Contact

mag The DS PLM Magazine

hydro power

Hydro-quebec
Shortens Refurbishing
Schedule by More Than
Three Years with DS PLM
Page 8

other renewable

Solar Century
Implements ENOVIA
SmarTeam in Just
Two Months
Page 12

future energy

Lawrence
Livermore National
Laboratory
Relies on ENOVIA PLM as
it Tackles Pressing Energy
Challenges
Page 32
 Editorial Perhaps no industry is more critical to the
world’s comfort, safety and economic well- overview
being than energy. But with demand growing 5 The Energy Industry and PLM
exponentially worldwide, energy companies
are under constant pressure to adapt and 6 DS Solutions for the Booming Energy Industry
keep pace with the changing needs of an
increasingly globalized economic community.
Sustainability is, quite simply, a must. hydro power
8 Hydro-Québec Shortens Refurbishing Schedule by
Achieving sustainability is a difficult balancing
More Than Three Years with DS PLM
act. Whether the facility is a modern nuclear plant, a wind farm or an
offshore rig, companies must bring new projects online faster and 10 UCM Resita: Business Transformation with
more efficiently than ever before. Yet while new approaches are being DS PLM
adopted, existing plants and facilities – many of which have been in
service for decades – must be maintained and upgraded to increase
output and meet increasingly stringent quality, health, safety and
environmental expectations and regulations.
other renewable
12 Solar Century: Solar Gain
There’s no debate. Meeting these challenges is a high-risk undertaking
with tight schedules and high costs for delays and overruns. To sustain
14 Wind Turbine Composites Design: Leveraging
business, energy companies must limit and manage these risks, Aerospace Advances for Improved Durability
protecting revenues, workers and the environment. Bottom line, 16 Pelamis: Harvesting the Ocean’s Power
energy companies must do what they do more efficiently. An
increasingly energy-hungry world depends on their success.

In the face of these challenges, energy companies are turning to the

oil and gas
power of PLM for managing complex project lifecycles. Just as PLM 18 Yantai Raffles Shipyard: Charting the Future With
has helped a broad spectrum of manufacturers operate more Dassault Systèmes PLM Solutions
efficiently for more than two decades, PLM is now being effectively
applied to planning, constructing, operating and maintaining both 20 ENOVIA Refined Preem
existing and new facilities throughout the global energy industry. 22 T3 Energy Services Ensures Design Revision
Accuracy with ENOVIA SmarTeam
Whether energy companies need information and project
management planning solutions to build, maintain and upgrade
plants more efficiently, or engineering analysis software to ensure
everything from wind turbines to offshore oil pipelines are equal nuclear power
to the environmental strains they encounter, Dassault Systèmes 24 Forsmark: Working Without a Glitch
PLM solutions are helping companies bring new projects online
faster and reduce costs and downtime. From training and keeping 26 Entergy Nuclear Simulates Nuclear Plant
workers safe to assembly and operating instructions, PLM Maintenance with DS PLM
solutions are poised to help keep energy installations running 28 Four Questions with EPRI: PLM and Nuclear Power
like clockwork.

Smart energy companies are tapping the power of PLM to

Plants of Tomorrow Require Innovative DS PLM Today lower risks, reduce outages, increase efficiency and improve future energy
safety for both new and existing assets. This special edition of 29 ITER Optimizes Design with 3DCS
Dassault Systèmes (DS) Product Lifecycle Management (PLM) solutions transform the entire Contact mag celebrates these pioneers and gives you a
nuclear plant lifecycle. Whether it’s a new build, outage planning or license renewal project, window into their innovations. Their success can be yours. 30 ITER: The Energy of Tomorrow with DS PLM
DS PLM helps plant owners / operators, EPC firms and NSSS suppliers minimize costly
Contact us today, and let us show you how. 32 Lawrence Livermore National Laboratory Relies
downtime, reduce risk, and meet stringent government and safety regulations. Our integrated
software suite – including CATIA, DELMIA, ENOVIA, SIMULIA and 3DVIA – delivers 3D, virtual on ENOVIA PLM as it Tackles Pressing Energy

]
simulation and project management tools for effective design, engineering, construction, Rolf Gibbels Challenges
operations and maintenance – allowing you to deliver projects on-time, on budget – every time. Director, Global Market Development,
Energy Industry, Dassault Systèmes
Visit www.3ds.com/solutions/energy to learn how PLM will power your profitable future. Rolf.Gibbels@3ds.com

©Dassault Systèmes, 2009. All rights reserved. CATIA, DELMIA, ENOVIA, SIMULIA and 3D VIA are registered trademarks of Dassault Systèmes or its
subsidiaries in the US and/or other countries.

Contact mag 3

Focus on Energy
With world demand for energy projected to increase by 45% by
2030*, securing long-term, environmentally friendly energy supplies
has become a top priority for governments and energy industry
companies. In this special feature on the energy sector, Contact Mag
looks at the trends and challenges ahead, Dassault Systèmes’
comprehensive PLM offering for the energy industry, and
a group of cutting-edge DS customers at the The Energy Industry and PLM
vanguard of the sustainable
energy drive.
Allan Behrens is a
director at Cambashi,
a management and
marketing consultancy
firm in the UK and US.
Contact Mag spoke
with him about the
trends and challenges
in the energy industry and the role PLM
can play.
Q: What are the major
trends and challenges in the
energy industry today?
A: Countries seek to diversify their energy
sources. They no longer want to be at the
mercy of a single supplier, but instead are
adopting a pragmatic approach and
breaking away from past habits by varying
the origin and type of energy they use. Only
diversification can provide energy security.
*2008 World Energy Outlook – OCED/IEA
But it takes a lot of time to reach the new
initiatives, and the amount of energy
produced by renewable sources is less
than what is required. We need to sustain
and maintain existing plants until we have
alternatives to replace them. Governments
are taking a tactical approach, using
proven methods and sources, like coal
and nuclear, until new ones come along.
Q: Why is PLM relevant
to the energy industry?
A: The sheer size of energy projects makes
PLM relevant. Power plants are large-scale
projects. Companies require tools that are
accurate at scales ranging from kilometers
to fractions of millimeters. Companies also
need multiple solutions to handle the design
of the different plant components, and a
single data management system to manage
all these systems. It is also important to
manage all the suppliers that participate in
designing and building the plant. Only a
robust PLM solution can orchestrate
everything efficiently.
PLM also addresses the challenge
of handover from the Engineering,
overview
Procurement and Construction (EPC) firm
to the owner-operator. It is not possible,
because of the complexity involved with
operating a plant, to wait until the plant is
finished. With downtime costing up to $1
million a day (in nuclear plants, for
example), it has to be a progressive
process so that operator training begins
as soon as possible. A PLM system can
help operators familiarize themselves with
the different plant equipment to see how
they function and how to operate them.
Finally, maintenance operations are greatly
facilitated by a PLM system that keeps
track of each component, the date it was
serviced, what was done to it. With a PLM
system, operators are able to simulate the
different refurbishing tasks to ensure they
can be done safely and without
interference. This is a huge opportunity for
PLM because it can help optimize on-site
operator intervention• )
For more information:
www.cambashi.com
Contact mag 5

By Rolf Gibbels
The global energy industry is
under pressure from every
direction. Demand is growing
exponentially, creating pressure
for new, sustainable energy
sources. New construction
and maintenance projects
are increasingly complex.
Aging infrastructure must be
upgraded and modernized to
meet stringent quality, health,
safety and environmental
regulations. And all of these
challenges must be met more
efficiently than ever before,
keeping the industry profitable
despite increasing demands
from regulators and consumers.
6 Dassault Systèmes
DS Solutions for the
] Booming Energy Industry
G
iven the nature of these challenges,
the energy industry is actively
searching for more efficient ways
of working. Increasingly, leaders across
the energy spectrum are coming to the
same conclusion: The same Product
Lifecycle Management (PLM) solutions
that help manufacturers operate more
efficiently are equally effective in designing,
building, operating and maintaining plants
– from nuclear and hydroelectric power to
oil refineries and from offshore production
platforms to solar and wind-energy farms.
Refurbishing projects
on the rise
The need to extend, modernize and
refurbish existing power plants offers
significant challenges. Many upgrade
projects involve hundreds of workers
in unique or infrequent operations.
Equipment weighing tons often must be
moved through spaces with clearances
measured in inches. Scheduling requires
precise choreography to ensure each
step occurs on time and in sequence –
critical in limiting outages and meeting
budgets. Safety considerations are
paramount.
PLM technology manages complexity and
puts lifelike experience at users’ fingertips to
minimize risk. DELMIA allows project
managers to visualize their maintenance and
installation activities and schedules as 3D
simulations, helping to identify unexpected
issues and determine optimal sequences.
Reducing outage time pays off; each day of
outage costs $1 million for replacement
power at nuclear plants and $7 million for
non-productive time at oil and gas
installations. At Entergy Nuclear’s Waterford
3 plant, for example, DELMIA simulations of
a motor-replacement project identified a
previously unrecognized obstruction that
could have added one to two days to a
planned outage (see page 26).
Once activities are planned, training with
3DVIA Virtools offers workers lifelike
experience in a virtual, immersive setting.
Crane operators, for example, can
experience the actual “feel” of moving a
heavy piece of equipment in virtual reality,
allowing infrequent operations to be
practiced efficiently and safely. Virtual
training ensures worker readiness for project
startup at the physical jobsite, without
interrupting ongoing operations.
PLM technology manages complexity and puts lifelike experience at users’
fingertips to minimize risk.
Nuclear power plants:
complex, large-scale
projects
Nuclear power is experiencing a
renaissance, with more than 230 plants
planned or proposed worldwide. Highly
complex and costing as much as $10 billion
each, plant construction requires efficient
management of multi-disciplinary projects
to meet budget and delivery obligations.
The handover process from construction to
the owner/operator is critical, requiring
a mature, scalable collaboration and
information-management platform.
Owner/operators, major equipment
vendors and Engineering, Procurement
and Construction (EPC) firms increasingly
rely on fully integrated DS PLM
environments to support a design-to-
operations approach that concurrently
optimizes design, construction and
resources. The DS PLM virtual construction
portfolio offers comprehensive capabilities
for plant construction planning, scheduling
and sequencing in a multi-CAD
environment. Virtual definition and
simulation reduces construction delays
and improves collaboration. In-work
product structures, digital mockups and
engineering bills of material (BOMs)
provide valuable early insights to project
developers and construction planners.
Managing project
complexity and
globalization
To bridge the interoperability issues that
complicate collaboration in a fragmented
environment and achieve efficient
collaboration with dozens of stakeholders,
the energy industry needs a centralized
and structured approach to managing
data in all its forms.
At Lawrence Livermore National Laboratory
(see page 32), for example, ENOVIA
manages massive amounts of planning
overview
and construction data, while collecting
and organizing data on daily operations
and maintenance spanning decades.
ENOVIA coordinates engineering data
and processes across the complete
product lifecycle and maintains
consistency by propagating changes to
related documents. ENOVIA also tracks
project progress and overall productivity,
and manages change orders and
workflows to ensure milestones are met
and projects progress efficiently.
Diversifying energy sources
The drive for energy independence and
greenhouse gas reductions, wild swings in
oil and gas prices, and rapid increases in
total energy demand, are driving the
development of local, sustainable energy
sources such as hydro, wind, solar, wave
and geothermal. From enabling advanced
composites technologies for wind-turbine
blades, to managing the vast resources
required to develop reliable fusion
technology or keep pace with soaring
demand for solar panels, PLM helps
alternative energy producers innovate,
develop, manage and replicate projects
while managing vast networks of
installations. Pelamis Wave Power (ocean
wave farms) (see page 16), ITER (nuclear
fusion) (see page 30), Vestas Wind Systems
(wind farms) and Solar Century
(environmental energy system design) (see
page 12) are just a few of the alternative
energy leaders meeting the unique
demands of their markets with DS PLM• )
For more information:
Rolf.Gibbels@3ds.com
www.3ds.com/solutions/energy
www.plmv5.com/delmiaenergy
Contact mag 7

