Advanced Initial Vessel Design

Most of the cost of the ship is committed in the initial vessel design stage, where fast propagation of design changes and the highest precision are required. The initial design comprises the hull forms, general arrangement, and naval architecture calculations, all integrated with the other design disciplines, ensuring data integrity, fast propagation of changes, multi-user access, and the reuse of information in later stages.

Basic Vessel Design

Basic Vessel Design provides the preliminary definition of a 3D model ship to obtain the reports and drawings required for the approval of class societies. It also supports a quick definition of the structural and outfitting elements in 3D. This capability covers global geometry, attributes, and scantling in an extremely efficient manner.

Hull Structure

FORAN Hull Structure provides a complete solution for the definition of the 3D model of the structure and the automatic generation of all information required for manufacturing and production.

Integrate Ship Outfitting & Machinery

Integrate ship outfitting with a complete set of advanced functions that 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.

Marine Electrical Design

Manage all relevant aspects in the design and production of electrical systems on ships. Create electrical diagrams to model electrical equipment, create 2D or 3D equipment and cableway layouts, calculate cable sizes, route cables, define cable terminations, manage instrumentation and control signals, and generate different types of reports and drawings.

Powerful Drafting & Mechanical ship CAD

The FORAN Drafting & Mechanical CAD application allows the generation of all types of drawings from the 3D model of the project from all FORAN design disciplines. Consistency between the model and related drawings is ensured, thus keeping the option to regenerate them after any update in the 3D model.

Shipbuilding with PLM Integration

Proper PLM shipbuilding integration considers all shipbuilding disciplines and 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.

The FORAN-PLM integration enables seamless integration and incorporates solutions to the most demanding requirements related to the alignment of BoM between the different business systems.

Virtual Reality in Shipbuilding

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-mounted displays) and for many purposes (such as design review, simulation of operations, ergonomics, marketing) using our virtual reality tool for shipbuilding. Benefits can be seen in fabrication and construction, where many costly errors can be easily avoided.

Wide-range Change and Access Control for Shipbuilding

Manage ship design and production 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. The integrity of the information and the security make it impossible to work without effective change and access control for shipbuilding to all engineering data.

3D Hull Structure Model

Includes tools for the smart definition of plate and profile parts on single planes, sequences of connected planes, or corrugated surfaces. Watertight or non-watertight notches, collar parts, edge preparation, split of secondary structures, are automatically created.

• Solid modeling of plates and profiles (BREP based), including thickness, end cuts, cutouts, drain holes, etc.
• Insertion of profile and welding openings, brackets, clips, face bars, and stiffeners.
• Calculation of weights, centers of gravity, and painting surfaces.

Access Control

Three different types of user roles are defined:

• The Administrator defines the areas to be controlled, creates units and assigns unit managers.
• Unit Manager controls access to their units and the definition of the settings related to change control.
• Designers will be allowed to read/modify only the units for which they have permission.
• Advanced tools allow the selection of multiple units, the possibility to share settings between units and management of user roles by groups.

Advanced visualization installations

Advanced Virtual Reality installations with the most suitable alternative, depending on the customer requirements. Type of installations:

• Scalable 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, 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.

Assembly Plan

Provides a powerful tool for configuring the assembly plan, or build strategy. All items of the 3D model, including structure, outfitting, and electrical, are organized in a hierarchical tree that simulates the assembly sequence.

Assemblies can be classified into categories, and each category can be assigned a drawing template. Generate an automatic drawing, with 3D and 2D views, details, automatic dimensioning, labeling, or part lists, based on a configurable template.

Cable Routing

Cable routing is based on routing paths or nodes connected by straight segments. Routing conditions controlling the segregations and filling rules are assigned to every segment.

Nodes representing penetrations can be assigned rules for controlling the cable population in the penetration: penetration fitting, allowed area or number, and type of watertight blocks.

Cables can be routed automatically, semi-automatically, or manually. A cable’s weight, length, center of gravity, and 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 – or manually. Cable penetrations or transits are automatically modeled based on the information given to the penetration nodes. Online clash checking can be used.

The user can generate different types of drawings, including automatic cable route pull sheets and cable tray isometric sketches.

Change Control

Supports efficient change control tasks, including the registration of changes made to units, freezing/unfreezing units, and generating reports. One of the main tasks is to avoid the modification of project elements that the unit manager has marked as ‘frozen’. A change viewer makes it easy to track changes by means of a set of filtering mechanisms.

Combined with PLM Integration modules, FORAN provides proven technology with access controls at all levels of the project.

Change Management

Once the design reaches a certain degree of maturity, managing changes becomes essential. Identify and define the need for the change. Assess the change impact. Notify process participants. Define tasks. Compare 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.

Class Drawings

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.

Configuration Management & Applicability

Configuration Management focuses on Applicability Management (or Hull Effectivity) in a class project composed of several ships. Other important aspects such as baselines, configuration states and product structures are managed.

The FORAN approach is based on the concept of a “series” or “class of vessels” project, which controls the common aspects of the series including:

• Standards.
• Unique identification of the items in the series.
• Applicability information.
• Common locking management across all vessels of the series.

Electrical Diagrams

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.

Electrical Reports

FORAN offers a complete report generator that includes predefined and configurable reports that can be exported into standard formats. It allows configuring, creating, viewing, and printing reports of the electrical design data.

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 catalogs, and cable nominal sizes. Available data includes cable composition, core size, overall diameter, and other mechanical and electrical characteristics associated with each nominal cross-section, classes and components of electrical equipment, fittings and instruments, cable segregations, and cable routing rules.

FEM Export

The model is created in true shape. Plate and profile elements are rendered as BREP solids, including thickness, openings, end cuts, and other details. For global FEM analysis, a tool 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.

