Smart 3D (SP3D) Plant Design
What Is Smart 3D (SP3D)?
Smart 3D is Hexagon’s flagship plant design platform, used on some of the largest oil and gas, petrochemical, LNG, and power generation projects in the world. The software enables multiple engineering disciplines to work concurrently on a shared 3D model, with each component carrying not just geometry but also engineering data: material grade, pipe schedule, design conditions, insulation requirements, and procurement status.
The product has gone through several name changes over the years, which causes some confusion in the industry. Here is the lineage:
| Period | Product Name | Owner |
|---|---|---|
| 1980s-1990s | PDS (Plant Design System) | Intergraph |
| Early 2000s | SmartPlant 3D (SP3D) | Intergraph |
| 2010-2016 | Smart 3D | Intergraph (acquired by Hexagon) |
| 2016-present | Smart 3D (part of Hexagon Asset Lifecycle Intelligence) | Hexagon |
Many engineers still call it “SP3D” or even “PDS” out of habit. PDS was a 2D/3D hybrid running on MicroStation; SmartPlant 3D was a complete rewrite built on a relational database architecture. Smart 3D is the current evolution of that same platform. The transition from PDS to SmartPlant 3D was a major shift; the transition from SmartPlant 3D to Smart 3D was more incremental, with improvements to performance, user interface, and integration capabilities.
Who Uses Smart 3D?
Smart 3D is used by many of the world’s largest EPC contractors and owner-operators:
| Company Type | Examples |
|---|---|
| EPC contractors | Bechtel, Fluor, Worley, Samsung Engineering, GS Engineering, Saipem, McDermott, Petrofac |
| Owner-operators | Saudi Aramco, ADNOC, QatarEnergy (via their EPC partners), Shell, ExxonMobil |
| Engineering consultants | WorleyParsons (now Worley), Jacobs, KBR |
The choice between Smart 3D and its main competitor (AVEVA E3D) often comes down to corporate standardization. Some EPCs standardized on Intergraph tools decades ago and have never switched. Others use AVEVA. A few large companies maintain licenses for both and select based on the project owner’s preference.
Architecture: Database-Centric Design
The fundamental architectural decision behind Smart 3D is its reliance on a relational database (Oracle or Microsoft SQL Server) as the single source of truth. Every object in the 3D model, from a 2-inch elbow to a 500-ton reactor vessel, exists as a database record with attributes, relationships, and rules.
This architecture has significant implications:
Multi-User Concurrent Access
Because the model lives in a database, multiple engineers can work on the same model simultaneously. A piping designer in Houston routes a line on Unit 1 while a structural engineer in Mumbai places steel on Unit 2, and an electrical engineer in London runs cable trays through the same area. Each user sees the others’ work in near-real-time (subject to session refresh settings).
This is fundamentally different from file-based CAD systems where each user checks out a file, edits it, and checks it back in. The database approach eliminates the “file locking” problem and enables genuine concurrent multi-discipline engineering.
Data Integrity Through Rules
Smart 3D enforces engineering rules at the database level. If a piping specification says that Class 150 carbon steel flanges cannot be used above 400 deg F, the software will flag a violation when a designer tries to place such a flange in a high-temperature service. These rules are configured during the catalog and specification setup phase (more on that below).
Scalability
A typical grassroots refinery or petrochemical project may contain 500,000+ objects in the 3D model. LNG mega-projects can exceed 2 million objects. Smart 3D’s database architecture handles these volumes, though performance tuning (server hardware, database indexing, session management) becomes critical on very large projects. Hexagon provides deployment guidelines for server sizing based on project scope.
The Downside: Complexity
The database-centric architecture is Smart 3D’s greatest strength and its biggest barrier to entry. Setting up the environment (database servers, reference data, catalogs, specifications, permissions, workflows) requires a dedicated administration team and significant upfront investment. Smaller companies or one-off projects sometimes find this overhead difficult to justify. This is where simpler tools like AutoCAD Plant 3D gain traction.
Multi-Discipline Coverage
Smart 3D is not just a piping tool. It covers the full range of plant design disciplines:
| Discipline | What It Models |
|---|---|
| Piping | Pipe runs, fittings, valves, flanges, gaskets, pipe supports, specialty items |
| Equipment | Vessels, tanks, heat exchangers, pumps, compressors, columns |
| Structural | Steel frameworks, platforms, ladders, handrails, foundations |
| Electrical | Cable trays, conduits, junction boxes, motor control centers |
| Instrumentation | Instruments, control valves, tubing runs, instrument stands |
| HVAC | Ductwork, dampers, fans, air handling units |
Piping is typically the largest discipline by object count, often representing 40-60% of the total model content on a typical oil and gas project. The piping module is also the most mature and feature-rich part of Smart 3D, reflecting decades of development driven by the process industry’s needs.