Hydro-Québec Shortens Refurbishing Schedule
by More Than Three Years with DS PLM
Hydro-Québec needed to assess the time and cost of refurbishing
]
By Emmanuel Boivin-Moreau
and Emil Dobrescu
generating stations. The company used CATIA and DELMIA to
simulate and optimize the refurbishing of its Manic-3 plant.
H
ydro-Québec is an integrated electric
company that generates, transports
and distributes almost all the
electricity consumed in the Canadian
province of Québec. With more than 23,000
More than 96 employees and a single shareholder (the
percent of the Québec government), its generating fleet
power Hydro- comprises 56 hydroelectric generating
stations, a nuclear generating station, four
Québec generates conventional thermal generating stations
is hydroelectric, and a wind farm, representing a total installed
making it one of the capacity of 35.5 GW. More than 96 percent
of the power it generates is hydroelectric,
largest renewable making it one of the largest renewable
energy producers in energy producers in North America.
North America.
Hydro-Québec continually focuses on its
three main priorities: energy efficiency,
complementary development of
hydroelectricity and wind power (the two
major renewable energy sources in
Québec), and technological innovation.
Additionally, the company manages a
number of rehabilitation projects and
rigorous programs of periodic maintenance
8 Dassault Systèmes
designed to optimize existing plant output
and efficiency.
Manic-3 refurbishing project
Many of Hydro-Québec’s plants have been
in operation for years. Refurbishing these
plants is necessary to reduce operation
costs, extend plant life and optimize
energy output levels. But replacing
outdated equipment and making repairs
takes time and requires that a plant be
taken offline during the refurbishment.
To optimize this process, Hydro‑Québec
decided to perform a refurbishing feasibility
study on its Manic-3 generating station in a
3D virtual environment using PLM solutions
from Dassault Systèmes. This enabled the
company’s teams to outline all the necessary
project steps, foresee eventual challenges
and optimize each refurbishing phase
before embarking on the actual renovation.
Hydro-Québec engineers had the original
drawings of the Manic-3 dating back more
Although the refurbishing study took six weeks to complete, from the
scanning phase through the simulation with DELMIA, Hydro-Québec was
able to eliminate 200 weeks from its refurbishment planning, saving
CAN$50 million and clearly demonstrating the real advantage of using a
solution like DELMIA.
than 30 years. But improvements and
repairs made to the station over the years
were not always documented in these
drawings. With no up-to-date documented
view of the plant, Hydro-Québec began
with its original 2D drawings.
The first phase of the study involved
updating the drawings of Manic-3. Laser
scanning was used to map the physical
plant’s current configuration. In only two
days, a complete, updated view of the
interior was generated. Engineers
compared the updated view with the
original drawings to see where
modifications had been made. The result
was a realistic 3D model of the plant’s
interior on which to base simulations.
CATIA for virtual design
and DELMIA for virtual
simulation
For the next phase of the study, engineers
used CATIA to create a 3D virtual model of
the station and all the equipment it
contained. They then used DELMIA to
simulate the different refurbishing tasks.
Disassembling, moving and reassembling
equipment were simulated during the
refurbishing study. Because such
operations require strict scheduling,
planning to ensure the safety of employees,
and working in limited space, the flow of
tasks had to be carefully sequenced.
For example, engineers simulated the
disassembly of the alternator – removing
its cover and all fixed and moving parts,
including the rotor, and identifying the
best place to set down the different
components. With DELMIA, interferences
were clearly visible on screen, allowing
engineers to adjust the trajectory of the
movement of every part. Being able to
identify and plan for such operations in a
virtual simulation avoids costly physical
mockups and time-consuming errors in
practice, particularly when each piece of
equipment is a complex assembly of
different parts that can weigh hundreds of
tons. Thanks to DELMIA, engineers were
able to simulate each movement with the
precision of a few centimeters, exceptional
for equipment of this size.
Savings of 200 weeks
and CAN$50 million
Although the refurbishing study took six
hydro power
weeks to complete, from the scanning
phase through the simulation with
DELMIA, Hydro-Québec was able to
eliminate 200 weeks from its refurbishment
planning, saving CAN$50 million and
clearly demonstrating the real advantage
of using a solution like DELMIA to optimize
study projects. As a result, Hydro-Québec
plans to deploy similar virtual simulations
on other refurbishing projects and extend
its use of PLM solutions to all steps of its
projects, from design and engineering to
construction. In fact, the Hydro-Québec
Estimation Team already is using DELMIA
to estimate concrete volumes and
optimize the sequence of concrete
placement in its new construction and
refurbishment plans• )
Emmanuel Boivin-Moreau is the CATIA
CAO 3D Manager, Information Systems, at
Hydro-Québec Administration and Control.
Emil Dobrescu, Mechanical Engineer, is
the PDM Team Leader, Information
Systems, for Hydro-Québec Equipment.
For more information:
www.hydroquebec.com
Contact mag 9
 hydro power

By Nicolas Maritan ]
UCM Resita, the leading hydropower
equipment producer on the Romanian
market, chose CATIA and ENOVIA
SmarTeam to cut operation costs by
10% and thereby reinforce its leadership.

UCM Resita: Business

DS PLM going
East at full speed!
Industries in Central and Eastern Europe
have demonstrated a continuous growth
over the past years, certainly accelerated
now by the expansion of the European
Union to 27 countries with Romania and
Bulgaria. Design engineering and techni-
cal support capabilities have become the
new business drivers consolidating the
well established manufacturing activities
(see the example of UCMR in Romania).
It is of no surprise, then, that Dassault
Systèmes has created a new organiza-
tion dedicated to this part of Europe. Its
headquarters is conveniently located in
Vienna, Austria, nearby Microsoft’s HQ,
and is now the hub for all DS teams ser-
ving customers and partners in Austria
and in Central/Eastern Europe.
Further to the East, we continue to
strengthen our very successful Moscow-
based organization serving Russia
and the CIS countries.
Patricia Doherty
Dassault Systèmes
10 Dassault Systèmes
Transformation with DS PLM
T
he energy sector in Romania is
undergoing a transition process from
a state-owned structure to a
competitive and liberalized entity. UCM Resita
has important manufacturing capabilities and
expertise in hydropower equipment, but
needed a radical business transformation to
broaden its market share on the European
market while remaining profitable.
In 2004, UCM Resita and Dassault
Systèmes’ Partner Cybernetics started
working together to define a smooth
transition from a 2D oriented organization to
a 3D PLM strategy based on CATIA and
ENOVIA SmarTeam.
“For the last year, we have been looking
for leading-edge design solutions to
develop high-quality, innovative and
competitive products. Our goal is to reduce
operation costs by 10% and increase
product quality while complying with
environmental regulations,” said Adrian
Chebutiu, President & CEO of UCM Resita.
With large projects like these in the process
industries, even savings of 1-2% can mean
millions of dollars and make the difference
between a profit and a loss.
Reduce time-to-market
UCM Resita began its PLM Project in 2005 by
implementing 72 seats of CATIA. A first
CATIA Fundamentals Training class, followed
by a pilot project in each UCM Resita
department, was delivered in order to define
the company’s best practices and optimum
working methodologies. This structured
approach optimized the learning process
while minimizing disruption and downtime.
Today, the engineering processes are
standardized on the CATIA development
platform, rather than being largely separate, as
in the past, where each UCM Resita
department used its own CAD system.
“To establish interdisciplinary project teams,
the use of the same system is of vital
importance,” underlines Mrs. Azuga,
implementation and IT director of UCM Resita.
After a 12-month use period, UCM Resita
teams have achieved astonishing results.
“The design of new assembly parts that
used to take several weeks now takes a
couple of hours. This means that we can
dramatically reduce our time-to-market.
Moreover, by moving from the previous 2D
system to CATIA, the number of errors
made during the design phase have been
significantly cut thereby improving quality
by 10%,” Mrs. Azuga says.
Optimizing knowledge reuse
In parallel to the implementation of CATIA,
a small working environment of ten ENOVIA
SmarTeam seats was created for some of
UCM Resita’s key users. After five months
of learning, testing and tuning to comply
with UCM Resita’s requirements, the
solution was extended to 72 seats.
“We needed to implement ENOVIA
SmarTeam in order to shorten new product
development times and reuse the
experience and know-how from former
projects,” states Mrs Azuga.
She adds, “We were using a file-based
man­a gement system and had difficulty
accessing information. We lost many
documents and spent hundreds of hours
recreating them. Now, ENOVIA SmarTeam
provides us with a robust platform that
securely stores and provides universal
access to product knowledge. Data from
CATIA can be shared, in real time, by our
engineering teams.”
Another major advantage for UCM Resita is
that ENOVIA SmarTeam automatically
generates all the documents necessary for
production launch. These were previously
prepared manually by UCM Resita’s
engineers, which not only took a lot of time
but also was prone to errors.
Future PLM projects
UCM Resita has recently signed a contract
with a Russian company to produce buses
on its platform. “We want to extend the
benefits of our PLM strategy to our
new activities,” explains Mr. Chebutiu,
president & CEO of UCM Resita.
In addition to the acquisition of new seats,
UCM Resita wants to migrate some of its
licenses to the CATIA PLM Express Portfolio
to take advantage of the Knowledgeware
concept and to develop ENOVIA
SmarTeam’s workflow capabilities to
streamline its business processes • )
For more information:
calin.ilici@cybernetics.ro
Contact mag
More about UCM Resita
UCM Resita has more than 230 years
of experience in the field of machine
building. For the past 45 years, UCM
Resita has been developing complete
hydropower and hydro mechanical
equipment.
The company also performs research,
development and testing activities and
provides specialized services such as
refurbishing and upgrading hydro units
in operation. In 2003 INET Group,
a Swiss investment consortium,
acquired UCM Resita.
www.ucmr.com
More about Cybernetics
Cybernetics is the leading Romanian
supplier of PLM Solutions including
CATIA, ENOVIA and DELMIA. Strong
involvement of Cybernetics’ engineers
during specification and implementation
phases, as well as the education of
UCM Resita’s engineers, has been
essential. Over a period of five months,
four engineers have been sent to
the UCM Resita site to provide the
necessary technical support.
www.cybernetics.ro
Contact mag 11
 other renewable

