Front-End Engineering Design for Process Engineering

Better Front-End Engineering Design

Bentley AXSYS®.Process improves Front-End Engineering Design (FEED) by allowing increased evaluation of conceptual design cases as well as leveraging corporate knowledge to reduce capital expenditure.

In any major plant project, 80 percent of the capital expenditure is committed during the conceptual design phase.  Front-End Engineering Design (FEED) must be done correctly to impact capital expenditure and Bentley's AXSYS®.Process is the FEED product to achieve better front-end engineering and help minimize capital expenditure.

Optimizing Front-End Engineering Design generally entails spending time evaluating alternative designs and then selecting the best case from these alternatives.  AXSYS.Process allows users to perform more designs in less time and better evaluate these designs in order to find the most cost-effective case.  AXSYS.Process has helped major chemical companies, such as Mitsubishi Chemical, reduce a FEED project duration by 45 percent, reduce engineering man-hours by 50 percent yielding a final cost-to-market reduction of about 50 percent.

How does AXSYS.Process achieve these results?  It does it by:

  • Allowing the Process Engineering team to rapidly prepare and evaluate design alternatives and case studies
  • Creating consistent process designs in the shortest possible time
  • Leveraging corporate knowledge to achieve best practices
  • Interchanging process simulation and engineering design data in a common environment, thus ensuring data consistency


AXSYS.Process delivers:
Interfaces with all the major process simulators, including HYSYS, AspenPlus, UniSim and Pro/II, so you can use the system of choice and properly manage the resulting data. Data from multiple simulation runs can be easily compared and new design cases quickly generated.

Automatic creation of Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs) using project-specific symbols and drawings can be output to multiple drawing formats.

Integration with the major heat exchanger applications such as HTRI and HTFS for faster Heat exchanger design. 

Use of Microsoft Excel to provide easy data entry and generation of intelligent datasheets and reports in your specific formats.

A managed workflow that incorporates graphics, data and work management for each user and tracks changes during the project, allowing users to revert to previous designs.

Intelligent documents and data that can be transferred into detailed design products including Bentley AutoPLANT and Bentley PlantSpace.

Improved Front-End Engineering Design and helps reduce capital expenditure. Users have proven this.

Advantages

Unique front-end engineering design tool integrating conceptual process design with functional project engineering

Bentley AXSYS®.Process is a powerful front-end engineering design (FEED) system that streamlines the workflow for conceptual plant design. A truly open system, AXSYS®.Process allows users to use the design tools of their choice, produce deliverables in the format of choice, and re-use design data, both as starting points for conceptual design cases as well as for continuing the design into detailed engineering.

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Enhances workflow across the whole enterprise

AXSYS®.Process has been designed with maximum flexibility and does not impose fixed or rigid work processes. Information can be integrated, analyzed, and edited from both a graphical and non-graphical environment, or it can be directly accessed via any OLE-compliant application. You also have control over your work process by utilizing the extensive change management features that are included. Information can be edited and manipulated directly and no matter where the information is edited, it is only stored once, providing guaranteed consistency throughout. Every user has an individual working area, with customizable authorization and control. Change reporting details both graphics and data changes, and user sign-off and approval procedures can also be implemented. Thus AXSYS®.Process manages the data flow throughout the enterprise while the work is in progress.

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Reduces engineering design effort

Since AXSYS®.Process manages the process data, it dramatically reduces design effort by linking directly to other engineering programs. AXSYS®.Process interfaces with major process simulators including Aspen Plus, Aspen HYSYS, PRO/II and UniSim Design. Information from a simulation can be loaded into AXSYS®.Process, including stream properties and detailed unit operation data, along with the associated connectivity. Once this information has been loaded, it can be manipulated or combined with other simulations to generate a complete plant simulation model.

For detailed heat exchanger calculations, AXSYS®.Process supports the major design programs from HTFS and HTRI. These applications can be run in both design or rating modes.