Piping Catalog and Specification Setup
Before a single pipe can be placed in the model, the piping catalog and specifications must be configured. This is one of the most labor-intensive and underappreciated tasks in a Smart 3D deployment.
What the Catalog Contains
The piping catalog is the master library of all piping components that can be used on the project. Each component record includes geometry data (face-to-face dimensions, bolt circle diameters, flange face types, bore sizes), material data (ASTM/EN material grade, pressure-temperature ratings), references to dimensional standards (ASME B16.9 for buttweld fittings, ASME B16.5 for flanges, ASME B16.11 for socket weld and threaded fittings, EN/BS equivalents), procurement data (commodity codes, short descriptions for MTO), and weight data for structural load calculations.
Hexagon provides a default catalog (called the “Bulkload” or “Reference Data” catalog) that includes most standard components per ASME, EN, and other standards. However, every EPC contractor customizes this catalog to match their company standards, preferred manufacturers, and project-specific requirements. Catalog customization is a specialized skill; many companies have dedicated catalog engineers who do nothing but maintain and update the reference data.
How Piping Classes Are Defined
A piping class (also called a piping specification or “pipe spec”) in Smart 3D defines which catalog components are allowed for a given service. For example, pipe class A1A might specify:
- Carbon steel pipe per ASTM A106 Gr. B, schedule varies by size
- Buttweld fittings per ASTM A234 WPB, matching pipe schedule
- Flanges per ASTM A105 Class 150 RF
- Gaskets: spiral wound per ASME B16.20, SS 316 inner ring, CS outer ring
- Valves: gate, globe, check, ball per the valve specification
- Branch connections: per the branch table (reinforced tees, weldolets, or swaged tees depending on branch ratio)
When a designer routes a pipe in Smart 3D and assigns it to pipe class A1A, the software automatically filters the available components to only those defined in that class. If the designer tries to insert a Class 300 flange into a Class 150 line, the system rejects it. This specification-driven approach is one of the key differences between Smart 3D and less sophisticated 3D tools, and it prevents a huge category of design errors.
Branch Tables
Branch tables define how branch connections are made depending on the header size and branch size ratio. For example:
| Header Size | Branch Size | Connection Type |
|---|---|---|
| 6” and above | Same as header | Buttweld tee |
| 6” and above | One size smaller | Reducing tee |
| 6” and above | Two or more sizes smaller | Weldolet |
| Below 6” | Any branch | Tee (no weldolets on small bore) |
These rules are encoded in the piping specification within Smart 3D, ensuring consistency across all designers working on the project. Without this automation, one designer might use a weldolet where another uses a reducing tee for the same header-branch combination, creating procurement confusion and potential code compliance issues.
The Piping Routing Workflow
Placing Pipe Runs
The piping designer’s daily workflow in Smart 3D follows a predictable pattern. The designer opens the work session and navigates to the area being designed using the 3D view and the hierarchy tree. From there, they create a new pipe run by specifying the line number, piping class, nominal size, insulation requirement, and design conditions, all drawn from the project line list and P&ID.
With the line attributes set, the designer routes the pipe by placing segments along X, Y, and Z axes, clicking to define the start point (typically at an equipment nozzle or tie-in point) and extending the pipe along the desired path with bends at direction changes. Components are inserted along the route as needed: valves, flanges, gaskets, instruments, branch connections, reducers, and specialty items. Smart 3D maintains piping spec compliance as each component is added.
Once the routing is complete, the designer connects to the destination at the target equipment nozzle, another line, or a battery limit. The final step is adding supports at appropriate intervals, following the project’s pipe support spacing criteria (typically per MSS SP-69 guidelines or project-specific tables).
Auto-Routing
Smart 3D has an auto-routing capability that can generate pipe routes between two points based on defined rules (minimum clearances, preferred routing planes, avoidance of obstructions). In practice, auto-routing works well for simple utility lines in uncongested areas but struggles with complex process piping in tight plot spaces. Most experienced designers use auto-routing sparingly and prefer manual routing for critical systems, because the “optimal” route from the software’s perspective may not account for maintenance access, operability, or constructability.
