The engineering and technology group SENER is ranked 32nd in the annual ranking of the top 225 international companies in engineering design published by the specialized journal ENR (Engineering News-Record).... [+]
Most of the cost of the ship is committed in the early design stages, where the fast propagation of design changes and the highest precision are required.
FORAN Initial Design comprises the Hull Forms, General Arrangement and Naval Architecture calculations, all integrated with the other design disciplines in the FORAN database, which ensures data integrity, fast propagation of changes, multi-user access and the reuse of information in later stages.
FORAN can define any type of hull forms from scratch, or can import third-party forms. It performs transformations and manages the lofting and fairing. The topological model based on references allows the fast generation of decks and bulkheads.
The general arrangement is performed in 3D. The definition of spaces is simple, as it is based on references to the model. The tool allows the insertion of attributes, such as the contents of tanks, and automatically calculates volumes, weights, centers of gravity and moments of inertia. Finally, the main equipment may be positioned in the model. As an output, tailored general arrangement drawings are generated automatically and can be updated after changes.
The new naval architecture solution groups all of the functionalities, including hydrostatics, longitudinal strength, loading conditions, intact and damage stability, including deterministic and probabilistic methods, power calculation and launching. The user-friendly and interactive interface and the more powerful capability gives more added value at this important stage, in addition to checking results against the most modern international criteria.
FORAN Initial Design Benefits:
- Solution integrated with the rest of FORAN design disciplines (Oracle database) or in a standalone format (SQLite database).
- The possibility to perform concurrent engineering ensures data integrity.
- The topology and the automation of tasks accelerates the model definition, the study of different design alternatives and the propagation of changes.
- Advanced capability for the management of hull forms.
- Highly innovative 3D general arrangement, avoiding errors and inconsistencies.
- Powerful calculation and user friendly interface for the naval architecture solution with continuous update of regulations.
Hull forms definition
FORAN provides advanced tools to define the ship surface model based on NURBS formulation:
- Conventional or special hull forms such as mono-hulls, non-symmetric vessels, multi-hulls and oil rigs.
- By means of interactive graphic functions, lofting facilities and surface curvature and smoothness controls, the designer can evaluate diverse design alternatives easily and rapidly.
- Quadratic transformations of the ship FORAN imports/exports surfaces from/to other standard formats (IGES, DXF, STEP… ), and also from/to proprietary third-party formats.
FORAN offers a comprehensive environment for the definition of deck and bulkhead surfaces of the ship, using interactive graphic commands with a simple parametric definition. Hulls, decks and bulkheads are associated topologically, so design modifications are automatically propagated to all related elements. Asymmetric or symmetric decks, with any type of sheer and camber, discontinuities, knuckles and steps are defined in a smart and efficient way, and their intersection with the hull surface is automatically calculated. In addition, it is possible to generate any type of flat or corrugated bulkhead.
The definition of the ship’s general arrangement (GA) is innovative and is done in 3D. The module offers several options for generating spaces, including useful 2D views connected to the 3D model. Any ship compartment can be subdivided into subspaces, which can be created selecting the boundary surfaces, defining several sections or parametrically. The topological definition of all these elements, based on references, ensures that any modification to their limits is automatically applied to the compartment geometry.
The insertion of data related to the contents of the tanks and associated attributes allow the calculation of relevant information that will be used later in the analysis, such as weights, cogs and volumes.
Additionally, it is possible to position all of the equipment that has already been defined in the database or interactively defined in the 3D model. This applies not only to machinery and equipment, but also to deck equipment, weapons or accommodation elements.
GA drawings are generated directly from the 3D model and are linked to it so any modification in the 3D model will generate updated drawings.
A 2D graphic editor in the FORAN drafting tool includes a complete set of functions, plus the possibility of adding smart dimensioning, symbols, standard components, configurable drawing templates and labels, and also generate parts lists from the drawing information.
A new application in FORAN groups all the naval architecture capabilities in a single tool with a user-friendly interface, interactive tasks and powerful calculation processes, with all data hierarchically organized. The process starts by defining the information necessary for the calculations, such as the watertight characteristics, appendages, draught marks, openings, wave and wind profiles, sounding lines and modular cargo.
FORAN features the complete calculation of hydrostatic values (Bonjean curves, Deadweight scale, Stability cross curves, Freeboard, Floodable and permissible lengths, Sectional areas or Trim diagrams).
All calculations are made in accordance with the latest national and international conventions, regulations, rules and resolutions, which are continuously updated in FORAN. Even users can define their own criteria.
FORAN enables an accurate calculation of the flooding conditions and damage stability according to the deterministic and probabilistic methods, taking into account the intact stability conditions, and associates the spaces to the geometric subdivision defined.
Complete dynamic calculations and analysis of ship launching over slipway and floating from dry dock processes are featured in FORAN, including graphic representation and static and dynamic stability calculations.
FORAN also estimates towing resistance using a number of modern powering prediction methods, including some warship-specific ones, and with several possibilities for propeller selection and analysis. The outputs are the main features of the propeller, power-speed curves, forecasted service and trial conditions (including trawl condition in trawler ships) and open-water propeller diagrams. Propeller geometry can also be calculated according to the requirements of classification societies.
FORAN allows the interactive design of the basic particulars of the rudder and the schematic ship stern profile, and an estimate of the maneuverability characteristics.