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Reduces handover time and effort

Decisions regarding 80 percent of a plant's capital costs are made during the front-end engineering design process. AXSYS®.Process allows better decision making at an earlier stage of the process due to the powerful data management tools incorporated within the product. Engineers can re-use data efficiently to do more case studies and hence evaluate the consequences of these designs to produce an end design which is better engineered, ensures better information for procuring long lead-time equipment and ensures that the as-built plant will meet the designed performance, thereby reducing the hand-over time for the plant.

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Provides a central repository for process engineering design cases

AXSYS®.Process is fully integrated with a central database that is Microsoft ODBC (Open Database Connectivity) compliant. This central database ensures data is consistent, manages the data in all the different design cases and also ensures that changes made during the design process are properly managed. Since this database architecture is "open," data can be shared with third-party applications to ensure these are fully managed during the FEED process.

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Automates production of deliverables

AXSYS®.Process automatically generates Process Flow Diagrams (PFDs) and Piping and Instrument Diagrams (P&IDs). These drawings are easily configured and extended to include project specific graphical symbols and associated data. The drawing process is rules-driven which produces "intelligent" drawings:

  • Automatic Layout - Each equipment item is automatically positioned on the PFD or P&ID based on the graphical size of the object in question. Based on connectivity rules, these equipment items are automatically connected.
  • Graphical Symbols - Symbols can be configured and new symbols easily created using an extensive set of manipulation tools.
  • "Intelligent" Symbols - Each symbol can also be defined with an unlimited set of default information-allowing the inclusion of standard vendor data as appropriate.
  • Configuration - Each of the automation rules can be customized on a per project or a per process basis-providing maximum automatic flexibility.
  • User Selection - Lets the user select the correct component during the automatic procedure and records that selection.

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Data-centric process eliminating data re-entry and duplication, as well as maintaining data consistency

Because AXSYS®.Process uses a central database to store and manage the FEED data, information is readily available to be used for third-party applications, input to other Bentley Digital Plant modules, as well as for consistent reporting. All reports can be easily customized for project-specific formats. Datasheets and report templates are provided in Microsoft Excel format and can be used for both data input as well as reporting, reducing data re-entry. Tools are also included to create batch output of result data for use in other software programs, again eliminating data re-entry.

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Incorporates change management to track all design changes

AXSYS®.Process incorporates a comprehensive change management system to track all changes made to data during the FEED project. The management system can manage multiple revisions allowing parallel design cases to be managed. The system tracks who made the changes, when the changes were made and retains the old values so that the changes can be reverted to previous values. Both drawings and data are managed within AXSYS®.Process. Changes can be reported in detailed change reports and can be highlighted on documents allowing changes to be readily identified and validated.

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Full interoperability and integration

AXSYS®.Process is a true open-system allowing input and output into numerous third-party software applications and engineering systems. AXSYS®.Process supports various drawing formats such as Visio, Smartsketch and Autodesk DXF format and supports export into many detailed 3D engineering systems including AVEVA Vantage, Smartplant P&ID and AVEVA's PDMS system.

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Proven productivity tool

AXSYS®.Process is a proven productivity tool.  Numerous customers have reported significant productivity gains by using AXSYS®.Process. Mitsubishi Chemical Corp has reported major productivity gains by using AXSYS®.Process. Project duration time was shorted by 45 percent, Engineering man hours decreased by 50 percent with total man hours decreased by 42 percent.  For process engineering, savings were found as follows:

  • Process Engineering Case Studies:  55 percent savings
  • Equipment Sizing and Selection:   55 percent savings
  • Transforming data to PFDs and Datasheets: 85 percent savings
  • Sketching PFDs and P&IDs:   60percent savings
  • Initial Cost Estimation:   70 percent savings
  • Heat Exchanger Sizing and Selection:  45 percent savings
  • Compiling Process Design Package:  30 percent savings
  • Detailed Costing:   70 percent savings
  • Deliverable PFDs and P&IDs:   25 percent savings

Total process and non-process engineering savings exceeded 45 percent

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