Specification-Driven Component Selection
One of Smart 3D’s strengths is that the software knows the piping specification. When a designer needs to place a valve, the system presents only the valve types and sizes allowed by the assigned piping class. This eliminates the possibility of placing a wrong-material or wrong-rating component, a mistake that in a manual drafting environment might not be caught until procurement or construction.
However, this only works if the piping catalog and specifications are set up correctly. Errors in the reference data propagate to every line that uses that specification. This is why catalog QA is critical and why dedicated catalog engineers are a worthwhile investment on large projects.
MTO Extraction
One of the most valuable outputs of a Smart 3D model is the Material Take-Off (MTO). Because every component in the model is a database record with complete attribute data (size, material, specification, quantity), the MTO can be generated automatically.
How MTO Generation Works
Smart 3D extracts MTOs by querying the database for all piping components in a specified scope (by line number, by area, by unit, or by the entire project). The output includes:
| MTO Field | Source |
|---|---|
| Item description | Catalog short description |
| Size | From the piping run / component attributes |
| Material / ASTM specification | From the piping class |
| Quantity | Count of components in the model |
| Unit of measure | Each (for fittings, valves) or meters/feet (for pipe) |
| Weight | Calculated from catalog data |
| Commodity code | From the piping specification |
MTO Accuracy
The accuracy of the MTO depends entirely on the accuracy of the 3D model. If the model is complete and correct, the MTO is complete and correct. If components are missing from the model (a common issue during the early design phases when routing is still preliminary), the MTO will undercount materials.
In practice, EPC companies apply MTO growth factors during the early phases:
| Design Phase | Model Completeness | Typical MTO Growth Factor |
|---|---|---|
| FEED (30% design) | 30-40% | 20-30% added for unmodeled scope |
| Detailed design (60%) | 60-70% | 10-15% |
| IFC (issued for construction, 90%+) | 90-95% | 3-5% (for field changes, wastage) |
The MTO feeds directly into the procurement process, where it becomes the basis for purchase requisitions and request-for-quotation (RFQ) packages sent to piping material suppliers.
Integration with SmartPlant Materials (SPMat)
Hexagon’s SmartPlant Materials (SPMat) is a materials management system that handles the procurement lifecycle: requisitions, RFQs, purchase orders, vendor tracking, expediting, and material receipt. When integrated with Smart 3D, the workflow becomes a closed loop. The piping designer creates the 3D model using the correct piping specifications, and the MTO is extracted from Smart 3D and loaded into SPMat. From there, SPMat generates material requisitions (MRs) grouped by commodity, material type, or procurement package. The procurement team then issues RFQs, evaluates bids, and places purchase orders within SPMat, which also tracks delivery schedules, expediting status, and material receipt at site. Material allocation (matching received materials to specific line numbers) can be managed within SPMat as well.
This integration closes the loop between engineering (what do we need?) and procurement (where do we get it, and when does it arrive?). On large projects with tens of thousands of line items, this kind of systematic material management is the difference between a well-supplied construction site and one plagued by material shortages and surplus.
Integration with SmartPlant P&ID
SmartPlant P&ID is Hexagon’s intelligent P&ID tool. Unlike a simple CAD drawing, SmartPlant P&ID stores process data (line numbers, equipment tags, instrument tags, pipe classes) in a database. When integrated with Smart 3D, the two tools share data bidirectionally.
Line numbers and attributes defined in the P&ID flow to Smart 3D. When the P&ID engineer creates line 6”-P-1001-A1A-1H (6-inch pipe, line number 1001, piping class A1A, with heat tracing), that line appears in Smart 3D’s line list, and the piping designer can route it with the correct attributes already populated. Consistency checking between the P&ID and the 3D model flags discrepancies, such as a valve shown on the P&ID but missing from the 3D model, or a pipe size mismatch between the two. Equipment data (nozzle counts, nozzle sizes, orientations) can also be shared between P&ID equipment definitions and 3D equipment models.
This integration is a significant advantage of staying within the Hexagon ecosystem. When companies use a mix of vendors’ tools (say, AVEVA P&ID with Hexagon Smart 3D), the integration requires middleware or manual data transfer, which introduces delay and error risk.