Innovative approach in FORAN for the definition of an early 3D model of a ship to generate the required outputs for class approval.
FORAN Basic Design is a solution for the preliminary definition of a 3D model of a ship, with the aim of obtaining the reports and drawings required for the approval of class societies. FORAN addresses the basic design through its powerful 3D modeling environment, which supports a quick definition of the structural and outfitting elements in 3D, covering global geometry, attributes and scantling in an extremely efficient manner. The structure model is topological, so changes introduced are automatically propagated to topologically connected structures and to drawings. Weight calculations and gross material estimates are very useful at this stage.
Class drawings are generated automatically from the 3D model, using the FORAN drafting tools. The system has the advantage that drawings will be regenerated after changes in the model.
One of the key aspects of having a 3D model at this stage is the possibility of exporting it for FEM analysis using an automatic idealization tool in FORAN, which provides bi-directional communication with any FEM suite.
FORAN provides a powerful tool for the definition of intelligent P&I and single wire (electrical) diagrams, allowing quick outfitting and machinery layouts.
The transition to the detail design is smooth, as the model can be progressively broken down and detailed.
FORAN Basic Design Benefits:
- Efficient tool for the early definition of the structure model in 3D.
- Automatic generation of class drawings.
- Smart export to FEM tools in standard formats, with an idealization capability to avoid unnecessary data for the analysis.
- Intelligent definition of P&I and single wire diagrams connected to the 3D model.
- Early machinery and equipment layout.
- Automatic regeneration of class drawings after changes in the model.
- Smooth transition to detail design and production stage.
- Considerable reduction in the number of man-hours by combining FORAN and pre-processor meshing compared with modeling directly in the pre-processor.
- Weights and materials estimate.
Structure for Basic Design
FORAN Initial Design tools provide a powerful set of tools for defining hull forms, or can import the hulls from any third party software.
- Modification of existing hull forms, using typical marine transformation methods.
- Modification of hull forms from curves, keeping boundary conditions.
- Pattern-based definition of decks and parametric definition of bulkheads (planar, corrugated and extruded).
- Topological relations between surfaces
Hull and deck structures
At the basic design stage, shell and deck plates can be modeled as areas of common grade and scantling, limited by any 3D curve on the surface (butts, seams, knuckles, etc.). These areas can be divided and detailed if the design progresses.
FORAN can insert sets of longitudinal stiffeners from end-to-end on each surface, and chop them at the points of change of scantling. As in the case of plates, stiffeners can be later detailed and split at block or part boundaries.
Openings can be defined projecting any 2D geometry on the surface. FORAN provides clipping of all the plates and stiffeners affected by the opening. Small openings can be included, and filtered out when exporting the model to FEM.
FORAN provides tools for defining planar, multi-planar or corrugated structures. In many cases, bulkheads, floors, web frames and beams, stringers, and other structural elements can be easily defined just with one click on a sequence of intersection lines, automatically provided on each working section. The smart or topological copy is of special interest at the basic design stage.
The FORAN structure model is created in true shape. Plate and profile elements are rendered as BREP solids, including thickness, openings, end cuts and other details automatically introduced by the FORAN modeling tools.
For global FEM analysis, FORAN provides an idealization tool that simplifies the structure model, removing thickness and non-relevant details, and then applies the necessary stretch or shrink to the elements to ensure that contacts and connections are kept.
FORAN divides all plate and profile elements at any contact and intersection. The result is a collection of connected elementary surfaces, exported in IGES or STEP formats, which can be easily meshed in most pre-processors.
The scantling and grade of each element is exported too. Many FEM pre-processors in the market include functions for reading the FORAN FEM XML files. It is also possible to configure the color coding according to the parts scantling.
In addition to the global ship analysis, where simplification of the model is mandatory, the detailed model can be directly used for local and fatigue analysis. Export to STEP, IGES, JT and other standard formats are available.
The FORAN drafting environment provides tools to create structure class drawings from the 3D model, in the traditional 2D structure style, and to update drawings after changes in the model. It is DXF compatible. Some remarkable features are the smart labeling, the possibility of automatically inserting symbols each time a drawing is generated, and propagating changes in the 3D model to each drawing upon user request.
Outfitting Basic Design
FORAN provides a smart 2D generator for piping, instrumentation and electrical schematics. Equipment, pipes and other elements on the diagram are transparently assigned with technological data and attributes from the machinery and outfitting libraries in the database.
- Full 2D editor, DXF compatible.
- Bidirectional integration with the 3D model.
- Connection consistency between equipment or fittings symbols and distributors.
- Automatic assignment and on-line edition of properties to elements.
- Automatic generation of parts lists.
- Management of multi-sheet diagrams.
Machinery and Outfitting Layouts
Outfitting and machinery layouts can be defined in the FORAN general arrangement tool, allowing ship configuration in the early stages of the project. This application follows the FORAN model-to-drawing approach, but also provides a 2D drafting environment that is DXF compatible and includes functions for placing and modifying equipment on the ship views. The 3D model is automatically updated when the 2D is modified.
Weight and materials estimate
FORAN provides accurate weight calculation of all parts included in the 3D model. The parts are considered with true shapes, including thickness, actual scantlings, openings, lengths and diameters, with the maturity level present in the model. The 3D model can produce material estimates in terms of tons of steel, areas of plate for each thickness and grade, total length for each profile section, material and scantling, number and type of fittings, pipes and equipment.
