-and-drop editing techniques. This additional information includes:
Annotations
Flow arrows
Floor and wall symbols
Reference dimensions
Supports and associated welds
Field fit allowances
Additional materials (pipe, plate, etc.)
Detail sketches used to convey assembly instructions pictorially
Other data can be quickly introduced to the pipeline using the powerful Get External Data feature,
such as:
Pipeline attribute data held in a line list
Other manufacturing-specific data such as non-destructive testing and heat treatment

information typically not present in the original IDF/PCF input data files
This ensures that all information required to fabricate, test, and erect the pipe spools is present on the
final drawing deliverables, and is included in any piping reports.
Once all required edits and additions have been made, spool isometrics (or full isometrics if preferred) are
automatically produced in seconds. These isometrics contain just the information needed to efficiently
manufacture the pipe spool in the fabrication shop, such as spool materials, cutting, welding, and NDT
data. The pipeline is automatically split into a number of new drawing deliverables without any manual
effort required.
Figure 9: Spool isometrics are automatically produced in seconds.
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Erection isometrics can also be produced. These depict how the spools for each pipeline need to be
assembled together to build the entire pipeline at the construction site, including all required erection
material items for hook-up.
Figure 10: This shows Sheet #1 of an erection isometric.
Figure 11: This close-up of Sheet #1 shows weld and spool numbering and the location of field welds.
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Decisions are made during detail design specifying how a pipe should be spooled. These spooling
decisions are often later changed by the piping contractor to:
Suit the capabilities of the workshop
Accommodate the skills of the workforce
Take account of feedback received from the construction site stating that field welds need to be
made in alternate locations to those originally specified by the piping designer to avoid possible
difficulties during erection
SmartPlant Spoolgens most fundamental purpose is to enable the piping contractor to change the
location of field welds, then produce new drawings showing the new locations (as shown in the lower
right corner of Figure 11).
4.3. Key Capabilities

4.3.1. Integrated Workflow Management
The integrated workflow database keeps a record of every pipeline (IDF/PCF) received into the project. It
identifies pipeline revisions and triggers the Replay (automatic edit) function. The database also prevents
users from working on the same pipeline. This ensures that duplicate drawings are not produced or
inadvertently issued to the shop.
4.3.2. Automatic Deliverables

High-quality, consistently presented, industry-standard ISOGEN isometric drawing deliverables are
produced automatically without manual intervention and require no further manual editing or touch-ups.
Drawing deliverables are automatically generated in accordance with customer presentation and content
needs, resulting in:
Significant time savings
Assured accuracy and quality during the manufacturing process
Reduced need for rework
4.3.3. Bills of Materials

Fabrication and erection materials are separated automatically no manual counting is necessary. Any
additional material items edited into the pipe are automatically accumulated and listed under the BOM
section of the drawing. The items are also output to the material control report for costing, procurement,
and material management purposes.
4.3.4. Piping Reports

Detailed piping reports are produced automatically from the piping data without any manual effort needed.
The content of most reports is user-definable. These reports include:
Welding
Cutting
Spool information
Assembly (welded and bolted joints)
Bending and cutting
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4.3.5. Replay
The pipeline can be automatically re-edited to include edits (spooling decisions) previously made to the
original or previous revision. These edits are automatically repeated on the latest piping revision received
from the engineering design contractor, saving time and cost.
4.3.6. Repeatability
Repeatability maintains data between revisions, generating the following benefits:
Weld and part numbers are not duplicated or re-used if previously cancelled, because they no
longer exist
Isometric split points and spool numbers ensure the same number of drawings with the same
spool numbers are produced
4.3.7. Integrated 3D Visualization

The integrated 3D view displays a true-scale, 3D view of every pipeline showing its relative position with
respect to all other pipelines. This enables better spooling decisions to be made and easier determination
of which pipelines need to be spooled in sequence based on construction needs.
4.3.8. Cut and Paste

Cut and paste enables the content of individual spool pieces to be altered. This optimizes spooling for the
shop or field. For example, it might be necessary for components that exist at the boundary of a pipeline
to be included in the next connected pipeline. Cut and paste functionality promotes the manufacturing of
better defined spool pieces.
4.3.9. Elbow to Bend Conversion