Isometric Drawing Extraction via Isogen
Piping isometric drawings are the primary construction deliverable for piping. They show each pipe spool in an isometric view with all dimensions, materials, weld numbers, and bill of materials.
How Isogen Works with Smart 3D
Smart 3D does not generate isometrics internally. Instead, it exports piping data to Isogen, a third-party isometric drawing engine originally developed by Alias (now owned by Hexagon). The workflow:
- The designer or drawing coordinator selects the pipe lines to be extracted.
- Smart 3D exports the piping geometry, components, and attributes in PCF format.
- Isogen reads the PCF file and generates the isometric drawing in the configured format (DXF, DWG, PDF, or raster).
- The isometric includes a BOM (bill of materials), a weld summary, and all dimensional callouts.
Isogen Configuration
Isogen is highly configurable. The output format, drawing border, BOM layout, symbol set, dimension style, and North arrow orientation are all controlled by configuration files (called “option switches” and style files). Every EPC company has its own isometric standard, and configuring Isogen to match that standard is a one-time (but significant) setup effort.
Common project-specific isometric customizations include:
| Customization | Purpose |
|---|---|
| Weld numbering sequence | Match the project welding procedure (sequential per line, per area, or per spool) |
| BOM format | Include or exclude procurement data, weight, painting requirements |
| Dimension units | Millimeters, inches, or dual units |
| Spool break marks | For fabrication shop, indicates where to cut spool assemblies |
| Stress node numbers | If stress analysis requires specific node identification |
| Material descriptions | Long or short form, referencing ASTM/EN specs |
A well-configured Isogen setup can produce construction-ready isometrics directly from the 3D model without manual drafting intervention. This is a major productivity gain compared to the old approach of manually drafting each isometric in AutoCAD.
Clash Detection
Clash detection (also called interference checking) is the process of identifying locations where objects in the 3D model physically occupy the same space. In a plant with thousands of pipes, structural members, cable trays, and equipment, clashes are inevitable during design and must be resolved before construction begins.
Built-In Clash Management
Smart 3D includes a clash detection module that runs interference checks across the entire model or within specified zones. The software classifies results into three categories. Hard clashes occur when two solid objects occupy the same space, such as a pipe passing through a beam or a valve sitting inside a cable tray. Soft clashes, also called clearance violations, occur when two objects are closer than a specified minimum distance; for example, a pipe insulation envelope within 50 mm of a structural member violates the insulation clearance rule. Point clashes occur when two objects touch at a single point, often caused by support-to-pipe contact, which may or may not represent an actual problem.
Clash Resolution Workflow
On a typical project, the clash management workflow follows a structured cycle. The process begins with running clash detection across the model, usually weekly or bi-weekly during active design. Each clash is then classified by severity: critical (must fix before IFC), minor (can resolve in the field), or accepted (not a real clash, just a modeling artifact).
From there, clashes are assigned to the responsible discipline. A pipe-structural clash might go to the piping designer (reroute the pipe) or the structural engineer (move the steel), depending on which is easier to change. The designer modifies the model, and the next clash run confirms the resolution. Any clashes that remain unresolved at IFC must be documented and communicated to the construction team.
On large projects, clash meetings are a regular occurrence. A senior piping engineer, a structural lead, and an electrical lead sit in a room (or a video call) with the 3D model on screen, walking through the clash report and making real-time decisions about who moves what. These meetings are where practical plant design knowledge matters: knowing that a certain pipe must stay at its elevation for process reasons, while a cable tray has more routing flexibility, determines who gives way.
Navisworks and SmartPlant Review
While Smart 3D has built-in clash detection, many EPC companies also use Autodesk Navisworks or Hexagon SmartPlant Review (SPR) for visualization and clash review. These tools can import models from multiple sources (Smart 3D, E3D, structural analysis software, vendor 3D models) and perform clash detection across the combined model. This is particularly useful on projects where different disciplines or subcontractors use different software platforms.