ENOVIA methodology provides business benefits Design Rule Tools for buness process automation
at Solar Century

«
Solar Gain
] By Nick Lerner
UK environmental energy system design and engineering firm By also using DRLTools, developed by
Solar Century is equipped with an IT infrastructure delivering self- Design Rule, to augment ENOVIA SmarTeam,
Burgess is able to more easily configure and
managed efficiency and automation - in record time.
fully utilize ENOVIA SmarTeam objects and
associated data, design his own forms and
ENOVIA allows us
to synchronize information
within and beyond our
enterprise more intelligently.
“Measuring and reporting project progress in
relation to business expectations is now
a simple process that offers the benefits
of being concurrent, consistent and in
real time,” Burgess said. “This delivery of
Lofty Ambitions
“Among the advantages of ENOVIA
SmarTeam is control over change orders
and the communication of engineering
concerns in a targeted way so that the
correct expertise can be efficiently brought
to a project,” Burgess said. “These factors
allow people access to pertinent information
and, as the company grows, these software
tools enable us to create new elements
to our workflow to accommodate varying
circumstances within our extended

B
ased in London and Waterloo, UK,
Solar Century designs and installs
solar panels across the world and
is the premier firm for this increasingly
significant part of the building industry.
Up on the Roof
With property owners increasingly aware
of their carbon footprint, Solar Century is
experiencing rapid business expansion, with
consequent increased demands on its own
infrastructure. The company employs around
100 people - and counting. Mat Burgess, the
company’s development manager, described
how by partnering with UK Dassault Systèmes’
Solar panels bring sustainable advantage
12 Dassault Systèmes
value-added reseller Design Rule, they have
introduced a flexible ENOVIA SmarTeam-
based methodology that provides the tools
to efficiently manage all future business
expectations. “Like many growing companies,
Solar Century was running a range of diverse
business management software which
was not effectively connected. This led to
inevitable operational inefficiencies which
we recognized and sought to address using
Design Rule’s expertise.”
Free The Power
Generating your own power and selling it into
the grid will become more profitable in the UK
as it grasps the realities of sustainability, and
this spells sunny times for Solar Century. Design
Rule MD Bob Hiller commented, “Inevitably,
companies that grow fast from a small
base have the same issues to deal with as
larger companies. Many outgrow their IT
infrastructure even before it has delivered
any real business benefits. To deal with Solar
Century’s plans, an ENOVIA SmarTeam solution
that matches the business’ current and future
requirements has been deployed that can
grow with them and is indeed grown by them
using their own resources.”
objects and link their content with the same
powerful ENOVIA SmarTeam technology and
reporting systems that are used by the world’s
leading design-to-manufacture enterprises.
He said, “Design Rule’s ENOVIA SmarTeam
Productivity Tools (DRLTools) allow us to
synchronize information within and beyond
our enterprise more intelligently,” Burgess
said. “Automatic actions are generated
from object input. This saves time on
every job because the data builds into a
single complete system that delivers all the
information that people need in the way that
they need it.”
Magnified Vision
All information in ENOVIA SmarTeam is validated
‘in process.’ Solar Century data covering
workflows, documentation, CAD, Bills of
Materials, version control, budgets, project
progression, materials specification, suppliers,
purchasing and quotations are managed
using SmarTeam Engineering Express,
Workflow, BOM and Community Workspace.
DRLTools is an enabler for delivering greater
user acceptance and consequent productivity
efficiency benefits.
current business intelligence allows decisions
to be made that are based on more reliable
information.”
Hiller added, “The technology used by the
world’s leading manufacturers to unlock the
value of company data was deployed at
Solar Century in just two months. By utilizing
Dassault Systèmes ENOVIA SmarTeam
methodology in a company with the size
of Solar Century, its ability to improve
efficiency is magnified. Profitability and
working efficiencies become instantly visible,
while a complete workflow methodology
becomes available.”
Many of Solar Century’s customers benefit from
a service that includes technical consultancy,
system design, panel manufacture and final
installation. The company also devises and
delivers other systems, including wind turbines.
The company has a strong network of partners
who are now able to collaborate with Solar
Century, generating concurrent working
practice. This allows for great productivity
gains since there is less reliance on
completion of one part of a project before
another can start.
supply chain. As the system grows, the
further automation that DRLTools helps
develop will create more intelligent
objects, while the data that they contain
or relate to become an increasingly
valuable business asset. Also, because the
system integrates with the Microsoft Office
suite of software, applications such as Excel
can be used to great effect and its data ENOVIA SmarTeam supports
bi-directionally integrated with ENOVIA Innovation at Solar Century
SmarTeam to create further efficiencies.”
Estimates suggest that if every building
in London were equipped with solar ENOVIA SmarTeam
panels, the scheme could pay back and DRLTools benefits:
in three years and provide more than
• Concurrent working practices
enough energy for the city’s needs for
• Greater control over processes
generations. The same is true for the whole
• Interoperability with Windows-based
planet. Solar Century is positioned to take applications
advantage of market growth, as it • Increased operational optimization
prossesses an IT infrastructure that is robust • Quick, intuitive and flexible software
enough to take the company safely into its configuration
future and is increasingly becoming an AEC • Greater control over the product lifecycle
industry standard technology toolset • ) • Visibility of project status
• Audit trial and adherence to standards
For more information: • Fast accurate communications enabled
www.solarcentury.com across the extended enterprise
www.designrule.co.uk
Contact mag 13