General Arrangement

Drawings are generated directly from the 3D model and are linked to it so any modification in the 3D model will be automatically updated in the drawings. Offers options for generating spaces, including 2D views connected to the 3D model. Any compartment can be subdivided into subspaces. Insert data related to the contents of the tanks and associated attributes to calculate weights, centers of gravity and volumes.

Generation of Drawings

Generate drawings containing any combination of selected elements 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.

Many 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.

Hull Forms Definition

A comprehensive environment for the definition of deck and bulkhead surfaces 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 with advanced tools to define the ship surface model based on NURBS formulation:

• Conventional or special hull forms.
• Interactive graphic functions for lofting facilities and surface curvature and smoothness controls.
• Supports standard formats (IGES, DXF, STEP… ).

Hull Penetration Management

Penetration management 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.

Hull Structure Standards

The FORAN Hull Structure standards library is comprised of materials catalogs (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.

Hull and Deck Structures

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. 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.

I/O Signals

To define I/O signals and each proper signal value, such as the type of signal (analog, digital or serial line), the I/O card type, the range of measurements, alarm data, etc., we need to assign a processing station and an instrument (field element) to the signal. In addition, we must choose the corresponding cable wires used for each signal to propagate. Several kinds of I/O lists can be extracted.

Integration Architecture

Based on a neutral framework, using standards like web services, XML and CORBA,  developed to be as independent as possible. Allows bidirectional communication between the two systems: publishing (transferring data from FORAN to PLM) and synchronization (transferring data from PLM to FORAN).

• Register all items and parts created in PLM and incorporate into the FORAN project and then published in the PLM.
• Control the publishing and synchronization processes.
• Mark items as locked to prevent modifications.

Integration Scope

The PLM is the single source for generating item identifications.

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 and supports, electrical diagrams, cables, and cable trays, penetrations, and welds.

JT Open is used for the 3D model perspective.

Internal Structure

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.

Kinematics

Set mechanical restrictions between solids based on their surfaces. Those restrictions would result in relative movements, according to the final degrees of freedom, such as 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.

Machinery & Outfitting Layouts

Outfitting and machinery layouts can be defined, allowing ship configuration in the early stages of the project. This application follows the 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.

Mechanical CAD Toolset

Generate and manipulate solids through a variety of methods. Once solids, the objects may be subject to 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. The graphic snap options enable dynamic links between entities, so further modifications are transmitted to the positions and orientations of the linked entities.

Naval Architecture

Conduct calculations, such as the watertight characteristics, appendages, draught marks, openings, lightship weight, wave and wind profiles, sounding lines, and modular cargo.

Calculate 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. Users can define their own criteria.

Also calculate flooding conditions and damage stability according to the deterministic and probabilistic methods, taking into account the intact stability conditions, and associating the spaces to the geometric subdivision defined.

Nesting

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.

Outfitting 3D Model

Work with equipment, piping, ventilation, cable trays (space reservation), auxiliary structures, and line supports. Data integrity prevents multiple accesses to objects.

Piping and HVAC ducts can be routed interactively or using user predefined solutions. Design any type of foundation, ladder, grating, and handrail, plus pipe, duct, and cable tray supports.

• Handle a large number of objects in the scene.
• Smart tools for the distributor generation.
• Automatic and interactive access to P&ID data from a 3D model.

Outfitting P&ID

Define pipe and instrumentation diagrams as part of the ship design, stored in the same database as the 3D model. A 2D environment contains the necessary 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, guaranteeing correspondence between the diagrams and the product, therefore facilitating the task of creating the as-built diagrams.

Outfitting Production

Outfitting production documents are highly automated, especially the pipe spool isometric sketches for fabrication and mounting. Both drawing types allow symbols, labels, dimensions, boxes, and paper formats, and are automatic. The fabrication drawings can export data to CNC files.

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.

Outfitting Standards

The Outfitting Standards Library includes technological attributes and built-in geometries so that pipes, fittings, and equipment are recreated from vendor catalogs. The pipes and fittings are organized in specifications and contain the complete list of attributes such as material, nominal and secondary diameters, schedule, and nominal pressure connection types. Define any 3D model for equipment and fittings by means of geometric macros.

Assign electric properties to equipment and fittings for full-electric calculation and wiring.

P&I Diagrams

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 online edition of properties to elements.
• Automatic generation of parts lists.
• Management of multi-sheet diagrams.

Penetrations Management

Pipe and HVAC fitters can 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. At the same time, they undergo a strict workflow from the Outfitting (and Electrical) Department to the Structure Department. The penetrations pieces have their own representation and can be included in the drawings and exported to BOMs.

Security Markings

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 a synchronization mechanism for the equipment items and library models.

Sheet Metal

Powerful handling of sheet-metal objects, typically the HVAC ducts and bespoke cabinets or lockers. In this case, the application can design and unbend all the parts for manufacturing. Even unbent sheets may be transferred later into the FORAN database for complete handling, including automatic nesting.

Structure Fabrication & Assembly

FORAN provides a complete set of tools for creating all necessary documents for fabrication and assembly.

• 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.

Structure for Basic Design

Surface model 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

Surface Generation

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. Key features:

• 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.

Virtual reality and design review in FORAN

Navigate the 3D model or use design tree information for object selection and information on model and annotations. Operate with groups of selected items, using clipping planes and advanced searching tools. Import 3D models in JT Open format and generate videos in 4K resolution.

• System and user-defined attributes
• Measurements
• Addition of notes
• Assembly simulation
• Collision detection
• Path editor to check removal and escape routes and design inconsistencies
• 3D stereo projection
• Auto install stand-alone application

Weight & 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.

Welding Traceability

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.