Smart 3D vs AVEVA E3D
AVEVA E3D (formerly AVEVA Everything3D, and before that, AVEVA PDMS) is Smart 3D’s primary competitor. Both tools serve the same market and offer similar capabilities, but their architectural approaches differ.
| Feature | Smart 3D (Hexagon) | AVEVA E3D (AVEVA / Schneider Electric) |
|---|---|---|
| Database backend | Oracle or SQL Server | AVEVA Dabacon (proprietary) |
| Architecture | Client-server with thick client | Client-server; E3D also has a web-based option (E3D Design) |
| Piping routing | Specification-driven, rule-based | Specification-driven, rule-based |
| Catalog management | Integrated catalog (Bulkload), highly customizable | Paragon/Lexicon catalog system |
| Isometric generation | Via Isogen (PCF export) | Via Isogen or AVEVA Isodraft |
| Clash detection | Built-in + SmartPlant Review | Built-in + AVEVA Clash Manager |
| P&ID integration | SmartPlant P&ID (same ecosystem) | AVEVA Diagrams / AVEVA P&ID (same ecosystem) |
| Materials management | SmartPlant Materials (SPMat) | AVEVA Procurement |
| Learning curve | Steep; complex administration | Steep; different paradigm (PDMS heritage) |
| Performance (large models) | Good with proper server tuning | Good; E3D improved over PDMS |
| Market share (global EPC) | ~40-45% | ~40-45% |
| Strongest region | Americas, Middle East, Korea | Europe, Asia-Pacific, China |
Key Differences in Practice
The database model is the most visible architectural difference. Smart 3D’s use of Oracle or SQL Server means that database administration skills (DBA) are needed on the project. AVEVA’s Dabacon database is lighter to administer but less transparent for custom reporting or data extraction.
The user interface paradigm also separates the two platforms. Smart 3D uses a Windows-style interface with ribbon menus and property panels. AVEVA E3D (especially the newer E3D Design) is moving toward a web-based interface. Engineers who learned on PDMS find E3D familiar; those who grew up on PDS/SmartPlant 3D find Smart 3D more natural.
Catalog management is labor-intensive in both tools, but the mechanisms are different. Smart 3D uses “Bulkload” spreadsheets to import catalog data; E3D uses the Paragon/Lexicon framework. Neither is simple, and both require dedicated catalog engineers. Switching from one system to the other involves rebuilding the entire catalog, which is a significant cost.
Ecosystem lock-in is a reality with both vendors, as each designs their tools to work best within their own suite. A full Hexagon deployment (Smart 3D + SmartPlant P&ID + SmartPlant Materials + SmartPlant Review + CAESAR II) provides tight integration. A full AVEVA deployment (E3D + AVEVA Diagrams + AVEVA Procurement + AVEVA NET) provides similar integration. Cross-vendor combinations work but require more effort.
Smart 3D vs AutoCAD Plant 3D
AutoCAD Plant 3D (by Autodesk) occupies a different market segment. It targets smaller projects, smaller companies, and teams that already use AutoCAD as their primary design tool.
| Feature | Smart 3D (Hexagon) | AutoCAD Plant 3D (Autodesk) |
|---|---|---|
| Target market | Large EPC projects (500M+ USD) | Small to mid-size projects |
| Database | Oracle / SQL Server | File-based (DWG + project database) |
| Multi-user support | Concurrent database access | File-based sharing (Vault or BIM 360) |
| Catalog depth | Very deep, highly customizable | Standard catalog, moderate customization |
| Piping spec enforcement | Strict, rule-based | Available but less rigid |
| Isometric generation | Via Isogen (full-featured) | Built-in isometric generation (simpler) |
| Scalability | Millions of objects | Practical limit around 50,000-100,000 objects |
| Licensing cost | High (server infrastructure + per-seat licenses) | Lower (subscription per seat) |
| Administration overhead | High (DBA, catalog engineers, IT support) | Low (standard AutoCAD IT requirements) |
| Learning curve | Steep | Moderate (familiar AutoCAD interface) |
When Plant 3D Makes Sense
AutoCAD Plant 3D is a reasonable choice for small plant projects (single-unit chemical plants, water treatment facilities, small power plants), brownfield modifications where the scope is limited to a few dozen lines, companies without the IT infrastructure to support Smart 3D’s database requirements, and projects where the client does not mandate a specific 3D tool.
For a grassroots refinery or LNG terminal with 50,000+ pipe lines, Plant 3D is not a viable option. The file-based architecture does not scale, the catalog depth is insufficient for complex piping specifications, and the multi-user collaboration tools cannot match a database-driven system.
Smart 3D vs Projectmaterials
Smart 3D and Projectmaterials address different phases of the piping material lifecycle.
Smart 3D is where the piping design is created. The 3D model defines what materials are needed: how many meters of 6-inch A106 Gr. B pipe, how many 90-degree elbows, how many Class 150 RF flanges, and so on. This information is captured in the MTO extracted from the model.