If permitted under contract, elbows can be converted to equivalent pipe bend geometry. For example, a
1.5D elbow can be replaced with a 1.5D pipe bend. This enables cost-effective pipe bending techniques
and available machine tools to be utilized in the manufacturing process. Note that this capability is only
functional if configured.
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4.3.10. Weld Gaps
Pipe fabrication requires accurate cut length information to ensure the dimensional accuracy of individual
pipe spools and to avoid unnecessary material wastage. EPCs usually dont model welds in the plant
design system. When theyre not modeled, ISOGEN (an integral part of the solution) will imply welds
when IDFs/PCFs are imported into SmartPlant Spoolgen by performing the following actions:
1. Automatically determines the correct weld types between the various inline fittings and pipe
2. Creates weld components
3. Sets an appropriate weld root gap (if the WeldGap feature is activated)
4. Numbers and prefixes each weld according to customer-configured rules
5. Calculates accurate pipe cut-lengths
6. Lists pipe cut-lengths under the cut list section of the drawing
4.3.11. Work Content Measurements

Automatic calculation of work content measurements can be automatically calculated, such as:
Surface area
Weights
Center of gravity
Weld Dia. Inch
These measurements are highly accurate since they are based on the original 3D piping design data. In
combination with the Get External Data feature, Weld Dia. Inch is configurable per company standards,
enabling accurate pricing of the welding work effort required for each weld on each individual spool piece.
4.3.12. Flat Spools

Drawings can be produced showing spools in their laid-down orientation rather than their erected
orientation, making it easier for the shop to understand complex angles and flange rotations.

4.4.1. Productivity
When drafting spool sheets in systems like AutoCAD or MicroStation, it can take the average drafter from
one to four hours per spool sheet, which means a typical pipeline consisting of eight spools might take at
least one man-day to produce all required drawings.
In comparison, a set of spool drawings from a single design isometric (IDF/PCF) can be created in 15
minutes or less using SmartPlant Spoolgen. All you need to do is mark up the locations of field welds.
The spooling algorithm in combination with ISOGEN drawing automation does the rest. No drafting is
required. As a result, companies have reported a tenfold improvement in drawing productivity.
SmartPlant Spoolgen offers many possibilities for data automation. Users have found that up to 95
percent of their manual data entry work (such as the addition of welding testing requirements) can be
eliminated by taking advantage of these powerful automation features.
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4.4.2. Efficiency
SmartPlant Spoolgen boosts efficiency because it enables you to employ relatively unskilled or junior
engineering resources, yet still create high-quality drawings and reports. Users do not need a detailed
knowledge of CAD to use SmartPlant Spoolgen.
The drawings and reports created in SmartPlant Spoolgen could, in many cases, be generated by the
EPC during the detailed engineering design phase. However, this is often an inefficient use of expensive
3D plant design software and engineering resources. Until a fabrication contractor is selected, details of
the workshop capacity and capability are unknown, so it may be impossible to create fabrication drawings
until just before they are needed. In this scenario, SmartPlant Spoolgen enables the optimal use of
engineering and other resources.
4.4.3. Accuracy
Deliverables accuracy is achieved by eliminating the possibility of transcription error. Data supplied
from the design contractor is preserved through the SmartPlant Spoolgen workflow. For example, when
a single design isometric is split into multiple spool sheets, the material takeoff is automatically divided
so the correct material is assigned to each sheet. Erection material is not shown on individual spool
sheets, but can be separately reported.
Likewise, dimensions are protected from the possibility of inadvertent error. SmartPlant Spoolgen users
cannot change the basic engineering design by accidentally deleting or editing pipeline components.
This minimizes manual checking, saving time and increasing accuracy.
4.4.4. Consistency
Many companies report that a significant benefit of using SmartPlant Spoolgen is the consistency of the
output. In contrast, when manual or CAD-based drafting is used, the individual style of the draftsman
can vary considerably from drawing to drawing and project to project. SmartPlant Spoolgen is completely
automated. This means you can configure all drawings so they have a consistent presentation. This helps
improve communication between engineering and the fabrication shop, and also the personnel working at
and receiving the spools at the construction site.
4.4.5. Quality Assurance

