Fast-track design
Because Hitachi now exchanges design and construction data electronically with its civil engineering contractors, any adjustments can be made in detail during a project's preconstruction phase. Among other things, sharing data through a common 3D-CAD platform permits parallel construction. Using computer screens to show where to set scaffolding and install equipment simplifies the collaboration process and makes it more precise. Another benefit is that all contractors can share temporary site facilities to a greater degree.
Hitachi uses the 3D-CAD platform in the field for construction schedule simulation, yard utilization planning, and installation of large equipment and modules. Module scope planning also is executed on the platform. Finally, Hitachi distributes work instructions for essential on-site preassembly and installation using 3D animations. The 3D-CAD platform interfaces with a construction support system interface that all subcontractors use.
Here are two examples of benefits. To mitigate peaks in on-site labor force, Hitachi has adopted the "floor packaging" construction method (Figure 9). With floor packaging, hydro-testing is conducted at each "floor" (partial hydro-testing), rather than waiting for the entire plant to be completed. Equipment in the basement is hydro-tested while the higher floors are still under construction. Hitachi also has developed a weldless closure jig to make partial-pressure tests more efficient. This approach avoids the need to have a new group of workers on hand during the scheduled full hydro-test period.
9. From the ground up. Floor packaging of modules reduces installation and start-up labor and, more importantly, construction time. Source: Hitachi
RFID instead of bar codes
To better track equipment, Hitachi makes use of RFID tags instead of bar codes. The tags, which can be reprogrammed, contain silicon chips and antennae that send data to an RFID transceiver. The use of RFID eliminates the need to scan equipment bar codes, reduces counterfeiting, and makes parts identification more accurate by reducing the effect of dust and other ambient factors.
The switch to RFID improves the quality of piping assembly and component fabrication (Figure 10), ensures that workers are qualified to handle components, makes on-site storage more efficient, and streamlines database and document interfaces (Figure 11). Hitachi calls RFID a "ubiquitous technology" because it can be applied to advantage in all aspects of a project's design, engineering, procurement, transport, construction, and installation phases.
10. Gone digital. Radio frequency identification (RFID) and personal digital assistant (PDA) technologies are deployed across all parts of the project. Courtesy: Hitachi
11. Digital supply chain. RFID allows all movements of components, activities, and workers to be tracked and coordinated in engineering and document databases, which streamlines management. Courtesy: Hitachi
—Timothy E. Hurst, PE, is president of Hurst Technologies (www.hursttech.com), a consulting engineering firm specializing in instrumentation and control systems for nuclear and fossil-fueled power stations. He also is a POWER contributing editor. Hurst can be reached at timh@hursttech.com.
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