Projectmaterials is where those materials are sourced from the global supply chain. Once the MTO exists, the procurement team needs to find qualified suppliers who can manufacture the pipes, fittings, flanges, and valves to the required specifications, at competitive prices, and within the project schedule.
The handoff works like this:
| Step | Tool | Activity |
|---|---|---|
| 1 | Smart 3D | Engineer designs piping layout per P&ID and process requirements |
| 2 | Smart 3D | MTO is extracted from the 3D model |
| 3 | SPMat or manual | Material requisitions are prepared from the MTO |
| 4 | Projectmaterials / procurement | Suppliers are identified, RFQs are issued, bids are evaluated |
| 5 | Projectmaterials / procurement | Purchase orders are placed; material certificates and inspections are managed |
| 6 | Logistics | Materials are shipped to site per the delivery schedule |
Smart 3D tells you what you need. Projectmaterials helps you get it. They operate in sequence, and both are necessary for a successful project.
Typical Deployment in Major EPCs
Deploying Smart 3D on a large EPC project is a significant undertaking that requires planning, infrastructure, and specialized personnel.
Infrastructure Requirements
| Component | Specification |
|---|---|
| Database server | Oracle or SQL Server on dedicated hardware; 64+ GB RAM, SSD storage |
| Application server | Hosts Smart 3D session services; multiple servers for large projects |
| Client workstations | High-end PCs with dedicated GPU, 32+ GB RAM, SSD |
| Network | Low-latency, high-bandwidth LAN between server and clients; WAN optimization for multi-office projects |
| Backup and disaster recovery | Daily database backups, tested recovery procedures |
Personnel
| Role | Responsibility |
|---|---|
| Database administrator | Manages Oracle/SQL Server, performance tuning, backups |
| Smart 3D administrator | User permissions, session management, model maintenance |
| Catalog/reference data engineer | Piping catalogs, specifications, branch tables, symbol setup |
| Discipline leads | Oversee design quality within each discipline |
| Piping designers | Day-to-day routing, component placement, support design |
| Drawing coordinators | Isometric extraction, plan/section generation, drawing QA |
On a large project (3+ years, 200+ engineering staff), the Smart 3D administration team alone might consist of 5-10 people. This overhead is justified by the productivity gains of having a single, consistent, rule-driven 3D model, but it makes Smart 3D impractical for small projects where the administration cost would exceed the design effort.
Multi-Office Projects
Many EPC projects split engineering across multiple offices (a home office and one or more satellite offices, often in different countries for cost reasons). Smart 3D supports multi-site operation through several mechanisms.
Global Workshare (GWS) replicates database content between offices, allowing each site to work on assigned areas of the model and synchronize changes periodically. Citrix or VDI access lets remote users connect to a central server via virtual desktop, avoiding database replication complexity but requiring good network connectivity. Increasingly, companies host Smart 3D on cloud infrastructure (AWS, Azure) with remote access, reducing the need for physical servers at each office.
Global Workshare is powerful but adds complexity. Merge conflicts (two engineers modifying the same area from different offices) must be resolved, and the synchronization schedule must balance timeliness against network bandwidth. Many projects have learned painful lessons about GWS configuration; getting it right requires experienced Smart 3D administrators.
Learning Curve and Training
Smart 3D has one of the steepest learning curves of any engineering software. This is not a criticism; it reflects the depth and complexity of the problems it solves. A piping designer does not just need to learn the software interface; they need to understand piping specifications, dimensional standards, plant layout principles, and constructability.
Training Path
| Stage | Duration | What You Learn |
|---|---|---|
| Basic software training | 1-2 weeks | Navigation, session management, basic component placement |
| Piping routing | 2-4 weeks | Creating pipe runs, placing components, connecting to equipment |
| Piping design proficiency | 3-6 months | Handling complex routing, understanding spec-driven design, resolving clashes |
| Independent productivity | 6-12 months | Designing full systems without constant supervision |
| Senior designer capability | 2-5 years | Training others, handling non-standard components, optimizing routes for stress, constructability, and maintenance |
Training Resources
Hexagon offers official classroom and virtual courses covering each discipline module, and these are required for new users. Most large EPCs supplement this with company-internal training programs tailored to their own standards and project templates. Beyond formal training, on-the-job learning alongside an experienced designer on a live project is the fastest way to gain practical skills. Software training teaches the buttons; project experience teaches the judgment. The Hexagon user community (formerly Intergraph CADWorx & Analysis Solutions User Group) also holds annual conferences and maintains online forums where designers share solutions and best practices.