SmartPlant Spoolgen provides a number of features that help ensure a high-quality work process. The
built-in workflow database automatically tracks all revisions of every pipeline. This enables the fabricator
to quickly identify changes between revisions and detect errors and inconsistencies in the data supplied
by the design contractor. For example, you can easily determine if the delivered drawing does not match
the data from which it was apparently derived.
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5. SmartPlant Isometrics
5.1. Overview
SmartPlant Isometrics is a simple-to-use yet powerful pipe-sketching application and is included as part
of SmartPlant Spoolgen. This application is used if new pipeline data must be generated, or if minor
changes are required to existing pipelines to reflect as-built conditions, such as to:
Add vents or drains
Modify the design to resolve construction clashes
Many piping contractors receive some of their work in hardcopy (paper) form. When isometrics have to
be redrawn, or a hand-drawn field sketch needs to be turned into a high-quality deliverable suitable for
fabrication, SmartPlant Isometrics can rapidly and accurately replicate the original hardcopy in electronic
form. This can be subsequently processed using SmartPlant Spoolgen to perform a variety of tasks, such
as to:
Change elbows to bends
Introduce weld gaps
Add field welds to define spool breaks
Automatically produce spool drawings or any other required drawing and report deliverables
This means a single workflow supports both electronic and hardcopy inputs.
Figure 12: The SmartPlant Isometrics user interface shows sketched and 3D pipeline views.
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SmartPlant Isometrics and SmartPlant Spoolgen are built on the same technology platform. Both
utilize ISOGEN to produce piping isometrics, meaning both can be interfaced with Intergraphs Piping
Controlling Database (PICODA) to exchange information bi-directionally.
Information can be exchanged in two ways. The first method is through the exchange of ISOGEN reports.
Another option is data integration provided by the Get External Data feature. This feature will link data
contained in external data sources, such as a line list in a spreadsheet or database. The final deliverables
will include the process information contained in the external data sources.

SmartPlant Isometrics extends the functionality of SmartPlant Spoolgen by providing design and pipe
editing capabilities. It is particularly beneficial when used on brownfield projects. SmartPlant Isometrics
offers a variety of benefits:
Possible 75-percent time savings in isometric production when compared with manually drafting
isometrics using 2D CAD (AutoCAD or MicroStation)
2D CAD or drafting skills not required to operate the software or to produce drawing deliverables
Rapid creation of high-quality piping isometrics (PCF input for SmartPlant Spoolgen) from
hand-drawn paper field sketches
Production of complete piping system circuit drawings for inclusion in hydrostatic pressure
test packages
Software can be deployed to the construction site to produce new drawings required to deal
with clash problems
Solution can be deployed to the operating plant to document the current as-built situation prior
to making the required design change in the software needed to repair, replace, or alter an
existing pipe
Specification-based design assures dimensional accuracy and ensures fewer material and
erection errors
New isometrics (PCF input for SmartPlant Spoolgen) can be quickly and easily created from
client-supplied paper drawings
High-quality, consistently presented as-built isometrics for client handover show the before
(existing) and after (modified) details, replacing poor quality marked-up paper isometrics
used previously
Insulation and heat tracing design is supported, including automatic generation of bills of
quantities required for installation
Newly created isometrics or modified (edited) isometrics (imported IDF/PCFs) can be supplied
electronically to the client to support the piping inspection or other site-based piping engineering
work processes
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Figure 13 shows a simple example of a marked-up, as-built isometric produced by SmartPlant Isometrics.
Detailing can be in accordance with industry practice and is fully configurable.
Figure 13: This marked-up, as-built isometric was produced by SmartPlant Isometrics.
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6. Spoolgen-Piping
6.1. Overview
Spoolgen-Piping is a solution that was born out of piping construction industry practice. Originally
developed over a period of 10 years by Hertel-Enning, a German piping construction company, the
technology (previously known as Pipe Control Database [PICODA]) and intellectual property are now
owned by Intergraph. Together with SmartPlant Spoolgen and SmartPlant Isometrics, Spoolgen-Piping
forms a core component of SmartPlant Spoolgen Plus.
Spoolgen-Piping is a database solution for piping management. It is a flexible and scalable integration
platform for all business processes and technical issues in the framework of piping construction and
maintenance, with a particular focus on welding and quality assurance.
Figure 14: The PICODA main menu offers a series of options.
Working in conjunction with SmartPlant Spoolgen (greenfield projects) or SmartPlant Isometrics

(brownfield projects), Spoolgen-Piping helps you to:
Accelerate the execution of piping projects
Reduce costs without compromising quality or accuracy
Secure value creation
Ensure a short-term return on investment
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Spoolgen-Pipings broad scope supports project management, such as:
Material handling
Purchasing
Logistics
Project controlling
Quality management
Change management
Moreover, intelligent, as-built digital data is delivered from the solution when the project concludes.
This data provides an electronic data handover to the facility owner operator, enabling further benefits,
including:
Significant reductions in piping maintenance costs
Improved reliability during the operational life cycle
6.2. Work Process