High performance solution for the fast, complete and accurate definition of the 3D model and output generation for any ship or offshore unit.
FORAN Hull Structure provides a complete solution for the definition of the 3D model of the structure, and for the automatic generation of all information required for manufacturing and production.
The solution can be applied in all stages of the design phase, starting with an early 3D model from an Initial design to class design, detail design and fabrication. The model is transparently stored in the FORAN database as it is created, and the transition between design phases is seamless, allowing the reuse of data. With a multi-user and concurrent modeling environment, all other FORAN disciplines offer access for reading, navigating, checking clashes, managing penetrations and referencing the structure model. Outfitting, machinery and electrical 3D models are also available when modeling the structure.
Modeling functions make extensive use of topology. Every structural item is stored along with its references to the surfaces and structures that support the item or define its boundaries. Topology enables a smooth propagation of the changes downstream of the modified item, and the use of smart copy functions.
The automatically oriented approach in FORAN ensures the fastest model generation, allowing shipyards and design offices to save designer man-hours.
FORAN Hull Structure provides a complete set of tools for generating all necessary documentation for fabrication and assembly.
FORAN Hull Structure Benefits:
- FORAN Hull Structure is strongly 3D oriented, and fully aligned with the FORAN model-to-drawing principle.
- Seamlessly applicable to all project stages, from initial design to production engineering and fully integrated with all other project disciplines.
- Fast, accurate, complete structure modeling environment.
- Extensive use of topology ensuring a fast definition of elements, smart copy functions and propagation of changes.
- Complete set of automatic fabrication and assembly outputs, configurable to the request of any yard or technical office.
- Regeneration of drawings after changes in the model.
- Customized NC data for shipyard machines.
- FORAN Hull Structure is completely integrated to the rest of FORAN design disciplines, including Machinery & Outfitting and electrical.
- Powerful management of penetrations.
- Build Strategy definition with advanced welding management.
Hull Structure Standards
The FORAN Hull Structure standards library is comprised of materials catalogues (gross plates and profiles), geometric standards and a number of configuration parameters controlling the modeling and the output generation processes. The parametric standards encompass brackets, clips, other standard plate parts, openings of different types, profile ends, edge preparations and multi-component building solutions.
3D Hull Structure Model
The structure is primarily built on top of the surface model.
- Solid modeling of plates and profiles (BREP based), including thickness, end cuts, cutouts, drain holes, etc.
- Automatic insertion of profile and welding openings.
- One click insertion of brackets, clips, face bars and stiffeners.
- Interactive or rule based part detailing, including edge preparations, welding bevels, precision assembly markings, margins and shrinkage.
- Calculation of weights, centers of gravity and painting surfaces.
- Visualization of the 3D model from other disciplines (piping, electrical) and definition of openings on penetrations requests.
FORAN provides functions for the definition of butts, seams and landings, as well as plate parts, profile parts and openings on the deck, bulkhead and hull surfaces.
FORAN Hull Structure includes tools for the smart definition of plate and profile parts on single planes, sequences of connected planes (extruded sections) or corrugated surfaces. Watertight or non-watertight notches, collar parts, edge preparation, split of secondary structures, are automatically achieved.
The FORAN Hull Structure modeling environment provides online access to the FORAN penetration management tool, which shows the list of opening requirements by outfitting designers and the status of each penetration. Structure designers can accept or reject each penetration request, and eventually make the hole in the affected parts.
FORAN provides a powerful tool for configuring the assembly plan, or build strategy. All items of the FORAN 3D model, including structure, outfitting and electrical, are organized in a hierarchical tree that simulates the assembly sequence.
Assemblies can be classified in categories, and each category can be assigned a drawing template. For every assembly, FORAN can generate an automatic drawing, with 3D and 2D views, details, automatic dimensioning, labeling or part lists, based on a configurable template. Other functions connected to the assembly plan are the calculation of welding lengths, weights and center of gravity.
Structure Fabrication and Assembly
FORAN provides a complete set of tools for creating all necessary documents for fabrication and assembly.
The following manufacturing and assembly tools are available:
- Plate and profile nesting, and CNC files for cutting, marking and lettering.
- Profile manufacturing sketches.
- CNC files for profile cutting robots.
- Plate expansion and bending.
- Jig drawings for curved panels assembly.
- Remarking drawings.
- Part lists and bills of materials.
- Automatic assembly drawings, 3D drawings and panel line drawings.
- Welding traceability drawings.
FORAN provides a highly efficient plate and profile nesting application. It can work in automatic or interactive mode, and supports both regular production nesting and global nesting for material estimates. FORAN nesting features part integrity between the 3D model and nesting, definition, and the reuse of scraps and symmetric/copied nesting.
FORAN provides advanced functions for the automatic calculation and classification of welding lengths, attending to different criteria such as type, position and assembly step. The welding calculation is performed downstream from one assembly, or from the complete project.
Machinery & Outfitting
A complete set of advanced functions manage equipment, distributors and related auxiliary structure design and fabrication.
FORAN Machinery & Outfitting continues the design process by incorporating all aspects related to equipment, piping, HVAC ducting and auxiliary structures into the same project-centric database used for the ship structure.