Wind Turbine Composites Design: Leveraging
Aerospace Advances for Improved Durability
With wind-installed capacity growing at a rate of 35% per year, wind
]
By Rani Richardson
turbines are the composite industry’s fastest-growing application.
Ultra-light, strong and durable, composites are ideal for producing
lightweight blades with tremendous performance capabilities.
Applying aerospace
W
ith high hopes riding on this
alternative energy source, the
best practices to wind turbine blade industry is
the challenges of working hard to improve manufacturing
wind turbine efficiency and address blade failure issues.
But challenges remain great, with failure
composites design rates as high as 20% within three years.
and manufacturing
creates the Wind turbines: more
plentiful, powerful
opportunity to According to the World Resources Institute,
effectively address production of wind turbines and systems
common challenges. has increased by a factor of 5.2 since 2000,
and by a factor of 115 since 1990. In 2008,
the Institute estimates that composite wind
turbine blades worth an estimated $5.9
billion were delivered globally. Composites
Market Reports (CMR) estimates that by
2017, the global value of all wind turbine
blades will reach $34 billion.
Wind turbines are not only becoming more
plentiful – they’re becoming more powerful.
14 Dassault Systèmes
Increased power is accomplished primarily
by increased length; according to CMR,
the fastest-growing segment of the market
is for turbines with a capacity of 1.6 MW or
higher – requiring blades of 37 meters
(123 feet) to more than 60 meters (200
feet) and weighing 12,000 pounds each.
Composite materials are ideal for producing
wind turbine blades, yet the structural
Wind turbine manufacturers must rapidly develop best design and
manufacturing practices that will help them meet market demand by
reducing design lead time . . . and optimizing manufacturing processes.
complexity of these materials also presents
difficult challenges in optimizing design and
manufacturing methods – especially over
such extensive lengths. As a relatively young
and fast-growing industry, wind turbine
manufacturers must rapidly develop best
design and manufacturing practices that will
help them meet market demand by reducing
design lead time, improving blade durability,
and optimizing manufacturing processes.
From a design and manufacturing
standpoint, wind turbine blades have many
similarities to helicopter rotorcraft blades
and other aerospace structures. Wind
turbine manufacturers, therefore, have the
unique opportunity to adapt and apply the
best practices developed and refined over
several decades in the aerospace industry
to help their businesses succeed in a tough
competitive environment.
Harnessing the wind
with composites
Composites dominate both the wind
turbine blade and rotorcraft blade markets
due to their superior fatigue characteristics
and stiffness-to-weight ratio, their unique
ability to fabricate complex geometries,
and their potential for aeroelastic tailoring.
In particular, the properties of composite
blades can be tightly controlled and varied
over their span through the appropriate
selection of ply orientation, thickness and
lay-up.
The ability to tailor composites to specific
loads and other requirements is among
their greatest strengths, but also increases
the complexity of the design process.
Optimizing the properties of the blades is
critical to delivering the needed bending
strength and fatigue performance while
minimizing cost and weight. Common
failure issues currently challenging the
composite wind turbine blade industry
include manufacturing errors, such as
waviness or overlaid laminates; bad
bonds, delamination and voids; leading-
edge erosion; trailing-end splits; and
damage caused by lightning strikes.
Lessons learned in the rotorcraft blade
industry can be used to dramatically
improve wind turbine design and
manufacturing and reduce failure rates.
The aerospace industry has developed
best practices such as structural zone-
based modeling and a grid-based
approach using analysis thickness laws or
stacking sequences that can be applied
early in the lifecycle of a part. Both design
approaches save time that can be used to
create more iterations in pursuit of a
superior design.
Best practices for
better blades
Best practices pioneered in aerospace
design can also substantially improve the
analysis process by integrating design
with finite element analysis (FEA) for fast
design-analysis iterations in full
other renewable
associativity with the zones and plies
definition. The latest FEA software provides
engineers with advanced capabilities for
simulating realistic composites behavior,
including delamination and failure.
Aerospace best practices also use
simulation to identify manufacturing
problems in the virtual environment,
making the first iteration of a design
correct or very close to correct and
eliminating the need for trial and error on
the shop floor. Composites design and
manufacturing data can also be linked to
nesting, laser projection, and tape laying
and fiber placement systems to streamline
downstream processes.
Applying aerospace best practices to the
challenges of wind turbine composites
design and manufacturing gives
manufacturers the opportunity to effectively
address common challenges such as
delamination, leading-edge erosion,
trailing-edge splits and manufacturing
errors such as overlaid laminates.
By borrowing best practices from the
aerospace industry, wind turbine
manufacturers can achieve better design
and layout results that will deliver more
reliable performance and help the wind
energy industry continue to grow its
contribution to a clean, sustainable energy
future•)
For more information:
To download a copy of the Dassault
Systemès white paper “Wind Turbine
Blade Composites Design: Leveraging
Aerospace Advances for Improved
Durability,” please visit
www.plmv5.com/composites
Contact mag 15
 other renewable
The Pelamis is a semi-submerged
floating structure, composed
of cylindrical steel sections
linked by hinged joints.

The Pelamis is designed

for offshore locations,

Harvesting the Power

giving maximum flexibility
and scalability.

«
of the Ocean The fluids we do
use are biodegradable
“It allows us to analyze ‘what-if’ scenarios of
nonlinear behavior that we cannot test for, such
as a ship driving into a farm of machines. Even
SIMULIA, a deciding factor in its choice of
solutions from the Dassault Systèmes brand.

Pelamis Wave Power Ltd chose Abaqus from SIMULIA to perform place to install a wave farm. PWP works
with project developers to select sites that
complex, nonlinear, finite element analyses (FEA) of its products meet criteria such as the availability of grid
and soon adopted it for all its design analysis needs. capacity, wave energy levels that produce the
highest yield of electricity, and sites that do
and nontoxic.
is done and where they incorporate input from
the different departments such as hydraulic
systems, electrical layouts and production
though this is highly improbable, it is nevertheless
a remote possibility and, for safety reasons,
we need to be able to design our machines to
resist this type of impact.”
“Abaqus has become the global finite
element package at PWP, which we now
use for practically all our analysis needs,”
said Jon Benzie “We use it for initial concept
analysis, general design work, detailed

P
elamis Wave Power Ltd (formerly known
as Ocean Power Delivery Ltd) is an
Edinburgh-based company founded
in 1998 to develop a novel offshore wave
energy converter called Pelamis. The Pelamis
is a semi-submerged, articulated structure
composed of cylindrical sections linked by
hinged joints. The wave-induced motion of
these joints is resisted by hydraulic rams, which
pump high-pressure oil through hydraulic
motors via smoothing accumulators. The
hydraulic motors drive electrical generators to
produce electricity.
16 Dassault Systèmes
Pelamis Wave Power has 75 employees with
expertise in areas such as mechanical, structural,
off-shore and hydraulics engineering as well
as control systems and naval architecture. It
positions itself as manufacturer and assembler
of the Pelamis technology, supplying machines
to utilities and energy companies such as EDF
or Scottish Power. Power projects consist of
arrays of interlinked Pelamis machines known
as ‘wave farms.’
Cost effective energy of
considerable potential
The World Energy Council estimates a large
global market potential for wave energy of
2000TWh/year - similar in scale to the existing
nuclear or hydroelectricity sectors. With one of
the lowest ‘opening costs’ of any preceding
technology, PWP states that wave energy has
the potential to be one of the most cost-effective
options over time – provided that there is
volume deployment into the market. A key
challenge that has faced the company is
not just the technical challenge of producing
a good-quality, reliable product, but the
need for political support to create the
‘feeder markets’ necessary for first projects.
Another challenge is finding the right
not interfere with other water users such as  assembly requirements. Since the lifespan of
merchant shippers, fishing fleets and
recreational users. Also important are
environmental concerns, which is why
environmental impact studies are normally
required in order to obtain a permit to install
and operate a project at a site. “We believe
our technology has the potential to be one
of the most environmentally benign forms
of electricity generation,” said Max Carcas,
Business Development Director at PWP. “We
make sure that we have no greases or fluids
in direct contact with the seawater. This is why
everything is sealed and the fluids we do use
are biodegradable and nontoxic,” he adds.
To develop a Pelamis machine, PWP begins
with an initial concept that comes from either
information received from prototype testing or
from existing designs to which performance
improvements for certain climatic conditions
need to be added. The initial design is then tested
both computationally and with scaled prototypes
during tank tests, where large waves are
simulated and nonlinear behavior is observed.
Once the global machine is defined, PWP
engineers design the key machine components.
This is where most of the finite element analysis
PWP also selected Abaqus because of its sub- design work and what-if scenarios. We
a machine can reach 20 years, PWP performs modeling capabilities, which allow it to perform are also looking to expand the types of
a considerable number of design iterations extensive and highly focused studies on the analyses we can do by tying it into our dedicated
on components that are put to the test with different sub-parts of a machine, thereby in-house analysis program to directly model
respect to fatigue performance and stress increas­ing the precision and reliability of the machine behavior in the waves. By coupling
analyses. Once the global design is complete, data. The software’s extensive material modeling this with Abaqus, we should get direct results
PWP creates the detailed design, which to date capabil­ities are also important to PWP since they of the machine’s structural component-level
has been independently verified by third-party need to experiment with different materials for behavior, hence providing additional stress
consulting firm WS Atkins. The Pelamis is then machine design to understand the behavior of and fatigue analyses”• )
assembled and installed by PWP’s offshore new materials as they seek to make machines
and installation team, which also performs all as efficient, cost effective and environmentally
maintenance activities. sound as possible. Finally, PWP was impressed
For more information:
www.pelamiswave.com
with the technical support provided by
Digital modeling and
simulation with Abaqus
PWP’s modeling program combines
advanced numerical work and computer
simulations with extensive use of
experimental models. Numerical modeling
is a vital part of the program, as it
allows rapid design evaluations and
optimizations to be made. Much of the testing
PWP performs revolves around nonlinear
analyses, which is why it turned to SIMULIA.
“We needed to extend our finite element
capabilities, and Abaqus from SIMULIA was
by far the best solution available,” said Jon
Benzie, senior engineer at PWP.
Contact mag 17

