The Diesel project at Neste Oil's refinery in the town of Porvoo is the first building project in which structural design incorporating concrete structures has been implemented from start to finish using 3D product modeling. Intelligent data transfer between systems enabled parallel progress in plant and structural design. The project also saw the creation of a joint design environment for use by several design firms based on the Tekla Structures system.
The Diesel project at Neste Oil's Porvoo refinery entails building a new production line comprising a residual oil unit and hydrogen unit. Significant extensions and modifications are also being implemented in the refinery's existing process units and infrastructure. With the new production line, which is due for start-up at the end of 2006, Neste Oil will gain the capacity to produce increasingly clean motor fuels from heavier and more sulfurous crude oil than before.
With a volume of close to 600 million euros, Neste Oil's refinery investment is a significant ongoing building project. Engineering and contracting work for the project will total an estimated 1.5 and 3 million hours respectively. 25 hectares have been cleared for the project, around five of which will be occupied by the actual process area. New buildings covering almost 13,000 square meters will be built and approximately 19,000 cubic meters of concrete and 5,000 tons of steel will be used in the project as a whole. Neste Jacobs, an affiliate of Neste Oil, is responsible for the Diesel project's engineering, procurement and construction. The design stage was launched in autumn 2003 and at its peak has employed more than 400 people at Neste Jacobs and several Finnish engineering offices.
Modeling and managing in 3D
Plant design has been implementedusing 3D modeling tools since the early 1990s. In Neste Oil's Diesel project there was strong motivation to take structural design comprehensively into the 3D era while enabling data transfer between stakeholders in a maximally intelligent format. 3D modeling was exploited starting from the underground pipes and structures upward in the first ever project to also model concrete structures entirely in 3D, including the reinforcements and cast-in embeds. The models were used to produce general drawings as well as those required for steel, element and cast-in-situ concrete fabrication and the related lists. 230,000 components were modeled and 9,800 drawings together with hundreds of reports were produced for a range of needs. Even though structural design represents just 0.4% of the Diesel project's total costs, linking it with the plant design has been vital to the project's success. Data communication between systems has made it possible for plant and structural design to advance in parallel,