Starting in the early design stages, the user can start creating libraries of models to be used even in the GA definition. Later, during the basic design stage, intelligent P&I diagrams are generated, linked to the 3D model. The transition to the detailed design stage is seamless, taking advantage of the early position of equipment developed earlier.
A single tool manages the equipment, piping lines, HVAC ducts, related auxiliary structures and supports. Finally, all information for fabrication and assembly is generated automatically, including spools, isometrics, drawings and reports. FORAN has online tools for clash detection during all design process, and manages the process in an integrated way with the hull structure and all penetrations created.
FORAN Machinery and Outfitting Benefits:
- Complete integration with the rest of the design disciplines in FORAN.
- User friendly element libraries at the basic and class design stage.
- Intelligent P&I diagrams linked to the 3D model with single definition of entities.
- Design integrity with full control of user accesses, roles and permissions.
- Fast & powerful modeling environment.
- Complete management of pipe routing, equipment layout, HVAC , auxiliary structures and supports.
- State-of-the-art online clash detection and management.
- Manufacturing parameters checking for pipes.
- Automatic generation of pipe isometric sketches (fabrication spools & assembly).
- Automatic generation of user configurable reports and BOM´s.
The FORAN Outfitting standards library comprises a set of technological attributes and built-in geometries so that pipes, fittings and equipment are easily and quickly recreated from the vendor catalogues. Moreover, users can define any kind of 3D model for equipment and fittings by means of geometric macros.
The pipes and fittings are organized in specifications applied to each system, and contain the complete list of attributes such as material, nominal and secondary diameters, schedule, nominal pressure connection types, and other attributes. On top of that, any type of user attribute can be incorporated.
The integration between disciplines allows the user to assign electric properties to equipment and fittings for subsequent full electric calculation and wiring using the FORAN Electric modules.
The FORAN application for the pipe and instrumentation diagrams allows the definition of the diagrams as part of the ship design, stored in the same database as the 3D model. A specific 2D environment contains all the needed functionality to handle the basic entities that make up the essential part of the diagrams (equipment, pipes, fittings and instrumentation).
All data included in P&ID´s is available when working in the 3D model, thus guaranteeing the fully correspondence between the diagrams and the product, and therefore facilitating the task of creating the as-built diagrams.
Outfitting 3D Model
The FORAN application for the 3D modeling in Outfitting gathers different working environments within the same module, thus allowing the designers to work with equipment, piping, ventilation, cable trays (as space reservation), auxiliary structures and line supports.
The locking policy to ensure data integrity prevents multiple accesses to the objects in the database, such as combinations between the ship zone, ship system, design discipline and designer.
Piping and HVAC ducts can be routed interactively or using user predefined solutions. During routing tasks, FORAN automatically checks the fabricability of the pipes and the compatibility of connections, and calculates bolts, nuts, gaskets and welds.
As auxiliary structures, users can design any type of foundation, ladder, grating and handrail, plus pipe, duct and cable tray supports from scratch, or they can take advantage of standard, predefined solutions. In the case of the supports, a strong link between the distributor and its support keeps the model consistent after changes in the distributor. All profiles and plates created as part of auxiliary structures and supports can be included in nestings.
- Powerful hard and soft clash detection functionality.
- Capable of handling a large number of objects in the scene.
- Dedicated and smart tools for the distributor generation with multiple options.
- Automatic and interactive access to P&ID data from 3D model.
- Piping-oriented specific commands.
- Handling of singular spaces.
The FORAN Outfitting modeling environment starts the process of defining the openings in the main structure of the ship. Pipe and HVAC fitters can fully identify each of the holes that must be cut into any plate for a watertight or non-watertight penetration. Penetrations carry their own data and are stored in the database, and, at the same time, they undergo a strict workflow from the Outfitting (and Electrical) Department to the Structure Department, where they are evaluated, approved and executed (if applicable). The penetrations pieces have their own representation, and can be included in the drawings and exported to BOM´s.
ISOM, FBUILDS, FDESIGN
The typical outfitting production documents are obtained from FORAN in a highly automated way, especially the pipe spool isometric sketches for fabrication and mounting. Both drawing types are capable of complete customization for symbols, labels, dimensions, boxes and paper formats, and are obtained in a fully automatic way. The fabrication drawings may include complete bending information and can export data to CNC files.
Similarly to the FORAN Structure, the outfitting entities may be assigned to any building strategy tree. Pipes, HVAC ducts, auxiliary structures, supports and corresponding hotworks can be added at any level of structure assembly, thus guaranteeing the pre-outfitting blocks and sections with the consequent savings in cost and delivery times.
All reports in FORAN are generated in a single application with powerful capabilities and user-friendly interface. The outputs can be easily generated and updated after changes.
Advanced and exhaustive design of the electrical project on board.
FORAN provides advanced functions to manage all the relevant aspects in design and production of electrical systems on ships. In particular, it includes facilities to create electrical diagrams, to model electrical equipment, to create 2D or 3D equipment and cableway layouts, to calculate cable sizes, to route cables, to define cable terminations, to manage instrumentation and control signals, and to generate different types of reports and drawings.
The Electrical Design package of FORAN provides an efficient connection between the electrical department and the other design disciplines.