Yantai Raffles Shipyard
Charting the Future With Dassault
Systèmes PLM Solutions
« ensure it would meet the building
S
ingapore-headquartered Yantai
The use of CATIA
Raffles Shipyard (YRS) Ltd. is a
and its intelligent leading offshore and marine
templates for design fabrication specialist. At its production
facilities in Yantai, China, YRS specializes in
allows YRS designers the construction of marine and offshore
to work more efficiently projects that include jack-up drilling rigs,
and gives them the semi-submersible drilling rigs, pipe lay
vessels, floating production, storage and
freedom to come up offloading vessels (FPSO) and other
with more creative and prototype vessels, as well as luxury yachts.
innovative ideas YRS is the largest rig builder in China,
boasting state-of-the-art building facilities,
Liu Hu, IT Manager,
Yantai Raffles Shipyard including Taisun, the world’s largest crane.
With the Shipbuilding and Energy industries
enjoying double-digit growth worldwide,
YRS is poised to increase sales and expand
its market share. But like its competitors, the
company is under pressure to deliver vessels
faster and at a lower cost. To stay truly
competitive, YRS needs to demonstrate
consistency in innovation, product quality
and customer service by optimizing its work
processes and use of resources.
18 Dassault Systèmes
DS PLM for improved design,
testing and manufacturing
processes
YRS realized it needed to quickly move from
2D paper-based systems to a 3D-based
model to stay ahead of the competition. It
adopted CATIA for offshore structural
designs and now has more than 50 users.
“The use of CATIA and its intelligent
templates for design allows YRS designers
to work more efficiently and gives them the
freedom to come up with more creative and
innovative ideas,” said Liu Hu, IT Manager,
Yantai Raffles Shipyard.
CATIA’s inherent information-sharing
capabilities make it simple for suppliers and
clients to review designs and update
information. And with SIMULIA, engineers
are able to conduct finite element analysis
on the fly to determine structural weaknesses
and quickly and seamlessly assess the
impact of design changes made in CATIA.
YRS uses DELMIA to enhance manufacturing
efficiency by virtually simulating
manufacturing processes in 3D. YRS
engineers can accurately determine what
resources are needed for each production
scenario, identify the best procedures and
the fastest way to fabricate vessels and
pinpoint possible problems before they
happen.
But designing and building ships involves
large volumes of data that are accessed,
shared and managed by different parties in
the lifecycle. ENOVIA VPLM ensures a
smooth flow of information among the users
by providing a central data repository. Its
advanced relational design manages the
knowledge captured in CATIA designs,
automatically propagating any changes
across hundreds of parts and communicating
them to the relevant teams.
YRS also uses the virtual assembly
capabilities of DS Digital Mock Up (DMU) in
CATIA and ENOVIA VPLM for simulation of
assembly and human maintenance flow.
“This helps us to ensure that the design can
actually be assembled and maintained, a
key factor given the limited space on
offshore vessels,” said Lan Gongying, PLM
user, Yantai Raffles Shipyard.
Better engineering with DS PLM
DS PLM solutions also have empowered the
company to build its own mega structure, a
crane known as Taisun. After seven years to
conceptualize and one year to build, Taisun
has a lifting capacity of 20,000 metric tons
– the equivalent of 10,000 cars in one lift.
This manufacturing marvel would not have
been possible without DS PLM solutions to
simulate the entire design process and
requirements. Using CATIA for offshore
structural design, DELMIA for crane
production and simulation, and ENOVIA
VPLM for creating digital 3D mock ups, YRS
accelerated Taisun’s building process,
reducing design errors that could have
driven up costs and significantly improving
production efficiencies.
YRS engineers used DS PLM solutions to
evaluate, understand and solve many of the
unique problems it faced in building a crane
of such magnitude. “YRS was able to design
Taisun in an unprecedented six months
oil and gas
rather than the two years it would have taken
without the use of PLM,” Lan Gongying said.
With Taisun, YRS will be able to build
offshore structures up to70% faster and see
increases in design productivity of as much
as 30%. This will allow a savings of more
than two million man hours on each semi-
submersible built, as well as increase YRS’s
overall building capacity.
DS PLM solutions also have transformed the
way YRS does business with third-party
suppliers. ENOVIA has opened the lines of
communication by making information easy
to share and update.
“Using ENOVIA VPLM to manage full 3D
digital mock-ups and standardize product
development processes, we were able to
outsource work to the best partners and
suppliers and ensure strict quality control,
design precision and other mission-critical
elements in the end-to-end process of
planning, designing, building and project
management,” explains YRS Executive
Chairman Brian Chang. “Moving forward,
our PLM platform will be an integral part of
our strategic plan to drive future business
and become the ‘Yard of Choice’ for partners
and clients.”
The benefits it has accrued from deploying
DS PLM have motivated YRS to further
expand its existing solution. It recently
deployed DS ENOVIA MatrixOne, which will
play a central role in managing the
collaborative product development business
and data processes of YRS and its
partners•)
For more information:
www.yantai-raffles.com
Contact mag 19
 oil and gas

Preem’s Refinery
in Lysekil, Sweden.

Lars-Martin Arendal
ENOVIA Refined Preem By Dora Lainé
]
«
S
Preem adopted ENOVIA trong demand for refined products Flexible plant data Role-based workflow Moreover, once all processes are documented,

SmarTeam to manage the

voluminous design data and
technical documentation for the
equipment in its Lysekil refinery.
ENOVIA SmarTeam enhanced
safety, quality and accessibility
of data and documents.
About Preem
Preem AB is the largest oil company
in Sweden. It accounts for 80% of Swedish
refinery capacity and 30% of Nordic refi-
nery capacity. In total, over 17 million tons
of crude oil are refined each year, making
Preem the biggest refiner in the Nordic
region. Over 60% of the production is
exported, making Preem one of the
largest exporters in Sweden. The com-
pany has 1400 employees and sales in
2006 of SEK 68 billion (US$11.3 billion).
Preem owns two refineries - PreemRaff
Lysekil and PreemRaff Gothenburg, which
are among the most modern in Europe.
www.preem.se
compels companies like Preem to
produce fuel at an accelerated pace in
a cost-effective way. At the same time,
environmental regulations require cleaner,
more efficient refining methods, forcing refining
companies to improve their processes for
optimized plant output during their 30- to 40-
year life span.
Long life span requires
robust data management
capabilities
At the PreemRaff Lysekil refinery, engineers
needed to replace the company’s obsolete
PDM system with a more robust solution
that could keep track of all equipment-
related data and documentation. The new
system was to become the long-term library
for equipment designs, where engineers
could find relevant drawings for many years
to come. Refineries have long life spans,
and Preem wanted a system from a well-
established company that would provide it
with support long into the future. “It’s
important to follow the evolution of a plant
over a long period of time, and ENOVIA
SmarTeam is flexible enough to adapt over
the years as the needs of the plant evolve,”
says Lars-Martin Arendal, CAD system/
design engineer, Preem.
management with ENOVIA
SmarTeam
To manage data and product documentation,
Preem chose Dassault Systèmes’ ENOVIA
SmarTeam. “Among the four candidates we
benchmarked, we found ENOVIA SmarTeam to
be more graphic, more visual,” says Arendal.
Preem was also impressed by the flexibility of
ENOVIA SmarTeam. Preem customized its
solution to suit the specific needs of the refinery
business. “For document numbering, we have
a specific numbering system that an out-of-the-
box system cannot natively manage,” says
Arendal. “With ENOVIA SmarTeam, we made
these changes with no problem. ENOVIA
SmarTeam has great flexibility that enables
users to easily tailor it to the needs of their
sector. Plus, additional customizations can
be done over the lifetime of a project to meet
changes in methodology.”
As the primary application for refinery technical
documentation management, ENOVIA
SmarTeam serves as the master register of
functions and equipment. Thanks to ENOVIA
SmarTeam’s vault functionality protecting
approved files, document safety is ensured.
Preem uses ENOVIA SmarTeam to manage
revisions to equipment designs, ensuring
that the correct parts are used for repairs and
ENOVIA SmarTeam
is flexible enough to
adapt over the years
as the needs of
the plant evolve.
that the refinery is correctly maintained over
time. “We have considerably enhanced the
safety and quality of our data and documents
thanks to ENOVIA SmarTeam,” says Arendal.
Project view over the plant structure, drawings and documents,
and meta data for a specific document.
Drawing of piping - shows the location
of the pipes at the plant.
management
In the near future, Preem will expand its
implementation by adopting ENOVIA SmarTeam
for workflow management to check and approve
new drawings. The company will map its internal
workflows in ENOVIA SmarTeam, using its role-
based approach, to enable standardized
automatic approval process management. It will
also handle drawing check-in and check-out.
By activating a formalized, documented
workflow that is managed by the system, Preem
will avoid human error and optimize all processes
in accordance with standard procedures.
they can be measured and analyzed to enable
continuous improvement. Following the
successful deployment of ENOVIA SmarTeam
at the Lysekil refinery, Preem management at the
Gothenburg refinery is considering implementing
ENOVIA SmarTeam as well, which would enable
the two plants to share common parts, processes
and related information, thus benefiting from
economies of scale • )
For more information:
Jonas.Gejer@technia.com
About Technia
Technia is one of the leading suppliers
of Product Lifecycle Management Solu-
tions for creating and managing product
information throughout the entire product
lifecycle. Technia, with more than 110
employees, is a strategic partner of more
than 200 companies. It has offices in
Stockholm, Gothenburg, Helsinki and
Oslo. Technia’s customers include: Erics-
son, Elcoteq, ESAB, Danaher Motion, GE
Healthcare, Marioff, Metso Paper, Mölnlycke
Health Care, Nokia, Perkin Elmer Life
Sciences, Proximion, Scania, Sectra
Mamea, and Sony Ericsson.
www.technia.com

