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Bentley > Case Studies > 3D Design and Modeling Streamlines Electrical Grid: A Case Study on PG&E Brownfield Substations
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3D Design and Modeling Streamlines Electrical Grid: A Case Study on PG&E Brownfield Substations

Technology Category
  • Sensors - Electrical Conductivity Sensors
  • Sensors - Utility Meters
Applicable Industries
  • Electrical Grids
  • Utilities
Applicable Functions
  • Maintenance
  • Product Research & Development
Use Cases
  • Microgrid
  • Virtual Prototyping & Product Testing
Services
  • System Integration
The Challenge
The San Francisco-based Pacific Gas & Electric Company (PG&E) owns and operates over 1,000 transmission and distribution substations across two-thirds of California. The Substation Engineering Department was struggling to keep up with the volume of projects due to the push to modernize the electric grid. About 95% of the utility’s USD 1 billion substation budget goes to brownfield locations, where existing infrastructure is primarily documented by 2D drawings. The practice of manually converting 2D drawings to 3D models for use on retrofit projects was time-consuming and inaccurate. The laborious process started with the engineers taking the existing 2D drawings of the facilities and filling in information gaps with field measurements. After about 120 hours of manual effort, the resulting models were frequently inaccurate due to errors in the legacy documentation and because the engineers were unable to go on-site to measure energized equipment.
About The Customer
Incorporated in 1905, PG&E is now one of the largest combined natural gas and electric energy companies in the United States. The investor-owned electric utility provides energy services to approximately 16 million people throughout a 70,000-square-mile service area in northern and central California. As a subsidiary of PG&E Corporation, PG&E is part of California’s massive electricity generation system, which produces more than 296,000 gigawatt hours each year. The utility has experienced near constant growth in demand for energy recently. In the past 50 years, the number of California households has nearly doubled from 6.5 million in 1970 to 12.5 million today. While the number of consumers has grown, the way consumers use energy and electronics has dramatically changed. Keeping pace with these changing demand patterns has posed significant challenges for utilities across the country.
The Solution
PG&E replaced the time-consuming process of manually converting 2D drawings to 3D models with reality modeling using Bentley’s ContextCapture, which shortened model production time by one-third. The software incorporates advanced image capture and processing technology to create engineering-ready reality meshes from high-resolution photography and laser-scan point clouds. By modeling existing conditions, ContextCapture provides context for new design, construction, and operations. To capture the imagery of its brownfield substations, PG&E deploys a combination of photographic techniques using unmanned aerial vehicles, man lifts, and on-ground equipment. ContextCapture automatically identifies the relative position and orientation of each photo, reconstructs the images in 3D, and maps the appropriate textures. The software produces a reality mesh that is then referenced into Bentley Substation. ContextCapture produces an intelligent 3D reality mesh, which is referenced into Bentley Substation where engineers can complete the entire substation retrofit design that unites electrical and physical design.
Operational Impact
  • Beyond the time and cost savings, reality meshes have proven to be powerful for visualizing projects and communicating with stakeholders. PG&E works collaboratively with surrounding communities to ensure that its facilities are safe, secure, environmentally responsible, and compatible with current and future development in the area. Up-to-date reality meshes allow stakeholders to clearly see the impact of projects. These real-time updates help avoid costly conflicts and changes in the field, as well as support long-term, sustainable planning. In compliance matters, reality meshes provide realistic renderings of planned upgrades for existing substations and other facilities. Illustrating the visual impact of a new security wall, for example, helps gain community acceptance of features required by the Federal Energy Regulatory Commission. PG&E has found creative ways to maximize the value of Bentley’s reality modeling software.
Quantitative Benefit
  • Automatically generating a 3D model with ContextCapture takes 80 less resource hours than manually converting 2D drawings into 3D models.
  • Bentley Substation reduced the cost of recreating existing substation equipment in 3D by 50 percent.
  • Using reality modeling with ContextCapture instead of manually converting 2D drawings, PG&E expects to reduce 3D modeling costs by 50 percent.

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