FORAN Electrical Design Benefits:
- All related information is integrated with the rest of design disciplines.
- Any element can be placed in more than one diagram, being still considered a single database entity.
- Automatic calculation of the cable size by different criteria.
- Online editing of all data of the elements in the diagram.
- Automatic and configurable labeling of all the elements in the diagram.
- Automatic generation of configurable graphic lists.
- Integration of pipe-fittings with electrical connections.
- Cable trays may be modeled automatically according to the cable tray pattern assigned to each segment or polygonal of the nodal network.
- Cable reports, equipment reports, routing cable spec reports, I/O signal loop sketches and cable connection sketches.
Electrical standard libraries
The definition of the electrical standards and elements includes basic data tables (cable segregations, nominal cross-sections, standard tray sizes, cable materials, etc.), cable catalogues and cable nominal sizes. Available data includes cable composition, core size, overall diameter and other mechanical and electrical characteristics associated to each nominal cross section, classes and components of electrical equipment, fittings and instruments, cable segregations and cable routing rules.
All cables and electrical equipment pieces placed in the diagram are automatically registered in the FORAN database and are ready to be reused in the rest of the applications. On-line, block, wiring and lighting diagrams are some examples of the types of documents that can be created.
- Information integrity.
- Automatic calculation of cable sizes.
- Online editing of all data of the elements in the diagram.
- Specific functions to handle equipment and fitting symbols.
- Automatic and configurable labeling of all the elements in the diagram.
- Automatic generation of configurable graphic lists.
- Integration of pipe fittings with electrical connections.
The cable routing is based on routing paths, or sequences of 3D points (nodes) connected by straight segments. Routing conditions controlling the segregations and filling rules are assigned to every segment of the path.
Nodes representing penetrations can be assigned to rules for controlling the cable population in the penetration: penetration fitting, allowed area or number and type of watertight blocks.
Cables can be routed either in automatic, semiautomatic or manual modes. The automatic mode evaluates the shortest path that fulfills the routing conditions and the existing filling rules. The semiautomatic mode allows marking some points mandatory or forbidden. Once a cable is routed, its weight, length, center of gravity and the cable tray population are automatically updated.
Cable tray modeling
Cable trays may be modeled automatically according to the cable tray pattern assigned to each segment or polygonal of the nodal network. Functions for manually inserting standard fittings are also available. Cable penetrations or transits are automatically modeled based on the information given to the penetration nodes. Online clash checking can be used to avoid mounting errors.
The user can generate different types of drawings, including automatic cable route pull sheets and cable tray isometric sketches. FORAN controls the consistency of the process and creates automatic connection sketches.
To define I/O signals, in addition to each proper signal value, such as the type of signal (analogue, digital or serial line), the I/O card type, the range of measurements, alarm data, etc., we also need to assign a processing station and an instrument (field element) to the signal, and choose the corresponding cable wires used for each signal to propagate. Several kinds of I/O lists can be extracted.
FORAN offers a complete report generator that includes both predefined and configurable reports, which can be exported in standard formats. It allows configuring, creating, viewing and printing reports of the electrical design data.
Drafting & Mechanical CAD
Generation of drawings from the 3D model and advanced mechanical CAD design tool.
The FORAN Drafting & Mechanical CAD application allows the generation of all type of drawings from the 3D model of the project from all FORAN design disciplines. Consistency between the model and the related drawings is ensured, thus keeping the option to regenerate them after any update in the 3D model.
This application is also used for advanced mechanical design, and for the generation of all the needed views, sections, details and BOM´s for manufacturing.
The application has powerful tools to generate and fair complex surfaces that can be integrated later as part of the hull surface of the ship, like anchor pockets or skegs. It may also be used as a complementary tool in conjunction with FSURF for importing and modifying any kind of surfaces.
ORAN Drafting and Mechanical CAD benefits:
- This tool allows the automatic generation of all drawings from the ship 3D model from all FORAN design disciplines: Initial Design, Basic Design, Hull Structure, Machinery & Outfitting and Electrical.
- Strong link between the model and the corresponding 2D drawings and automatic updates after changes in the model.
- Powerful 2D graphic editor with the possibility to create smart dimensioning, symbols, user-configurable drawing templates, insert labels and generate parts lists from the drawing information.
- Standalone 3D solids modeler, with a wide range of functions for the creation of casting parts and other complex pieces.
- A complementary tool for importing and modifying any kind of surfaces from other formats (iges, step, dxf and others).
- Rendering capabilities and Global Shape Modeling (GSM).
- Kinematics for generating motion videos.
Generation of Drawings
The application allows generating drawings containing any combination of selected elements of the 3D model such as hull structure, equipment, vent ducts, cable trays, piping and accommodation. Theoretical lines and surfaces as frames, decks and bulkheads can also be included in the drawings.
Any kind of drawings can be generated, including main orthogonal projections, sections by any plane and perspective views with any orientation, with the type of representation and the selection of the elements to be drawn and format of drawings fully customized. This graphic information can be completed with labeling and dimensioning, both automatically updated after changes in the 3D model.
- Reading of all type of entities in the project.
- Automatic and smart labeling and dimensioning.
- Link between the 3D and the 2D files for automatic update.
- Automatic BOM´s from the 3D scene.
- Fully customized drawings and BOM.
