Chiyoda Corp is one of the world's leading engineering, procurement and construction (EPC) contractors.

Its business fields include gas processing (such as huge liquefied natural gas projects), petroleum refining, petrochemical, chemical, pharmaceutical and environmental control. Established in 1948, Chiyoda now has 4000 employees working throughout the world. The company is based in Yokohama, Japan, and it has major ongoing projects in Asia, the Middle East and South America. Asia-Pacific Engineer discussed Chiyoda's project engineering system with two leaders of the company's information technology (IT) efforts.
Yoshihiro Shirasaki is the senior executive officer overseeing technology and engineering for Chiyoda. He is responsible for engineering and technology development, including project engineering IT systems. Shuji Nagano is the general manager of the project IT development office for Chiyoda. He is responsible for planning and developing the company's project IT environment.
What approach is Chiyoda taking toward IT for its EPC projects?
Yoshihiro Shirasaki: "Chiyoda has been aggressive with applying information technology to engineering, procurement and construction, and we have extensive experience executing many projects using information technology. In order to apply IT efficiently on the complicated and dynamic work activities of the EPC business, all IT systems should be categorised into several groups according to the work activities. Chiyoda has established the concept of 'project IT'. By applying this concept, all software applications - including those developed by Chiyoda and technology providers such as Intergraph - could be categorised and linked to each other by developing interfaces among them. We have named this concept i-PLANT21. The 'i' in i-PLANT21 stands for 'integrate' and 'intelligent'."
How does i-PLANT21 function?
Shuji Nagano: "i-PLANT21 consists of seven subsystems: i-FRONT, i-ENG, i-3D, i-MAT, i-FIELD, i-DMS and i-PMS. First, there's the front-end engineering system, which we call i-FRONT. This system provides integrated functions for process simulation, database-driven process flow diagrams, intelligent process and instrumentation diagrams (P&IDs) and automatic plant layout. The information from i-FRONT is electronically transferred to downstream systems as required.
"Then there is i-ENG, the engineering database for each discipline's design activities. Process data transferred from the process database and item data extracted from intelligent P&IDs in i-FRONT are connected to each other and stored in i-ENG. The connected data is used by disciplines for their detail design. We also have i-3D, which is the 3D design system. Intergraph Plant Design System (PDS) is at its core. With its review capability, the 3D model is reviewed by discipline engineers and clients to confirm that all requirements - such as process requirements, operability, constructability, accessibility, maintainability and safety - are fulfilled. i-MAT is the project materials management system. It controls all materials at all project phases, from material takeoff, through procurement and transportation to field construction. The takeoff information is electronically transferred from i-3D. For field construction, we have i-FIELD, which provides field material control, preparation of isometric/spool drawings linked to i-3D, piping welding control, plant turnover control and schedule, cost and progress management. i-DMS is our document management system. Finally, there's i-PMS. This project management system allows us to plan and execute the work, mobilise the required resources, monitor schedules, costs and progress - and then take any necessary corrective actions. "
What are the benefits in integration and intelligence?
Yoshihiro Shirasaki: "Completing the field construction work within the planned schedule, quality and cost is the final target of EPC work. We reduce construction rework, such as pipe welding work, to a minimum level: 2to4percent. Also material surpluses and shortages at the construction site are reduced to a minimum level: 1to3percent. Virtual single office operations (VSOO) are established among overseas low-cost engineering centres and Chiyoda's Yokohama office. Worksharing with them gives us enough engineering resources at a low cost and with high quality. This is realised by applying the common IT environment such as a data-centric data warehouse."
Can you elaborate on the advantages Chiyoda expects from knowledge management?
Yoshihiro Shirasaki: "The engineering information of an EPC business can be classified into two categories: 'flow' and 'stock'. 'Flow' is live project information. 'Stock' is the knowledge extracted from the 'flow.' i-PLANT21 is a system to manage 'flow' information. On the other hand, systematic integration of 'stock' information is in the knowledge management domain.
"Extracted knowledge from live project information is stored in a knowledge management system, and this stored knowledge can be used for the next project and used to solve any issues in all projects."
What is being done to achieve this level of engineering?
Shuji Nagano: "Standardisation is required for developing an IT system. One example is i-ENG, our engineering database. To exchange engineering information through the IT environment, Chiyoda itemises and specifies the definition of 30000 pieces of engineering data for process, mechanical, piping, instrumentation and electrical. Symbol and attribute data of intelligent P&IDs (i-FRONT) and bulk material code of the material management system (i-MAT) are other examples of standardisation for IT systems."
What technology is available now to achieve this?
Yoshihiro Shirasaki: "We have chosen to employ SmartPlant Foundation (the information management solution from Intergraph) as our worldwide project engineering and document management system. SmartPlant Foundation will enable Chiyoda Corporation to consolidate engineering information into one secure source with its ability to manage revisions of engineering data and documents.

For more information, visit www.chiyoda-corp.com or www.ppo.intergraph.com