Figure 15 provides an overview of the general workflow in projects. Data is transferred electronically
between the various project phases, including a handover of as-built digital data to operations and
maintenance.
Figure 15: SmartPlant Spoolgen Plus enables electronic data exchange and workflow in projects.
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The main inputs to Spoolgen-Piping include:
Process information Typically received via a line list in spreadsheet or database format,
this is produced by process engineering design tools like SmartPlant P&ID
Isometric information Materials, valves, instruments, welds, spools, supports, etc. are
received from the design isometrics (IDF/PCFs), which are imported and processed through
SmartPlant Spoolgen or SmartPlant Isometrics
6.3. Key Capabilities

Spoolgen-Piping offers an excellent value proposition with a variety of general capabilities, as shown in
Table 1.
Capability
Work preparation
Progress management
NDT management
Welding management & documentation
Types of data supported
Spooling
Fabrication details
Material assignment and reservation
Documentation
Requirement specifications
Spools
Welds
Supports
Valves
Inch dia.
Weight
Length
Calculation factors
Scope specification
Test plan
NDT order management
Sub-contractor documents
WPS
Heat number
Certificates
Repairs and extensions
Welder performance
22
Capability
Constructability reports
Pressure circuit management
Punch list management
Material management
Cost accounting
Change management
Types of data supported
Material
Spools
Supports
Valves
Scaffolding
Punch list
Planning
Valve handling
Documentation
Fabrication
Erection phases
Bulk MTO lists
Material balances
Fabrication materials
Erection materials
Pipeline
Spool
Weld revision handling
Table 1: PICODA provides a variety of general capabilities, such as the ones listed here.
Spoolgen-Pipings most important capabilities are described in the following sections.
6.3.1. Automatic Classification of Pipelines According to ASME/PED

Spoolgen-Piping is initially populated with data imported from a line list. It consists of the process data
for each pipeline, such as:
Fluid
Pressure
Temperature
Pipeline material
This information enables Spoolgen-Piping to automatically classify every pipeline according to the
American Society of Mechanical Engineers (ASME), the European Pressure Equipment Directive
(PED 97/23/EC), or other engineering and quality assurance standards.
23
Figure 16: This pipeline is classified in accordance with PED.
Figure 17 shows a pictorial representation of the classification according to PED for the currently selected
pipeline.
Figure 17: This pipeline is classified according to PED.
24

The classification also determines the testing and inspection requirements and QA documentation
needed to satisfy ASME/PED.
Figure 18 shows the testing requirements that must be passed prior to pipeline handover.
Figure 18: The confirmation of handover test is offered by Spoolgen-Piping.
Figure 19 shows the final testing requirements for the pipeline.
Figure 19: PICODA presents a confirmation of final testing.
25

6.3.2. Weld Management
Welding processes are particularly important for any piping contractor. Spoolgen-Welding promotes the
management of welds associated with those processes.
Spoolgen-Welding is a module included in the SmartPlant Spoolgen Plus bundle, as shown in Figure 20.
The module manages all aspects of weld production and testing. It produces detailed welding
documentation for the shop and field.
Figure 20: PICODA-WELDING supports weld management.
The form shown in Figure 20 is initially populated with weld data received from SmartPlant Spoolgen.
Configurable, automated, rule-based selection methods are driven by code lists. This helps the user
to quickly specify a variety of items, such as:
Weld properties
Heat numbers
Material and welder certificates
WPS
NDT data (not shown here) is also set on this form.
26

When everything is set, welding documentation is automatically produced. This documentation then
accompanies the piping isometric drawings produced by SmartPlant Spoolgen into the shop. The welding
input form is shown in Figure 21.
Figure 21: This welding input form is provided by Spoolgen-Welding.
27

6.3.3. Automatic Production of Final QA Documentation
QA and final handover documentation can be generated automatically using Spoolgen-Piping.
Figure 22: Spoolgen-Piping enables automatic production of final QA documentation. In this example, it is in accordance with PED.
Template documents provided with Spoolgen-Piping can be configured to meet the needs of the user.
See Section 7 for samples of some of the reports shown in Figure 22.
28
Established, proven solution based on industry practices
Systematic CAE procedure with an electronic data workflow
Enables shop, field, and QA work processes to be streamlined
Delivers efficiency and productivity gains
Reduces operating costs and schedule
Electronic data exchange
Is configurable to any piping contractors work practices and deliverables needs
Reduces manual data entry and paper handling
User-configurable, flexible reporting options
Provides status and progress information on demand for management and other
stakeholders
Consistent results due to capture and automation of work process decisions and rules
Significant man-hour savings due to data-driven, automatic production of documents and reports
Classifies lines according to ASME/PED (or other standards)
Produces welding & QA handover documentation in accordance with ASME/PED (or other
standards)
29
7. Sample QA and Final Handover Documentation