Mechanical CAD Toolset
As a standalone application for advanced mechanical design, the application has the capability to generate and manipulate solids through a variety of methods. Once solids, the objects may be subject of different transformations, including Boolean operations, linked copies and symmetries, scaling and others. Other commands, oriented to the mechanical operations, allow drilling holes and generating shafts with specific characteristics, like thread, tapering and angle.
An extensive use of the graphic snap options enable dynamic links between entities, so further modifications are transmitted to the positions and orientations of the linked entities.
The drawings may be automatically obtained by applying custom-made templates for views, drawing formats, sections, details and BOM´s.
The application enables setting mechanical restrictions between solids based on their surfaces, by setting the reference and the moving solids. Those restrictions would result in relative movements, according to the final degrees of freedom. Typical relative movements are rotations, linear slides, tangent slides along curved surfaces, spherical roller bearings and the like.
By driving some key restrictions using smart dimensions, it is possible to control movements over a given time. It is also possible to combine them for a complex movement, providing the overall mechanism is consistent.
Another powerful feature from the mechanical CAD toolset consists on the handling of sheet-metal objects, typically the HVAC ducts and bespoke cabinets or lockers. In this case, the application has the capability to design and unbend all the parts for manufacturing. Even the unbent sheets may be transferred later into the FORAN database for complete handling, including automatic nesting.
The application is particularly powerful in the generation and fairing of surfaces, with intuitive and visual checking of the smoothness and curvature of the patches that later on will become part of the hull surface, or even the shell of a casting piece from which to obtain all the required sets of drawings.
- Curve and surface generation and fairing.
- Curves and surfaces may keep the link with the generating traces for updates.
- Curves and surfaces connection with continuity restrictions.
- Import and export of surfaces in various formats.
A complete integration considers all shipbuilding disciplines covered by the FORAN System, as well as all the associated information for vessel manufacturing and lifecycle.
FORAN-PLM advanced integration is a solution that offers efficient communication of information, processes, systems and databases during the design, production and operation of ships.
Product Lifecycle management (PLM) tools can be defined as the management of evolving and maturing product information throughout the lifecycle of a product. For medium and large shipyards developing complex vessels, the PLM system usually represents the formal central repository for product information disclosure.
While traditional CAD-PLM integration only considered document management and partial exchange of product structure, the FORAN-PLM integration enables a seamless integration and incorporates solutions to the most demanding requirements related to alignment of BoM between the different business systems.
The solution has been built taking into consideration the higher demands of large naval projects, in order to bring a state-of-the-art answer covering all stages of the vessel life-cycle, from the conceptual and basic design to the operation of the ship in all FORAN disciplines (Hull forms, General arrangement, Naval architecture, Hull structure, Machinery and outfitting and Electrical design).Integration with the major PLM Systems in the market is currently available in the latest version of FORAN, and is being used in the development of large naval programs such as submarines, aircraft carriers, patrol vessels, landing vessels, etc.
FORAN-PLM integration Benefits:
- Strong and complete integration between FORAN and different major PLM tools available in the market.
- Scalable for large and complex projects, especially in the naval field, with hundreds of users working simultaneously under tight security restrictions.
- The architecture of the solution is neutral and it is based on standards such as XML, web services and CORBA (Common Object Request Broker Architecture).
- All FORAN design disciplines are integrated and during all design stages, from concept design to manufacture and life-cycle.
- FORAN-PLM integration ensures a single source of data within the organization during the entire design, production and operation process.
- The right answer for managing sister ships. one of the most challenging demands in the naval shipbuilding industry.
Integration is based on a neutral framework, built on standards such as web services, XML and CORBA, specifically developed to be as independent as possible from the specific characteristics of each PLM system.
Integration relies in two key processes to allow the bidirectional communication between the two systems: publishing, which means transferring data from FORAN to PLM, and synchronization, which means transferring data from PLM to FORAN.
From the data structure perspective, integration is controlled by a set of tables in the FORAN Oracle database to allow the control of the following actions:
- Register all items and parts in the FORAN project published in the PLM, along with their PLM master data to be shared with FORAN.
- Register all items and parts created initially in PLM allowing them to be incorporated into the FORAN project and then published in the PLM.
- Control both the publishing and synchronization processes.
- Mark items as locked from the PLM context to prevent modifications in the FORAN context.
From an administration perspective, FORAN-PLM integration incorporates a utility to allow the mapping and configuration of the data model in the two systems, including an attributes manager to configure which attributes will be shared between the two systems as well as which is the “master” system for each attribute. The PLM can be the single source for generating item identifications.
As regards FORAN components (standard parts), the integration controls the bidirectional transfer of equipment components (mechanical and electrical), pipe/HVAC fittings components, cable tray components, types and sections of cables and transit types.
The integration comprises all entities, including equipment, hull structure, P&I diagrams, pipelines and duct lines (3D), auxiliary structures (seats) and supports, electrical diagrams, cables and cable trays (3D), penetrations and welds.
From the 3D model perspective, the publishing mechanism generates JT Open (the ISO standard format for viewing and sharing lightweight 3D product information) files with the geometry of each particular part.
In addition, the integration allows the publishing of the FORAN build strategy and incorporates a full set of functions to allow the direct use of the PLM full Document Management functionality (Download, Checkout, Search, etc.) from all FORAN modules generating documents.