Common Frustrations for New Users
New Smart 3D users frequently struggle with catalog issues, especially when they try to place a component that does not exist in the project catalog. The fix is usually to request the catalog engineer to add it, not to work around the system. Session management is another stumbling block: When to save, when to publish (make changes visible to others), and how to manage version conflicts takes time to internalize. Performance in large models can also frustrate newcomers, and learning to use volume clipping, level of detail settings, and filtered views matters for staying productive. Finally, Smart 3D’s error messages can be cryptic, and experienced users gradually develop an internal database of “I know what that message actually means.”
Advanced Topics
Structural Modeling
While piping gets the most attention, Smart 3D’s structural module is heavily used for pipe rack design, equipment platforms, and steel structures. Structural members are placed using standard sections (W-shapes, HSS, channels, angles) from a catalog, and the software generates framing plans, connection details, and material lists.
For piping engineers, the structural model matters because pipe supports sit on structural steel. The pipe support locations defined in the piping model must align with available structural steel. This requires close coordination between the piping and structural disciplines, both in the 3D model and in the clash resolution process.
Equipment Modeling
Equipment in Smart 3D can be modeled at various levels of detail. During early-phase layout studies, simplified shapes (cylinders, cones, boxes) are sufficient for space allocation and routing clearance checks. As the design matures, parametric equipment models built with Smart 3D’s equipment tools capture nozzle placement, saddle supports, and dimensional parameters with greater accuracy. When detailed vendor geometry becomes available, those 3D models can be imported in neutral formats (STEP, IGES, SAT) for precise fit-up verification.
The critical interface for piping engineers is the equipment nozzle. Nozzle locations, sizes, and orientations defined in the equipment model become the connection points for piping routes. Errors in nozzle placement cascade through the entire piping design; getting nozzles right early in the project prevents massive rework later.
Reports and Custom Queries
Because Smart 3D stores everything in a relational database, custom reports can be generated using SQL queries, Crystal Reports, or Hexagon’s built-in reporting tools. Common piping reports include:
| Report | Purpose |
|---|---|
| Line list status | Shows which lines are routed, checked, approved |
| Component count by spec | Supports procurement planning |
| Support location list | Input for structural design and stress analysis |
| Valve list with tag numbers | Coordinates with instrumentation and operations |
| Weld count summary | Input for welding planning and NDE scheduling |
| Insulation summary | Input for insulation subcontractor scope |
These reports automate work that would otherwise require manual data collection from drawings. On a project with 10,000+ pipe lines, manual data collection is not practical; database queries are the only viable approach.
The Future of Smart 3D
Hexagon continues to develop Smart 3D, with recent emphasis on several fronts. Cloud deployment is reducing on-premises infrastructure requirements, making the tool accessible without heavy local server investment. Visualization improvements, including better rendering and virtual reality (VR) walkthroughs, are strengthening design review workflows. Data analytics capabilities are emerging to identify design patterns, predict clashes, and optimize layouts. Perhaps most significantly, digital twin integration is connecting the as-designed 3D model with as-built data and operational data, extending the model’s value across the asset’s full lifecycle.
The core product is mature and stable, which is exactly what EPC companies need. Radical changes in the software would disrupt established workflows and require expensive retraining. Hexagon’s strategy appears to be incremental improvement and ecosystem expansion rather than revolutionary redesign, and that approach aligns with the conservative, risk-averse nature of the oil and gas industry.
Summary
Smart 3D (SP3D) is one of the two dominant 3D plant design systems in the EPC industry, alongside AVEVA E3D. Its database-centric architecture, specification-driven piping design, multi-discipline coverage, and integration with the broader Hexagon ecosystem make it the standard choice for large, complex projects. The software demands significant upfront investment in infrastructure, catalog setup, and training, but it pays back that investment through consistent design quality, automated deliverable generation, and reliable material take-offs.
For piping engineers, Smart 3D is where the design takes physical shape. The pipe classes defined by the material engineers, the line list defined by the process group, the equipment layout defined by the layout team, and the P&ID defined by the process engineers all converge in the 3D model. Getting the piping design right in Smart 3D means fewer clashes in the field, accurate MTOs for procurement, correct isometrics for fabrication, and a solid foundation for the stress analysis that validates the design.
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