20 Dassault Systèmes Contact mag 21


T3 Energy Services Ensures
Design Revision Accuracy
with ENOVIA SmarTeam
H
ouston-based T3 Energy Services,
Inc., designs, manufactures and
repairs custom-machined well-
control performance parts and components
for oil and gas industry installations along the
U.S. Gulf Coast, as well as in Canada, Mexico
and around the globe. The company’s more
than 500 employees are spread across
multiple sites in North America and work with
suppliers and partners worldwide.
T3 Energy has long relied on 3D CAD
software for its product designs. But as the
number of T3 locations proliferated and the
distance between them increased, so did
the challenges of managing its product data
and securing its intellectual property.
To solve these challenges T3 Energy
selected ENOVIA SmarTeam from Dassault
Systèmes. ENOVIA SmarTeam met T3
Energy’s need for multiple data vaults
serving widely dispersed physical sites. Its
multi-CAD capabilities ensured compatibility
with T3 Energy’s 3D CAD system. ENOVIA
22 Dassault Systèmes
SmarTeam also easily maintains part, model,
drawing and assembly relationships while
improving revision control.
ENOVIA SmarTeam’s check-in and check-
out features ensure that all users, regardless
of location, access the latest version and
that no changes are overwritten accidentally.
T3 Energy currently has 24 sites and six
product lines that use ENOVIA SmarTeam.
Therefore, keeping everyone in synch is
critical.
STAGED IMPLEMENTATION
One of ENOVIA SmarTeam’s key advantages
for T3 Energy was the ability to start small
and roll out in a step-wise fashion across
the company’s key product lines. T3 Energy
began with its Pressure Control Group.
“We used Pressure Control as our pilot to
work out our implementation process,” says
Danny Wolfe, engineering manager for T3’s
Pressure Control Group. “Once we had our
process defined to an acceptable level, we
«
Once we had our process defined to an
acceptable level, we could integrate another product
line and bring them onboard quickly. Being able to do
it that way, and keep it contained to a small group
of users in the beginning, was highly beneficial.
Danny Wolfe, Engineering Manager for T3’s Pressure Control Group
could integrate another product line and says. ENOVIA SmarTeam Navigator makes
bring them onboard quickly. Being able to product data widely available throughout
do it that way, and keep it contained to a the company in an affordable way.
small group of users in the beginning, was
highly beneficial.” FOCUS ON RAZORLEAF
The outsourced support T3 Energy receives
Wolfe says the same approach was from Razorleaf Corporation, a Dassault
used with view-only users, including T3’s Systèmes consulting partner, also solidified
manufacturing, sales and quality control the company’s choice. “We have a very high
teams. These users rely on ENOVIA level of confidence in Razorleaf’s product
SmarTeam’s Navigator web interface, a and process knowledge,” Wolfe says. “We
capability that proves its value on a continuing get an entire team of experts that are all very
basis. “Remote access is paramount as new good and respond well to customer needs.”
groups and partners come on board,” Wolfe
For example, Razorleaf helped T3 Energy
create a Bill of Materials (BOM) report that
associates an individual item with all of its
related documents. This report is a hybrid of
items and document specifications, with parts
and their related documentation all included
in one navigable, hierarchical structure.
The BOM report accommodates T3 Energy’s
unique needs by creating a snapshot of the
“parent-child” links, allowing users to access
associated sub-documents stored with
the BOM. The same code that generates
oil and gas
the report also pushes metadata from
ENOVIA SmarTeam to T3’s distributed ERP
(enterprise resource planning) systems.
“We no longer need to do dual entry of data,
so ENOVIA SmarTeam has become the hub
at the spoke of the wheel for us,” Wolfe says.
A FAST START, A BRIGHT FUTURE
ENOVIA SmarTeam will eventually become
the designated repository for all revision-
controlled documents at T3 Energy.
“Documents for legal, human resources,
manufacturing – it will branch out from
engineering until eventually every group at
T3 uses ENOVIA SmarTeam for its product
data management,” Wolfe says.
The company is even working on mapping its
ISO/APQ1 quality system, with plans to store
and manage its data in ENOVIA SmarTeam.
T3 Energy also plans to begin using the
“items” capability of ENOVIA SmarTeam to
represent physical components, in place
of its current document-centric approach.
T3 Energy further plans to extend ENOVIA
SmarTeam to link with its computerized
numeric control (CNC) milling machines,
eliminating the potential for errors and their
associated costs.
“Some of our single components are
20,000-plus pounds, so having the right
version of a design available to the
shop floor can easily prevent a mistake
that would cost $10,000 to $20,000,”
Wolfe says. With such savings, ENOVIA
SmarTeam is quickly paying for itself and
generating a substantial return on T3
Energy’s investment• )
For more information:
www.t3energy.com
www.razorleaf.com
Contact mag 23

Forsmark Nuclaer Power plant, located in North Roslagen,
is one of Sweden’s largest producer of electricity.
Forsmark Nuclear Power plant in Sweden selected ENOVIA SmarTeam to share data between different
environments, thus increasing efficiency. Technia met Christer Eriksson, Business Information Officer at
Forsmark, to better understand how PLM supports plant lifecycle management.
Contact Mag: What are the biggest
challenges facing the Nuclear Power
industry?
Christer Eriksson: Our company and
business face big changes – we are in the
middle of major modernization projects of
plants and facilities, and we have an aging staff
PLM for the process industry
Data management through PLM (Product
Lifecycle Management) has historically
been associated with product development
in the manufacturing industries. However,
petroleum corporations and nuclear power
plants have now seen the benefits of PLM
as well. Companies in the process industry
apply PLM strategies to record data about
equipment and assets, as well as specifica-
tions, general documents, service contracts
and spare parts. A short stoppage of their
production costs them a fortune. Using
PLM for Asset Data Management has been
seen to significantly reduce the risk of unex-
pected stoppages by facilitating planned
shutdowns. It can also lead to more efficient
planning of upgrades and thus contributes
to creating a safer workplace.
24 Dassault Systèmes
Working without a Glitch
where many experienced employees will soon
retire. A major portion of our staff has been
working with us since the plants were built a few
decades ago. As a result, our company risks
losing indispensable knowledge related to
these plants. Information resides in these
employees’ minds and passing it onto future
employees requires that we consolidate all
information in one place. This is where PLM
strategies come into play. Through PLM we can
record and then leverage this knowledge,
leading to better management of our plants and
documentation. Companies in our business often
use many different systems for asset and
document management, which store data in
different formats and locations, making it
difficult to find the correct information when
something fails. Furthermore, we have an
increasing number of safety and environmental
regulations to follow, and this can be managed
by our PLM System.
C.M.: Why has Forsmark invested in PLM?
C.E.: It all began with a need to manage our
document and product data in a coherent and
consistent way. Other possibilities existed, but
By Erik Johansson,
Technia AB ]
they involved using different systems that did
not necessarily communicate with one another.
It was functional, but we needed to increase
efficiency by sharing data between different
environments. Furthermore, the sources often
became corrupt when adding the “same” data
in different systems. We conducted a study of
different PLM systems and found that ENOVIA
SmarTeam suited our needs best.
C.M.: How many people use the solution?
C.E.: We’re managing all our documentation
with ENOVIA SmarTeam. As a result, our entire
staff of more than 1000 employees is involved
at some level. This is important because
everyone should be able to collaborate using
the same system. A key reason we wanted to
manage all information with one system was
because we wanted to bring together the entire
company and share a common culture across
the different organizations. There are often
many different subcultures in a company due to
the fact that they generally work with several
information systems. The maintenance
department has its own culture, whereas
constructors have another, for example.
« Efficiency and traceability are some of the most
important benefits derived by using ENOVIA SmarTeam.
Today it’s much easier to find the right information of
any particular part of the plant. It has also helped us
obtain a common view of the plant’s structure.
C.M.: How was the solution implemented?
C.E.: The implementation started back in 2006
and involved only documentation management.
Over the years we expanded the use of the
system, and now all product data is managed
with ENOVIA SmarTeam. It was not until the last
few months that we used the system as it was
meant to be used, thereby deriving the most
benefit from our implementation. Today all our
legacy systems are integrated into one.
C.M.: What are the specific benefits that
you have seen so far?
C.E.: Efficiency and traceability in our work.
Today it’s much easier to find the right
information of any particular part of the plant. It
has also helped us obtain a common view of
the plant’s structure. As mentioned earlier, our
systems are now fully integrated with one
another and communication between them has
been possible thanks to our PLM system.
Each of Forsmark’s three water
boiler reactors produces every
year enough electricity to cover
Stockholm’s needs.
Furthermore, specific task-oriented
documentation, for example maintenance
tasks, can more easily be defined and linked
to the documentation for the actual equipment
in question. Review and approval flows can
be tailored for specific document types and
thus be supported by the PLM system.
Control of revisions is very well supported in
the system. The ability to classify a
document’s lifecycle in different work-classes
is a particular strength of the PLM system.
C.M.: What is in store for the future?
C.E.: We plan to expand our PLM
implementation. The next step in our PLM
strategy is to integrate the import/export
capability so that, for example, our
subcontractors can work with us using the
same system. We’re also planning to optimize
our project environment in order to have even
better control over project documents • ) lycke Health Care, Nokia, Perkin Elmer
For more information:
Jonas.Gejer@technia.com
nuclear power
More about Forsmark
Forsmark is the most recently built nuclear
power plant in Sweden. The three reactors
were all commissioned between 1980
and 1985. The total power output is
approximately 3,160 MW. Forsmark has
950 employees and an annual turnover
of around SEK 5.5 billion. The company
was founded in 1973 by Vattenfall AB and
Mellansvensk Kraftgrupp AB. The current
owners are Vattenfall (66%) Mellansvensk
Kraftgrupp (25.5%) and E.ON Kärnkraft
Sverige (8.5%).
www.vattenfall.com
More about Technia
Technia is one of the leading suppliers
of Product Lifecycle Management Solu-
tions for creating and managing product
information throughout the entire product
lifecycle. Technia, with more than 110
employees, is a strategic partner of more
than 200 companies. It has offices in
Stockholm, Gothenburg, Helsinki and
Oslo. Technia’s customers include: Erics-
son, Elcoteq, ESAB, Danaher Motion, GE
Healthcare, Marioff, Metso Paper, Möln-
LifeSciences, Proximion, Scania, Sectra
Mamea, and Sony Ericsson.
www.technia.com
Contact mag 25