Different options exist in FORAN to allow the locking of an entity because it has reached a certain maturity level. FORAN modules also provide additional scene visualization capabilities based on the maturity state of the entities in the scene.
A new representation group (Secure) has been implemented to contain the geometry to be shown to non-authorized users during the reading process for each model object.
FORAN-PLM integration also contemplates the use of Access Control List as a combination between groups/users and authorization levels. The access control list of an item will be defined in the PLM and then transmitted to FORAN by means of synchronization mechanism for the equipment items and library’s models.
Once the design reaches a certain degree of maturity, managing changes becomes essential. In the case of FORAN, the process is managed by PLM, which provides the Change Manager functionality to support the change process, including:
- Identifying and defining the need for the change.
- Assessing the change impact.
- Notifying participants involved in the change process.
- Defining tasks to implement it.
- Comparing before and after product configurations.
Change Management in FORAN is controlled by ECN (Engineering Change Notice, in a design context) processes and FORAN deals with aspects like the identification, impact assessment, ECN viewer, task development and comparison of product configurations.
Configuration Management and Applicability
Configuration Management in FORAN-PLM integration focuses on Applicability management (also known as hull Effectivity) in the context of a class project composed of several ships. Other important aspects of Configuration Management such as baselines, configuration states and product structures are managed in the PLM system.
The FORAN approach to Applicability is based on the concept of a “series” or “class of vessels” project, which controls the common aspects of the series including:
Unique identification of the items in the series.
Common locking management across all vessels of the series.
Applicability can be defined for all FORAN entities of the project at different levels, including at the item level in some cases (i.e. equipment). The applicability context of each item in the series project will be handled by means of a FORAN database table common to all the units in the project.
Once the applicability of an item has been defined or modified, the subsequent changes on that item (modifications or deletions) will take into account the new applicability values of the item so FORAN will automatically propagate the changes across all affected vessels of the series project.
FORAN also incorporates tools to visualize one or several vessels of the series and/or make comparisons.
Immersive solutions for real time access to review the FORAN 3D virtual model.
The FORAN Virtual Reality solution provides access to the 3D model of the ship developed in FORAN, taking advantage of the latest technologies. Visualization and model navigation can be managed from different devices (one side view environment, complex multi-wall simulator as caves or head mounting displays) and for many purposes (design review, simulations of operations, ergonomics, marketing, etc.). Benefits can be seen in fabrication and construction where many costly errors can be easily avoided.
Simulation of the real environment is achieved by interaction with movement tracking systems that allow the user to interact with “virtual prototypes”, with full immersion in the scene. As a result of this high degree of 3D immersion, product operation is very close to reality.
The functionality of FORAN Virtual Reality solution includes, among others, the ability to “walk through” the ship model in real time, queries can be made about properties and attributes, collisions can be detected and managed, annotations inserted, clearances and distances measured and on-board ergonomics studied. On top of the software, the FORAN Virtual Reality solution covers the creation, installation and set-up of complex environments adapting itself to the most challenging demands and requirements.
FORAN Virtual Reality Benefits:
- Complete set of solutions to navigate and review around the FORAN 3D model.
- SENER can provide customizable installations including large screens, caves, head mounting displays or tablets.
- FORAN offers a virtual reality viewer that can handle a huge amount of data and can be applied for the design review.
- Ergonomic studies and operations simulations.
- Training activities in a virtual environment.
- Marketing applications.
- Better product design, avoiding many costly errors in production.
- Faster decisions and savings in maintenance costs.
FORAN Virtual Reality solutions can be applied to engineering design, engineering review, manufacturing, development and planning processes in an interactive and collaborative environment.
- Resolve complex design or manufacturing issues in a collaborative environment.
- Validation of complex assembly processes.
- Virtual prototypes, variants and configurations to achieve the final design.
- Detection of design errors.
- Improved production and maintenance operations.
- Ergonomic studies (reachability & usability).
- Training of assembly personnel.
- Training of new personnel in ships and offshore platforms.
Advanced visualization installations
SENER supplies advanced Virtual Reality installations with the most suitable alternative, depending on the customer requirements.
Type of installations:
- calable wall systems using large screens.
- Multi-walled visualization environments (caves).
- Portable solutions, when mobility is required.
- Immersive Head Mounted Displays (HMD).
The solution includes 3D projectors according to the resolutions required, tracking systems (optics & ultrasounds), computers (robust cluster infrastructure and multi-channel high performance graphics engine), infrastructure (supports, cables), VR Hardware (Wand, glasses...) and VR software.
Virtual reality and design review in FORAN
FVIEWER is an application that allows users to navigate the 3D model. The design tree information is displayed in the main window for object selection and to find information about the model and annotations. Selection of components is done using different criteria. It is possible to operate with groups of selected items, always with the aid of clipping planes and advanced searching tools. Finally, it is possible to import 3D models in JT Open format and to have screenshots and generates videos in 4K resolution.
Information about ship references.
System and user defined attributes.
Measurements between items.
Addition of notes.
Assembly simulation manager.
Collision detection, which can be highlighted by means of sounds and color, and also stored.
Path editor is available allowing to check removal and escape routes and design inconsistencies.
Overview map allowing easy changes in position.
3D stereo projection.
Tracking systems support.
Auto install stand-alone application..