This section presents sample QA and final handover documentation produced by SmartPlant
Spoolgen Plus:
Welding documentation
Confirmation of pressure test of pipes according to PED
Confirmation of final test of pipes according to PED
Confirmation of handover test of pipes according to PED
Manufacturers declaration for pre-fabrication and erection of pipe
30
Figure 23: SmartPlant Spoolgen Plus produces welding documentation.
31
Figure 24: This form shows the confirmation of pressure test of pipes according to PED.
32
Figure 25: This confirmation of final test of pipes according to PED was created with SmartPlant Spoolgen Plus.
33
Figure 26: The confirmation of handover test of pipes according to PED is generated with SmartPlant Spoolgen Plus.
34
Figure 27: This shows the manufacturers declaration for pre-fabrication and erection of pipe.
35
8. Conclusion
For the owner operator or the primary engineering contractor, using SmartPlant Spoolgen Plus for all
piping operations downstream of 3D design means that data can be accurately and reliably passed
through the digital chain. Loss of integrity and errors due to transferring data between different systems
and recreating drawings can be eliminated. Any piping subcontractor, whatever its size and the scope
of its work, can be relied on to produce a consistent output and to be able to accurately describe its
progress at any point.
Any general piping contractor using SmartPlant Spoolgen Plus can support electronic data transfer
from almost any client and use the same workflow for all of them.
For the project as a whole, the productivity gains delivered by SmartPlant Spoolgen Plus offer faster,
higher quality deliverables of all kinds generated from a single source. Drawings and documents are
automatically generated to a consistent standard to form part of handover packages to plant construction,
commissioning, and operating teams.
36
For more information about Intergraph, visit our website at

www.intergraph.com.
Intergraph and the Intergraph logo are registered trademarks
of Intergraph Corporation or its subsidiaries in the United States
and in other countries. Other brands and product names are
trademarks of their respective owners. Intergraph believes that
the information in this publication is accurate as of its publication
date. Such information is subject to change without notice.
Intergraph is not responsible for inadvertent errors.
2012 Intergraph Corporation. All Rights Reserved. 3/12
PPM-US-0142B-ENG

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SmartPlant Spoolgen Plus

3. SmartPlant Spoolgen Plus .......................................................................................... 6

4. SmartPlant Spoolgen .................................................................................................. 9

5. SmartPlant Isometrics ............................................................................................... 17

SmartPlant Spoolgen Plus

7. Sample QA and Final Handover Documentation ....................................................... 30

SmartPlant Spoolgen Plus

Effectively plan and prepare work packages (drawings and reports)

Efficiently utilize all available resources machinery, materials, and man-power

Procure materials on time, and cost-effectively

Operate materials management proficiently in-house and at the site

Measure work progress and productivity to control costs and schedule

Manage the impact of piping revisions on production

Reduce the potential for error and avoid unnecessary rework

Perform quality assurance (NDT) to relevant standards

SmartPlant Spoolgen Plus

SmartPlant Spoolgen Plus

2. Work Process Modernization

denominator with paper and Microsoft Excel being commonly employed.

SmartPlant Spoolgen Plus

Faster work preparation

More efficient resource utilization

Improved internal and external communications

Shortened production hold-ups due to effective change management

Elimination of islands of duplicated information

More accurate materials procurement

Improved materials delivery schedules

Better materials management

Reduced errors and rework

Increased accuracy and quality

Lower operating costs

Shortened project schedules

Meeting of tight delivery schedules

Fewer construction delays

Enhanced business reputation

Satisfied clients leading to repeat business

2.1. Piping Data Transfer from 3D Plant Design to Construction

Figure 4: ISOGEN is widely used by all leading plant design solutions.

SmartPlant Spoolgen Plus

SmartPlant 3D and CADWorx Plant Professional

SmartPlant Spoolgen Plus

3. SmartPlant Spoolgen Plus

SmartPlant Spoolgen Plus is bundled into three distinct parts:

New plant constructions

Revamps and retrofits

Plant expansions and extensions

Maintenance and repairs

Modifications and debottlenecking

Turnarounds and shutdowns

SmartPlant Spoolgen Plus

Offer openness and interoperability with client design systems

Benefit from ease of use and operation

Enable productivity and efficiency gains

Support project schedule reduction

Deliver project cost reduction

Enhance and assure attainment of quality

Enable a digital data handover to the client

Help the business win repeat orders

3.3. Business Benefits

Solution accommodates both paper and electronic data input

Project execution is improved thanks to enhanced communication between QA/QC and