Why Do Refineries Use E3D and Caesar II Together?

Sep 19

4 min read

Introduction:

Re-refinery projects consist of thousands of pipes, equipment pieces, structures, valves, supports, and instrumentation that all work as part of a very complicated system. Even a minor design error may lead to serious complications in fabrication, construction, maintenance, or operation of the plant. Due to the complexity of the project, engineers use specialised computer applications to create 3D models of their designs and check if their piping systems are able to operate under certain conditions. Two applications that are used in different but related engineering fields are AVEVA E3D and CAESAR II. E3D is primarily aimed at 3D plant design and engineering coordination, whereas CAESAR II is used for pipe stress analysis.

Understanding the Role of E3D in Refinery Design:

AVEVA E3D is an environment that can be used to create detailed 3D engineering designs of various industrial plants. For example, during a project for a refinery plant, engineers can create 3D models of all equipment, piping, structures, cable trays, and other plant components using a single environment. The 3D model gives a visual representation of how the plant will look after the construction process is completed. Using such 3D modelling, engineers can check equipment positions, pipe routing, accessibility, maintenance clearance, and possible clashes before construction starts. Therefore, E3D becomes very useful for multidisciplinary coordination. Piping designers, mechanical engineers, structural engineers, and others can work around the same plant model.

How is CAESAR II Used in the Pipe Designing Process?

Although a 3D model shows where the pipe is located, it cannot be considered enough for determining whether the system of piping is safe from mechanical and thermal loads. In this case, CAESAR II comes to help because this software is used for pipe stress analysis. Engineers use CAESAR II to analyse how the piping behaves under different loads like thermal effects, pressures, weights, etc. This analysis allows engineers to understand whether the piping system needs any corrections before fabrication or construction. Piping engineers can learn through Caesar II Software Training about piping modelling, load and boundary condition application, analysis result interpretation, and stress design considerations. Engineers can analyse factors such as:

Thermal expansion and contraction.
Sustained weight loads.
Operating conditions.
Pressure effects.
Equipment connection loads.
Pipe support requirements.
Displacement and stress behaviour.

Why Both Tools Are Needed?

E3D and CAESAR II solve different types of engineering problems. In essence, the problem that E3D solves is: "Where should the piping and equipment be placed, and how do all components of the facility fit together?" The problem that CAESAR II solves is: "Is the piping system able to withstand the loads that it is subjected to?"

Both answers are required for an oil refinery. A piping line can perfectly fit into a 3D model, but still be subject to engineering alterations due to excessive stresses, thermal expansion, and loads on connected equipment. On the other hand, the piping line can pass the stress analysis test, but fail because of its interference with other elements.

Connecting Design with Stress Analysis:

The general workflow could include the design of the piping layout in E3D, followed by the creation of the associated analytical model to analyse the stresses. Subsequently, the piping engineer performs the stress analysis of the structure under the relevant design conditions. In case of high stress, displacement, and/or improper support structure, modifications to the design could be required. Such design modifications will then form part of the plant design. For instance, let us consider the situation where the thermal expansion of a long pipeline in a refinery results in high stress. The stress engineer can conclude that there needs to be increased flexibility or an alternative support structure. The design engineers can modify the physical layout in the 3D environment accordingly.

Reducing Expensive Design Changes:

Detecting any problem associated with the engineering process in the design phase proves more realistic than when discovered during the construction process. The changes needed in case of the occurrence of the problems may require extra materials, labour, engineering effort, and time delays. Utilisation of both 3D design and stress analysis enables the detection of different types of problems. E3D can detect physical and spatial problems, while CAESAR II detects the behaviour of the piping system under certain loading conditions.

Enhancing Multidisciplinary Coordination:

The design of refineries involves multidisciplinary engineering processes. Piping systems may have an impact on other engineering aspects like structures, equipment, instrumentation, electrical systems, insulation, maintenance activities, and construction process. Having a coordinated E3D model provides the team with a shared visual tool. Stress analysis provides additional engineering support for critical piping systems. This process can contribute to the improvement of communication between the designers and engineers since the changes can be analysed both physically and engineering-wise.

Building Skills for an Engineering Career:

Professional individuals who have an interest in plant design can find it helpful to learn more about different engineering applications. Individuals can take E3D Training, which will give them knowledge of 3D plant modelling, equipment placement, piping design, project structure, specifications, and design coordination. Learning through practice is especially important in industrial project settings where there are multiple components involved, rather than modelling activities.

Preparing for E3D Technical Interviews:

Having information about software commands might not be sufficient for engineering roles. Interviewers expect their candidates to have an idea about reasons for certain design decisions and interactions between different engineering activities. Individuals who prepare for the interviews with Aveva E3D Interview Questions should study software functions and plant design concepts. Information about the interaction between E3D and stress analysis will assist candidates in explaining their contribution to the overall engineering lifecycle.

Structure of E3D projects and Databases.
Modelling equipment and piping.
Specifications and Catalogues.
Clash detection.
Design coordination.
Concepts of piping support.
Data management.
Interaction of Design and Analysis teams.

Conclusion:

Refineries use E3D along with CAESAR II for the reason that plant design and piping analysis solve different engineering issues that, however, must be integrated. Thus, the program E3D allows the creation of the physical environment where piping and equipment should be located. At the same time, CAESAR II is useful for the evaluation of the structural and mechanical properties of pipe under design loads. Professionals interested in administration and project settings can consider the E3D Admin Certification Course, which provides exposure to topics such as project administration, databases, specifications, user management, and system workflows. It makes the engineering process more integrated. Rather than analysing the layout and performance of piping separately, design data and analytical results may be used in concert in order to improve systems prior to their fabrication and construction.