Developed in native 64 bits, the system takes advantage of the latest graphic card capabilities. This solution can efficiently handle a huge amount of data. With an interactive and user-friendly approach, the module helps the user during navigation of the 3D model.
FORAN viewer incorporates optimized data management tools, which make it easier to handle big scenes and huge amount of data.
In addition, the module uses a number of performance enhancement techniques, such that geometry hidden behind other geometry is not sent to the graphics pipeline, and incorporates better visualization capabilities without penalizing performance.
Change and access control
Strong solution to be used in complex ship projects with high security and control demands.
FORAN change and access control provides the customer with a powerful single application to manage ship design and production. Shipbuilding is demanding more security to develop the projects in complex and distributed environments, with many agents working concurrently, but keeping the necessary security restrictions. This issue is particularly crucial in the naval field, where the integrity of the information and the security makes impossible to work without powerful change and access control to all engineering data.
The access control in FORAN allows each user to access to specific data, based on predefined criteria. In addition, FORAN introduces several simple change control tasks, including the registry of changes made on units, freezing and unfreezing of units and generation of reports. One of the main tasks is to avoid the modification of project elements that have reached a certain level of maturity.
Additionally, this tool can be used as a standalone version as a viewer, for visualization purposes only, without access to the FORAN database, and for importing/exporting tasks.
For more demanding security and control environments, as well as for solving matters such as configuration management, FORAN offers a strong and bidirectional integration with the major PLM tools existing in the market.
FORAN Change and access control benefits:
- Single application for change and access control to be used in complex environments with security restrictions.
- Different and powerful administration of the different users accessing the information, considering the role of the designer, discipline, task or even functional, geographical or sequential stages.
- Advanced tools to manage access control with hundreds of users.
- Efficient change control tasks with registration of changes and change viewer.
- Control of maturity level with the ability to “freeze” designs and generate reports.
- Standalone version for visualization purposes, able to read any FORAN model.
- Strong and bidirectional integration with the major PLM (Product Lifecycle Management) tools available in the market, for highly demanding project control management.
Change and access control in FORAN were introduced in response to the increasing needs of managing confidential data, as well as outsourcing the design but retaining the administration of the project.
Parallel to the distributed design scenario, new demands for access and change control arise. From a shipyard perspective, access control to parts of the project becomes a key issue, due to several reasons:
- Critical areas for which access must be restricted.
- Distribution of the work among the users.
- Restrict undesired modifications according to maturity.
- Subcontracting policies for certain parts of the ship.
- Protect proprietary intellectual property.
As FORAN stores all information in a single database, Oracle provides a first level of control that is based on i) the role of the user (designer, viewer) and ii) the specific task or discipline in which the user is authorized. Thus, database access is fully controlled at all times. This functionality allows, for instance, preventing a structural designer from modifying piping items. In addition, FORAN allows the use of Corporate Authentication Systems (LDAP, Active Directory).
The distributed design may be based on distribution by disciplines (functional), by zones (geographical) or by design stages (sequential), which creates the need for additional control. The second level of access management is provided to allow or forbid access by functionality (system), geography (zones) or both. This functionality is based on the concept of a Control Unit that represents the area subject to either access or change control.
Each unit is defined by a discipline and an activation level, it is managed by one or several unit managers, and it contains the configuration to be applied for access and change control as shown in the following table:
The activation level defines what level of the FORAN hierarchy is to be controlled, and often coincides with a working area (e.g. Zone & System). An activation level can belong to more than one discipline, and may be used to define different control units such as:
- Hull Structure – Materials – Table of standard gross plates.
- Hull Structure 3D Model – Deck and Zone.
- Outfitting standards – Components – Model library tree.
- Outfitting 3D Model – Equipment - Zone & System.
- Electrical – Cables – ‘From’ or ‘to’ device – Zone & System.
For the purpose of controlling access and changes, three different types of user roles can be defined:
- The Administrator defines the areas to be controlled, creates units and assigns unit managers to the already defined units.
- Unit Manager responsibility includes the configuration of access to their units as well as the definition of the settings related to change control.
- Designers will be allowed to read/modify only the units for which they have sufficient permission.
Unit Managers can activate access control to a unit at any time. A designer running any FORAN module will be allowed to read or modify the corresponding unit only if the Unit Manager has previously authorized him/her.
The solution includes advanced tools to allow the selection of multiple units, the possibility to share settings between units and management of user roles by groups, which are of special relevance in the case of large organizations working on complex projects with several users. Using LDAP, authentication of groups can be reused/shared with other Enterprise applications.
In addition to access control, FORAN introduces several simple but efficient change control tasks, including the registration of changes made to units, freezing and unfreezing units and generating reports. One of the main tasks of the change control system is to avoid the modification of project elements that have reached a certain level of maturity and, consequently, the unit manager has marked as ‘frozen’. A change viewer is provided that makes it very easy to track changes by means of a set of filtering mechanisms.
The concept of external freezing (or locking) has been developed in order to facilitate the integration with external applications like PLM or ERP systems. The use of flags updated externally may be used to indicate if the modification of an element is acceptable to the corresponding external applications. Other flags can also be used in order to, for example, allow changes in a unit only after a warning message has been sent to the user.
Combined with PLM Integration modules, FORAN provides proven technology with more sophisticated access controls at all levels of the project.
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