the largest desalination plant of the world has been...

CAEsoft Amelia Martínez Lobo [email protected] - Communication

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After more than 100,000 engineering work hours, 6.000 drawings, 3.000 piping lines, 5.000 valves, 140 P&ID’s and 16 months of work, the plant will work completely next 2013

The largest desalination plant of the world has been designed with AutoCAD Plant3D in record time and with high level detail

“With any other industrial plant design software, it would have been impossible to carry out this project at this steady pace”, Aljendro Clara says, who is in charge of Sadyt technical department and who counts with more than 30 years of experience designing industrial plant in 3D.

It is the largest desalination plant of the world. Placed in Ashdod, Israel, and uses reverse osmosis technology, one of the most efficient systems to desalinate and make the water potable. It will produce 384.000 m3/ day, it means that it could fully supply to a one million population city.

Plant general view: ultra filtration plant, effluents treatment plant, reverse osmosis plant and pots processing plant


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Project chronology

Jul/2010 - Software purchase Mar/2011 – Contract signature Sep/2011 – Basic project deliver Dic/2011 – Begins civil construction Abr/2012 – Detailing engineering deliver Jun/2013 – Construction end Dic/2013 – Deliver- Production

Mekorot, the national water distributor in Israel, put the project out to tender to design and carry out a reverse osmosis desalination plant in Ashdod, the sixth larger city in the country and with the largest commercial port, that receives the 60% of Israelis imports. The join venture Sadyt-Minrav won the bidding and Sadyt, water division of Sacyr-Vallehermoso group has been in charge of the whole process and mechanical engineering project.

The desalination plant will produce potable water for human consume, which will be distributed trough a coast parallel pipe, supplying multiples cities, among them, Tel-Aviv, the capital. To know the magnitude of the project, it is necessary to look at it in deeper detail: the plant has 77.000m2, means, the size of seven football stadiums. It

has 3.000 pipe lines – four times more that in a medium project – 140 P&ID’s – 5 times more than the average – and 5.000 valves – almost 10 times more than in medium projects. And everything in 16 months. In less than 2 years from the beginning of the first draft drawings, the desalination plant will be working 100%. “With any other software that hadn’t been AutoCAD Plant3D, it would have been impossible” Alejandro Clara says, technical department Manager in Sadyt. And Clara knows what he is talking about; in fact he counts with more than 30 designing industrial plants in 3D. He has designed paper mills, food industries, and several desalination plants.

Alejandro Clara Studies

Industrial Eng. 3 years (Uruguay) Naval Eng. 2 years (Uruguay) Oil and refinery Eng. 2 years (Uruguay) Multiple Specilization courses (Argentina) ASME code (Argentina)

Previous experience 30 years designing plants (first 3D project in 1982)

Water plants Food plants Paper mills

Emblematic projects One of the largest desalination plant in

the World in Barcelona. This plant uses electro dialysis technology and has 1.800 valves.

Valencia Zoo(2004). Irrigation system design, canalization and water distribution, ponds, etc. under the Zoo.

Alejandro Clara, Head of technical office in Sadyt


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Proyect data Budget: 300 mill € Production: 384.000m3/ day Use: potable water Final price: 0,66 $/m3 Caudal: 3m3/sec Eng. hours: 110.000 hours Plant surface: 77.100 m P&ID’s: 140 Pipes lines: 3.000 Equipment: 200 Valves: 5.000 valves

2800 big valves Buildings: 7 process build. Planes: 6000 Software: AutoCAD Plant3D,

Navisworks, Revit

The project

With AutoCAD Plant3D has been carried out 100% of the mechanical and process engineering of the plant

Sadyt has been in charge to carry out the 100% of mechanical and process engineering of the plant, as well as the reverse osmosis chassis design. In general terms, it means, 26% of the full project (structures, foundation, etc.)

Effluent plant detail The desalination plant is composed by: one ultra filtration plant, one effluent treatment plant, one reverse osmosis plant, one post processing plant and many distribution tanks. The ultra filtration plant receives the sea water. The 95% of the water goes to the reverse osmosis plant, the other 5% is treated in the effluent plant, where the residues are dehydrated and put in a dump.


