The use of 3D design and modelling software paved the way for the smooth commissioning of an ambitious Save-All project for the No 3 Paper Machine at Norske Skog Tasman's Kawerau mill.
The paper-making process circulates around 20,000 litres of water per minute, and it quickly becomes contaminated with small bits of wood fibre. A Save-All is a filter that separates the two, allowing the fibre to be recycled and the water to be re-used. Filtering also cuts the load to the effluent plant.
Beca AMEC was engaged to prepare a feasibility study to develop the process design and a capital cost estimate. After approval, the team was commissioned to implement the project, providing:
- project management and engineering design services (process, mechanical, piping, electrical, power, civil, structural, geotechnical, fire protection and controls)
- contract management and procurement
- construction management
- commissioning and start-up assistance.
Use of the 3D, Plant Design Management Software (PDMS) for mechanical and piping design was the project's dominant feature. The 3D model conveyed the design ideas to the various project stakeholders and provided project savings through improved communication and reduced re-work costs during construction.
Operator training and plant commissioning was facilitated by IDEAS™ software, used to create a dynamic process model for simulating the new plant. It also provided the basis for the control system checkout prior to commissioning. The project was completed within budget and handed over ahead of schedule, with start-up taking place without any loss of production.