Entergy Nuclear Simulates Nuclear
Plant Maintenance with DS PLM
«
The use of
DS PLM during the
planning process
reduces overall
risk and improves
scenario planning for
any major project.
John M. Mahoney, Innovation
Leader, Entergy Nuclear
ENTERGY NUCLEAR
26 Dassault Systèmes
Entergy is a U.S. energy provider with nearly 15,000 employees,
30,000 megawatts of generating capacity, and 2.7 million customers.
Entergy Nuclear manages the second-largest fleet of nuclear reactors
in North America with 11,022 megawatts of capacity – roughly
equivalent to the peak power demand of New York City in 2003.
M
ost US nuclear power plants are
having their licenses extended,
bringing their permitted life from
40 years to 60 years or more. Maintaining
and updating the plants often require
complex, one-of-a-kind maintenance
operations. Many involve moving objects
that weigh tons through spaces with
clearances of as little as two inches.
Planners must have confidence the operations
are feasible, safe and can be completed in
brief maintenance shutdown periods.
Traditional tools, including physical mockups,
tabletop exercises and walkthroughs, are
effective but expensive, and each day added
to an outage by unanticipated issues can add
$1 million to the cost.
In search of a better way, Entergy Nuclear
chose Dassault Systèmes PLM for three
projects at its Waterford 3 plant near New
Orleans, Louisiana. Dassault Systèmes
Industry Services (DSIS), the DS
professional services arm, conducted
virtual modeling and simulation for the
projects, leveraging CATIA to create virtual
models, DELMIA for virtual simulation, and
DS-partner AREVA’s laser scanning
solution to capture updates to the plant not
reflected in the original plans.
Waterford 3 has accepted the simulations
for a project to replace a 9,700-horsepower
reactor coolant pump (RCP) motor that
weighs more than 57 tons. Other projects
in process include analyzing the potential
impact of a fire on a fire-control panel in a
key plant area and replacing the in-core
instrumentation (ICI) “thimbles” used to
monitor core processes.
“We are using 3D PLM digital simulation for
large projects where risk is high because
Entergy Nuclear officials estimate that if not identified and planned for in
advance, the obstructions could have added one to two days to the outage,
at a cost of $1 million-$2 million.
of potential impacts on operations or
electricity production, and wherever
radiation exposure can be reduced,” says
John M. Mahoney, corporate innovation
leader for Entergy Nuclear.
The RCP motor simulation was so
successful – spotting two previously
unrecognized obstructions that could
have added one-to-two days to the project
– Waterford 3 is investing in CATIA and
DELMIA software and training to create
future models and simulations in-house.
Entergy Nuclear management also is
evaluating ENOVIA for global collaborative
lifecycle management for planning,
construction and long-term maintenance
of new nuclear power plants.
CATIA accurately models
complex facilities
Waterford 3 began operating in 1984, long
before 3D technology was available to the
nuclear industry. DSIS used CATIA to
create accurate 3D models of the RCP
motor removal path and equipment.
Models were built from the original plans
for the facility, with dimensions validated
to within 0.25 inches using AREVA laser
scans. Mahoney notes that the models
“provided project planners, workers and
engineers with a true representation of
plant areas that cannot normally be
accessed during power operations.”
DELMIA simulations improve
planners’ “comfort level”
Once the 3D models were built, all
underlying engineering processes were
simulated in the DELMIA DPM Assembly
package as an animated video. The
simulation identified two previously
unrecognized obstructions. Entergy Nuclear
officials estimate that if not identified and
planned for in advance, the obstructions
could have added one to two days to the
outage, at a cost of $1 million-$2 million.
DSIS delivers
on-demand solution
To validate DS PLM’s effectiveness in
simulating complex maintenance projects,
Waterford 3 turned to the modeling and
simulation experts at Dassault Systèmes
Industry Services (DSIS). Working from
engineering drawings, photographs and
AREVA laser scans, DSIS modeled the
complete environment in CATIA. It then
simulated the removal processes
developed by Waterford 3 in DELMIA to
test for any unanticipated issues. The
work, including data collection, modeling,
and a complete simulation video, was
completed in about six weeks.
Minimizing radiation exposure
through simulation
DELMIA provides for simulation of potential
radiation exposure, a critical element of the
ICI thimble replacement planning scenario.
nuclear power
Although not currently in use at Waterford
3, radiation simulation offers the capability
to accurately predict radiation exposures
and test different scenarios and placements
of workers to identify and develop
procedures with the lowest total exposure.
Cutting costs by eliminating
physical simulations
3D models, 4D visualization of the project
and schedule, and simulations with DS
PLM allow Entergy Nuclear to generate
new engineering ideas and explore
alternative solutions faster and at less cost
than pilots with custom-built mockups. DS
PLM also helps outage planners coordinate
all tasks, test and change sequences, and
boost contractors’ productivity. “3D
modeling and simulation with DS PLM was
that extra check to gain the comfort level
we had to have,” says Don Marpe, the
project manager who led the early use of
DS solutions on the fire protection, RCP
motor, and ICI thimble projects.
Improving training and
capturing institutional
knowledge
Nuclear plant refueling, which occurs only
once every 18-24 months, involves about
2,000 discrete tasks, half a dozen
contractor companies and dozens of
skilled craftspeople – few of whom have
ever been inside the plant’s containment
building. 3D video simulations improve
workers’ familiarity with their surroundings
and reduce the risk of human error• )
For more information:
Entergy: www.entergy-nuclear.com
www.3ds.com/solutions/energy
Contact mag 27
 nuclear power
The Electric Power Research Institute
(EPRI) is a global, not-for-profit
corporation that performs collaborative
R&D and technology deployment for its
members, the owners and operators of
electric power generation and delivery
systems. John Gaertner, Technical
Executive, and Ken Barry, Senior Project
Manager, specialize in nuclear power.
Q: Today’s nuclear power
plants are having their
licenses extended from 40
years to 60 years. What are
some of the challenges, and
how can PLM help?
A: About 20 years ago, experts realized the
condition of the plants was so good that
they should be able to run for much longer
than 40 years. To do so, however, major
maintenance and modifications are often
needed that were not anticipated in the
original design. So the industry is facing
many new planning and logistical
challenges, and investigating the
contribution PLM can make. Owner
operators can translate their paper
28 Dassault Systèmes
Four Questions with EPRI:
PLM and Nuclear Power
blueprints into 3D CAD models. They can
laser-scan the actual facilities to capture
the changes and document dimensions to
fractions of an inch. Then they can use PLM
to simulate the maintenance operations,
train workers, and manage information
through the entire plant lifecycle.
Q: So how has the industry
managed all these years
without 3D PLM?
A: Very well, but at great expense. In the
nuclear industry, you never do anything
until you’re sure you can do it right, so the
industry invests significant time and
resources in trying to anticipate and cover
every possibility. PLM can be a much
more efficient and effective way, because
it allows you to plan virtually instead of
physically. And it offers the potential to
add that extra margin of safety and
precision the industry constantly strives
for, at a very attractive cost.
Q: What is the benefit of
using PLM to train workers?
A: With lifelike 3D models, workers can see
precisely what they need to do before they
attempt it. That’s especially helpful when
you’re tasked with doing something that has
never been done before or is only done
during an outage, which normally occurs only
once every 18 to 24 months. With PLM, owner
operators can develop simulations that work
like video games to give the workers near
real-life experience in a virtual environment,
before they report to the job site.
Q: What about PLM
and new plants?
A: The benefits will be much the same as
for existing plants, but they will be achieved
more readily because the new plants are
being designed in 3D PLM. Because they
will be built from the ground up using
these technologies, applying it to long-
term maintenance will come more easily
and naturally• )
For more information:
www.epri.com
To download the expanded flyer, visit:
www.3ds.com/contactmag-extra
ITER Optimizes
Design with 3DCS
D
imensional Control Systems, Inc.
(DCS), a Dassault Systèmes Premier
CAA Gold Software Partner, has
assisted ITER with the implementation of
3DCS CATIA-based software in the design
process of the ITER fusion powerplant. The
joint international research and development
project aims to demonstrate the scientific and
technical feasibility of fusion power.
INTEGRATED TOLERANCE ANALYSIS
DCS was contracted by ITER to dimensionally
assess several aspects of a fusion plant. For
over eight months the DCS Team meticulously
created 3DCS Tolerance Analysis Models
representative of the design and
manufacturing processes of the ITER plant.
DCS’s mission was clear: to streamline
selective dimensional aspects of the product
and ensure that all components can be
assembled the first time, without the need for
rework or modification. “Because of the
complexity involved in assembling a fusion
plant, it is necessary to have a comprehensive
assembly process,” stated Bob Kaphengst,
president and CEO of DCS. He credited the
“robustness” of 3DCS as the reason it was
able to handle many non-traditional assembly
methods. The assembly process required
significant complex modeling, which was
handled fairly easily using the capabilities of
3DCS, such as multistage assembly
modeling, pin-ability, hole winking, collision
detection, etc.
future energy
ITER Cutaway
] By Mike Ulicny
& John Sienkowski
“DRIVING” THE DESIGN 3DCS is a state-of-the-art
The use of 3DCS at ITER had a positive dimensional tolerance analysis
influence on the design and assembly
tool for simulating design
process. 3DCS tolerance analysis modeling
helped ITER establish realistic tolerance
and manufacturing assembly
requirements with respect to function, processes. Fully integrated
performance and cost. The up-front analysis in CATIA, 3DCS Tolerance
is beneficial in the early stages of the project, Analysis software has been
when changes can be made with no negative successfully implemented in
effect on cost or timing. “ITER is finding that
the ITER fusion project in
many of its engineers now prefer to wait for
analysis results before making their “next
Cadarache, France. This is
move” since the data helps “drive the believed to be the “first ever”
decision-making process,” noted Jens Reich use of tolerance analysis
of the ITER Project Office, Design Integration for this type of product.
- Configuration Control. Tolerance analysis
modeling has never been more accurate,
efficiently performed and easy to use • )
For more information:
jsienkowski@3dcs.com
More about DCS
DCS is a world-class provider of
dimensional engineering consulting
services and software solutions. DCS
provides corporations the tool set for
improving and validating the design in a
virtual prototype arena. Two core software ELM Coil
Support Rail
technologies are available to aid in design
and production quality: Tolerance Analysis
and Quality Data Analysis and Reporting.
www.3dcs.com
Contact mag 29