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Ultra filtration plant

The reverse osmosis plant is composed by 24 chassis, 12 of them of first processing (energy recover). The other 12 are of second processing. They are necessary to make the water potable and has no more than 0,4 mg of boron per m3. The sea water has more than 4 mg of boron per m3, what makes completely necessary the 12 second chassis.

Ultra filtration plant interior (filters on the top has been omitted)


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In the post processing plant the water is reminaralized, adding calcite.The water, already potable and ready for the human consume, is stored in several tanks managed by Mekorot. Taking into account the water inlet distance and the sea water current, an strategic point has been chosen to put the brine back in the sea.

Post processing plant model

After this process, of every 100 m3 of sea water, 45 m3 of potable water and 55 m3 of brine are got and put it back in the sea. Every engineering project has technical problems. This project is not an exception. Because it is sea water, materials must be of high quality, as stainless steel. This means that materials price is higher. Also, the land, a very unstable sandy area, forced to put piles in the whole plant. And the environmental issues have to be added and battle with. On the other hand, the distance (Spain-Israel) forces to get the highest level of detail. The over cost derived of projects undefined are very high, that’s why it is crucial to get the maximum level of detail. And this level of detail got with AutoCAD Plant3D is optimum.


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Software Implementation The key of the success and work speed was the training process. CAEsoft-2aCAD carried out the consultancy and training job. This binomial group has a large experience on their backs with different piping software, which was determinant for the software implementation success. The training provided during a hard work week, was materialized soon. In less than one month, the technical team had already delivered the first drafts. After four training days in Specs, one single person just needed one month to elaborate the Specs of the whole project.

Structure design simplicity Piping professionals don’t waste time modeling geometries with complex

tools. AutoCAD Plant3D helps to design structures in a very simple and fast way.

The performance success in structures modeling stems from the simplicity. 3D plant conceptual models can be modeled in a very quick way. That’s

perfect for quotations or first drafts. Work Speed People Work Time

2 140 P&ID’s 4-5 months 1 Specs 1 month 1 Building models (800 lines) 35 days 1 Steel structure 2 weeks 1 400 lines 1 month 4 Whole model modification 5 days


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One the symbols and components properties are customized, P&ID’s drawing is quick and easy. Instantaneity reports can be generated and sharing data with other

is possible

Isometric generation is automatic, which helps to get high performance and make changes faster. AutoCAD Plant3D 2011 runs with ISOGEN standard.


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Orthographic view generation Even though we are in a 3D work space, planes have

always to be generated as the final design process. That’s why the orthographic views are so important.

Orthographic views have quite intelligence in the component information. We can also find the elements

in 3D, select elements or make plant sections

A further step in the level of detail

“The level of details achieved with AutoCAD Plant3D improves the quality and precision of the project”

To get a higher quality and more accurate design, custom catalogs are elaborated and customized. The catalogues are included in AutoCAD Plant3D. They are composed by intelligent elements, it means, every element, pipe, etc. has associated all the information we would like to include. And the work speed is amazing: it is not necessary more than one week for one single person to elaborate 100 accessories catalogue.

Navisworks: software that is able to read massive geometries. With Navisworks any model size can be moved, even with a high level of detail. Navisworks also helps to integrate external data base, construction process simulation o photorealistic presentations very fast.


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Custom Part For the very first time, a industrial plant design software achieves a high level of

detail due to the possibility to incorporate custom catalogues. The components are created from manufacturer solid models; they have great geometry fidelity and are useful to clash detection. Also it is possible to view a

more realistic model. With no functionality loss in 3D review (thanks to the graphic power of Navisworks) we can keep generating isometric and orto views without any

other problem.

“Level of detail, precision and speed… in significant projects”

To conclude, the features to emphasize are: high level of detail achieved with AutoCAD Plant3D, therefore higher quality achieved. It means, projects are more defined and the risks and over cost from the interferences are reduced. Speed and work flow are spectacular. With AutoCAD Plant3D it is possible to carry out huge engineering projects. 100% process and mechanical engineering of the largest desalination plant has been carried out with this software. With the right training, the implementation in the company is easy. And the result backs it up: in less than 30 days the first drawing were delivered and in less than 2 years the plant will work fully. A fact, as Alejandro Clara says, “impossible with any other piping software”.

the largest desalination plant of the world has been...

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