Virtual plant model is the cornerstone of Yara’s data management: all plant area information now available in one place
At Yara’s Uusikaupunki facility, design, operations and maintenance have been made easy: essential documents, diagrams, and ERP data are integrated into a seamless whole in a virtual plant model that accurately reflects reality.
Managing large volumes of data and ensuring data accessibility are typical challenges in plant environments – Yara is no exception.
The combination of Elomatic’s laser scanning services and CADMATIC eShare digital twin software solved data management challenges and significantly improved information flow. All information related to the entire plant’s design, maintenance, and servicing was compiled into a visual format in a virtual plant model that is an accurate copy of the plant area.
The purpose of the collaboration was not just to visualize information, but to combine information into a coherent whole in one place. Surface models created from scanned material and eShare software transformed the entire plant into a data hub that integrates information from different systems and thus facilitates finding and sharing information.
The digital twin provides particularly great benefits to project managers and designers, who can share design and status information between different parties in the virtual model. For viewing lighter sub-models and quick information retrieval, Yara also uses the CADMATIC eBrowser application, which works alongside eShare and complements the package of digital tools.
3D scanning creates an accurate twin of the plant
The creation of the virtual plant model originally began with scanning the entire plant area using a helicopter. After that, Elomatic has scanned production buildings both inside and outside using more detailed methods.
The collaboration with Elomatic has been efficient. Familiar scanners know the sites and can navigate the plant area, which speeds up the work.
Heikki Lehto, Head of Projects, Yara
In creating the digital twin, a surface model is created from the scanned material, which is then classified and transferred to the design model server. The material and measurement data produced by scanning thus form the foundation for the entire plant model.
Laser scanning has significantly improved the plant model’s accuracy, Lehto explains.
“For instance, 3D models from other design programs were brought into the design model in the past, but their information may not necessarily be accurate. By scanning, we ensure that the area in question is incorporated into the model precisely as it currently exists, so we have up-to-date information about the entire plant area.”
eShare compiles information into an easy-to-use format
The virtual plant model for the Uusikaupunki facility was built using Cadmatic’s software products.
“eShare connects scan data, documents, diagrams, and ERP links in the same view, which helps keep the plant model information up to date,” Lehto tells.
The virtual plant model enables the compilation of different types of information, serves in verifying location data, locating components, and allows interface linkage to other software, such as maintenance systems. The visual model is user-friendly: documents and other information needed for work are easy to find.
In the jungle of digital tools, eShare’s key advantage is its ease of use. It is browser-based, and learning to use it doesn’t require lengthy training. The visual user interface also streamlines work and accelerates implementation.
With the single plant model strategy, information is always up to date
Data management for the entire plant area in the same digital model has proven to be sensible at Yara’s Uusikaupunki facility.
“When all information is in the same virtual plant model, it facilitates data accessibility: everyone has access to information about the entire plant area, and there is no need to search for information in different places. The advantage of a single model is also that maintaining and updating it is more effortless,” Lehto explains.
The model is used by project personnel, maintenance, and production workers alike. The same model serves the needs of different users, as essential documents and other data for each user group’s daily work can be added to it.
Seamless data management enhances work efficiency
Data management at Yara’s facility is now clearer, faster, and more reliable than ever. Now designers can check the consistency of diagrams and models directly in eShare, maintenance personnel can quickly find up-to-date information, and project managers can easily see what has been updated.
The accuracy of 3D material has reduced the need for repeated measurements, and misunderstandings have been minimized. eShare’s linkages encourage keeping information and attributes up to date, which is reflected in better data quality and more efficient work across all departments.
Next, Yara will focus on improving the model by supplementing attribute data throughout the entire plant model. With smart data and continuous development, the model’s potential will grow even further.
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