Cryostat, magnets, vessel
and in-vessel components
ITER: The Energy
of Tomorrow with DS PLM
Harnessing nuclear fusion as
a new energy source for mankind
is the goal of ITER, the world’s
largest fusion energy research
project. ITER’s objective is to build
a demonstration fusion power plant
capable of producing electricity in
a safe and environmentally
friendly way. ITER selected
Dassault Systèmes’ CATIA,
ENOVIA, and DELMIA to engineer
the reactor and plant, structure its
design methodology, and ensure
long-term data interoperability
across the organization.
Inside the tokamak
30 Dassault Systèmes
I
TER is an international organization
composed of the central ITER body and
seven domestic agencies: the European
Union, Japan, the People’s Republic of China,
India, the Republic of Korea, the Russian
Federation, and the USA. Each domestic
agency will develop elements of the ITER power
plant, which will cost €10 billion to construct
and operate, and that will be located in
Cadarache in the south of France.
ITER’s key business challenge is to
orchestrate a pioneering international
scientific research project via a small central
team. Real-time coordination and
collaboration are vital to the project’s success
since the participants span the globe.
Considerable effort will be spent
on coordinating the design of a phenomenally
complex facility made up of 10 million parts
with extremely rigorous quality requirements.
CATIA: a global design solution
CATIA is the master 3D design solution for
both the tokamak (a toroidal device for
producing controlled nuclear fusion) and the
plant that will house it. The ITER Design
Office creates the plant breakdown structure
up to ‘build to print’ level, and domestic
agencies then take over the design of specific
components. Using the digital mock-up
(DMU) capabilities available in CATIA and
Cross-section of vessel
and internal components
ENOVIA, the Design Office ensures that the
millions of complex critical parts in and
around the tokamak will interface clash-free
at assembly time.
ENOVIA VPLM:
single-source database
ENOVIA VPLM acts as a single repository for
all design data. It enables engineers to work
together on the most current designs within
the context of a part, a large assembly, or an
entire product; important capabilities that
both improve decision-­making and promote
design reuse.
ENOVIA VPLM gives ITER design teams
access to consistent up-to-date product
information. The ability to design concurrently
on a project of this complexity is essential.
Concurrent design also permits ITER to keep
the size of its design office to a minimum. “We
have a limited team of about 90 designers,
meaning that the design effort has to be
distributed. Without ENOVIA VPLM, it would
be very difficult to do the job, and we would
need a much larger Design Office team,” said
Eric Martin, Design Office Head, ITER.
ENOVIA VPLM also provides a rich search
capability. For plant design, for example,
engineers use virtual ‘Room Books’ that
provide full details of all assemblies and
« Without ENOVIA VPLM,
we would need a much
larger Design Office team.
systems found in a given ‘room,’ ENOVIA
enables them to use 3D to search and
download all components for a given room
using a customized automatic location
attribute function, simplifying the process of
verifying component compliancy or the
impact of a design change.
DELMIA: process analysis
platform
ITER is introducing DELMIA as its process
analysis platform. DELMIA planning tools will
be used to optimize resource usage
throughout assembly and maintenance
processes. The process detailing features,
including tools for defining equipment
kinematics and robotics, will allow deeper
analysis of critical processes and the
associated equipment, using 3D models
directly linked to the latest digital mock-up.
ITER simulates collision-free paths in the
assembly and maintenance context thanks to
the solutions of DS software partner Kineo
CAM. ITER also uses DELMIA to simulate and
validate critical parts of the assembly schedule
by linking DELMIA operations to the project
master schedule in Primavera. ITER also is
considering a possible integration of DELMIA
with remote-handling supervision tools.
Concurrent engineering,
quality assurance
The ITER Design Office selected Dassault
Systèmes PLM solutions because it offers the
only integrated solution that could deliver a
unified vision of the mechanical and plant
design data, enable concurrent engineering
over a widely distributed network, and ensure
control by a small central design team. ITER
Cross-section
of vessel
Design Office engineers use CATIA to create
‘skeletons’ or design templates. By providing
a rigorous yet flexible framework to the sub-
contractors who will create ITER’s highly
complex components, the skeletons ensure
adherence to quality standards. The reuse of
design skeletons also reduces the time
needed to make duplicate components.
“One designer took my methodology and
added his own ideas to the skeleton. The first
component took him six weeks, the second
one week, and the third just days,” said
David Lightowlers, vacuum-vessel design
coordinator, ITER.
International collaboration,
local ownership
Using DS PLM, the ITER Design Office
provides master designs to distributed
teams of designers, engineers and
subcontractors around the world. The ability
to delocalize has given domestic agencies a
sense of local ownership of their work. It is
also crucial in a project where fusion
expertise is rare and cooperation among
multi-national teams is essential.
Vacuum vessel - Me-
chanical design
future energy
Future trends
ITER plans to expand its DS PLM solutions to
drive the project forward and further optimize
control over the data and its distribution.
ENOVIA, for example, will be used to provide
the backbone for a procurement tool,
enabling bidding agencies to have upstream
access to complex data.
ITER is investigating the use of ENOVIA
MatrixOne to manage project workflows and
as a repository for all engineering data,
including product/geometry breakdown
structure views, documents, configurations,
requirements, 2D/3D coherency, and more,
in a collaborative mode.
Finally, a key element of the DELMIA
implementation will be to verify virtually
whether the intended plant assembly will
operate to specifications. This could save
hundreds of millions of euros in testing the
project’s numerous interfaces before building
begins• )
For more information:
www.iter.org
Contact mag 31

Lawrence Livermore National
Laboratory Relies on ENOVIA PLM as
it Tackles Pressing Energy Challenges
«
ENOVIA
Engineering Central
is at the core of
our Enterprise
Configuration
Management System.
Bernie Merritt, NIF Configuration
Management and Integrations
Manager, Lawrence Livermore
National Laboratory
32 Dassault Systèmes
Lawrence Livermore National Laboratory (LLNL), a US Department
of Energy (DOE) research and development facility, pursues
research projects ranging from energy independence and
environmental protection to national and nuclear security.
A
t the National Ignition Facility (NIF),
legions of LLNL scientists,
engineers, technicians and
designers have developed the world’s
largest laser system. At least 60 times more
powerful than any previous laser, NIF will
direct 500 terawatts (a thousand billion
watts) of light at a nugget of frozen hydrogen
isotope smaller than a pea.
Temperatures greater than 100 million
degrees Celsius will start a nuclear fusion
reaction – the same process that makes
stars shine – and release up to 20 times
more energy than that used by the laser.
The technology could be applied to create
fusion-driven power plants to generate
vast amounts of clean, inexpensive
electricity from hydrogen fuel.
NIF recently demonstrated the ability to
focus the high-energy laser onto a target,
LLNL-JRNL-414092
with plans to achieve fusion ignition in
2010 – a feat never before accomplished.
Practical use of the technology for power
plants could follow in about ten years.
Challenges of a
Vast R&D Facility
As one of the most ambitious projects ever
undertaken at LLNL, NIF faced significant
challenges in managing massive stores of
data associated with the project –
especially regarding equipment design
and safety protocols for the system’s
nuclear materials. This included data for
current work, plus thousands of legacy
documents from the previous ten years
and hundreds of thousands more expected
throughout the 30-year NIF lifecycle.
This daunting task was addressed with an
Enterprise Configuration Management
System (ECMS) based on Dassault
«
ENOVIA Engineering Central helps LLNL demonstrate good
stewardship of taxpayer resources to the Department of Energy.
Frank Papp, NIF CIO, Lawrence Livermore National Laboratory
Systèmes ENOVIA PLM. With more than
1,600 users throughout LLNL, ENOVIA
Engineering Central provides a single
digital source of information across the
complete product lifecycles of various
business units. By controlling CAD models
that drive many other documents, the
system effectively ensures that all related
documents reflect all revisions. Pioneered
by NIF, ECMS is now used by eleven other
LLNL business units.
“We’re not just controlling drawings and
documents, but managing the underlying
data within the CAD model,” says Bernie
Merritt, NIF configuration management
and integrations manager. “By managing
this source data, we maintain strict control
over data and processes required by DOE
regulations.”
With the total cost of NIF at $3.5 billion,
DOE and Congressional reviewers maintain
close oversight of funding, especially in
light of a desire for increased transparency
into how tax dollars are spent.
“The system provides a granular overview
of productivity and the overall progress of
the project in monthly status reports to the
DOE,” says Frank Papp, NIF CIO. “It
demonstrates our ability to meet major
project milestones within a fixed budget
and available resources.”
Broad Scope of ENOVIA
“ENOVIA was selected based on numerous
factors, but certain capabilities are
particularly well-suited for ECMS,” says
Michael McDaniel, PLM process leader
and Engineering Records Center manager.
Ease of use is critical to ensure quick
training and greater productivity,
especially given the matrix organization of
LLNL, in which personnel move in and out
of projects as needed. Out-of-the-box
functionality with configurable solutions
helps adapt the system to particular LLNL
processes. Tight integration with other
software supports external business
systems required for electronic data
transfers among downstream processes.
“By allowing the organization to streamline
work processes and leverage design data,
ECMS has increased operational efficiency
in engineering processes, as well as
downstream procedures in groups outside
of engineering, including those in ERP and
Procurement,” McDaniel says. “As the data-
driven engine of ECMS, ENOVIA Engineering
Central has resulted in significant enterprise-
wide efficiency gains.”
At the LLNL Engineering Records Center
(ERC), documents are stored for long-term
retention per DOE and National Archives
Records Administration guidelines.
Integrating ENOVIA Engineering Central
with the ERC process automated many
formerly manual steps, increasing ERC
throughput by six times – from 15 documents
per day to more than 100 per day.
Five-fold productivity gains were achieved
future energy
in processing engineering change
requests (ECRs) and engineering change
orders (ECOs). Documents are now routed
electronically based on detailed workflows
in Engineering Central. ECRs and ECOs
that formerly took up to a week to process
can now be completed in a day.
“Some of the greatest gains in productivity
and accuracy have been achieved in the
creation and handling of bills-of-material
(BOMs),” says Ed Krieger, PLM strategist at
NIF. “By automatically extracting BOM data
directly from Engineering Central into ERP,
we eliminated substantial workload and
potential for error.” Support documents for
bids and quotes that once took a week or
more to process are usually completed in
less than a day. Similar gains were made in
an automated warehousing system.
“As our research efforts move into the
future, we must rely on the state-of-the-art
technology and process control that
continues to be built into ECMS,” says
Darwin Dobson, PLM enterprise manager
at LLNL. “Without the capabilities of state-
of- the-art PLM systems, such projects
would not be practical”• )
For more information:
www.llnl.gov
To download the expanded flyer, visit:
www.3ds.com/contactmag-extra
Contact mag 33
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