Development of digital factory saves Chinese steel and iron company $ 6 million

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Am’s steel and iron industrial facility in China is shaping up to be a cutting-edge innovation in the development of green, advanced and modern factories, thanks to MCC Capital Engineering and Research and Bentley Systems.

The facility, located in Tangshan, Hebei, comprises 42 factories over 534 hectares, all connected by a 26-kilometer-long road. The facility has a complex processing system that required a massive multidisciplinary approach to design, planning, procurement and construction.

He Zhang, BIM manager of MCC Capital Engineering Research, explains that the project involves different areas of the business that are both complex and complicated, such as equipment, industrial pipelines and infrastructure.

“Therefore, how to minimize errors, omissions and collisions at the design stage and achieve a high quality design posed a huge problem for the project team.”

MCC Capital Engineering needed a collaborative building information modeling (BIM) environment in a connected data environment that could help the company understand the steps to build its vision of a smart digital factory. To do this, the BIM methodology required a digital factory that synchronized design, build, delivery and operation with the physical factory.

But it was not without its challenges – it required comprehensive integrated modeling and analysis applications to generate digital models of every part of the plant infrastructure. In addition, the supporting technologies had to provide all the components of these models, and it was also necessary to incorporate artificial intelligence and the Internet of Things to create a true digital factory.

The company turned to Bentley Systems, a provider of BIM processes capable of streamlining workflows, reducing errors and reducing design complexity.

MCC’s multidisciplinary team, which were all spread across different geographies and across four design units and 13 construction units, needed to communicate effectively. The company selected Bentley Systems’ ProjectWise to achieve this goal, shortening the design cycle to 35 days.

MCC also used several other solutions from Bentley Systems including ContextCapture to process oblique photography and generate an actual mesh of the entire site, and SYNCHRO 4D to perform construction simulation for precise layout and installation in limited space. , reducing commissioning costs by 75%.

MCC also used AssetWise ALIM to develop an engineering database that could integrate all resources, including asset information, design, procurement, manufacturing, construction, and installation data.

Bentley Systems’ OpenPlant design software has more than quadrupled the design efficiency of external pipelines. The software also resulted in significant savings of US $ 6 million, particularly in the ability to generate accurate material lists directly from the models, which avoided material wastage.

To ensure the factory stays truly smart, MCC used a digital twin to perform real-time simulation monitoring and analysis, and to achieve smart manufacturing production.

Bentley Systems technologies have helped MCC create a digital twin and design, build and combine operational information. With these implementations, MCC was able to improve its visual data integration and asset management, resulting in a 50% improvement in operational efficiency and a 40% reduction in spare parts orders through maintenance. optimized equipment.

The project also serves as a benchmark for the development of green and digitally intelligent metallurgical factories.

Read the full case study here.


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