Consol Energy and Farnham & Pfile use product lifecycle management solution to develop ultra-efficient energy-producing facilities

Belle Vernon, Pa., and Paris, October 24, 2002 — IBM and Dassault Systemes announced that CONSOL Energy Inc. and Farnham & Pfile Construction, Inc. chose an IBM Product Lifecycle Management Solution to develop and maintain a computer-controlled coal-processing plant that ranks among the world’s most efficient energy facilities.

The solution is based on Dassault Systemes’ 3D PLM CATIA and ENOVIA virtual product design and product data management applications.

CONSOL Energy, a producer of coal and coalbed methane, and its contractor, Farnham, & Pfile, selected IBM and Dassault Systemes to enhance the coal processing plant built in Mondsville, West Virginia. The new plant, in operation since August, is capable of processing up to thirteen million tons of coal a year, operating twenty-four hours a day, seven days a week.

CONSOL Energy and Farnham & Pfile selected CATIA for its powerful product development capabilities (design, analysis, and manufacturing), and ENOVIA for its extensive product data management and global lifecycle collaboration features.

Using CATIA and ENOVIA, the two companies were able to consult each other and make design modifications in real time during the 16-month construction period.

“CATIA V5 gave us a big advantage over our competition through cost savings and process improvement,” said Tom Porterfield, vice president of operations at Farnham & Pfile.

“For the new plant, we were able to provide our ceramic pipe suppliers with detailed drawings that ensured less liability and fewer potential errors. As a result, supplier costs were reduced by 30 percent and we passed on those savings. With $5 million worth of piping in a plant, that adds up to substantial savings.”

“Plant owners and operators constantly strive to maximize productivity while minimizing maintenance costs and related downtime,” explained Dan Yanchak, general manager of preparation services for CONSOL Energy. “At the outset of this project, we realized that CATIA V5 would be valuable and integral to the ongoing operation of the plant. With CATIA’s digital mock-up and reviewing tools, data is digitally available and current and, thanks to ENOVIA, always available online.”

In the design and construction phases of the new facility, the process flow sheet, piping, equipment and all processing were performed with CATIA. This included development of the plant’s intelligent piping library, a unique application that dramatically reduced costs and ensured that designs were initially accurate. For maintenance, ENOVIA enables engineers to review and extract real time plant data, including the history of each equipment unit and its role in the facility, such as the number of hours a pump has been running and connecting piping and equipment.

“We plan to integrate ENOVIA V5 with our SAP system for tight integration with business processes – an initiative that will keep CONSOL Energy at the forefront of the energy industry,” Yanchak said.

“IBM has long been committed to providing energy companies with the solutions to provide sustainable competitive advantages,” said David Samuel, general manager,
IBM Energy and Utilities Industry.

“By facilitating integration, collaboration, knowledge management and asset lifecycle management throughout the energy supply chain, IBM technology and that of our longtime partner, Farnham & Pfile, play a major role in the development of what will be one of the world’s most modern and efficient coal processing facilities.”

“CONSOL Energy and Farnham and Pfile have proven that the same benefits of using CATIA and ENOVIA in the aerospace, automotive, and shipbuilding domains can be extended to the plant domain and its business improvements,” said Philippe Forestier, Executive Vice President Sales and Marketing, Dassault Systemes. “We believe owner-operator-driven 3D PLM is the future of the plant domain and are proud to be part of a project that will turn this potential into reality.”

About CONSOL Energy Inc.

CONSOL Energy Inc. is a producer of high-Btu bituminous coal and an exporter of U.S. coal. CONSOL Energy has 24 bituminous coal mining complexes in seven states, two Canadian provinces and Australia.

In addition, the company is a producer of coalbed methane, with daily gas production of approximately 130 million cubic feet.

The company also produces electricity from coalbed methane at a joint-venture generating facility in Virginia. CONSOL Energy has annual revenues of $2.3 billion. Additional information about the company can be found at its web site:

About Farnham and Pfile

Farnham & Pfile Construction, Inc. was founded in 1985 under the laws of the Commonwealth of Pennsylvania by Douglas B. Farnham, John V. Pfile and Robert F. McMahon. Since its founding, Farnham & Pfile Construction, Inc. has grown from an industrial construction company to an engineering and contracting company with total turnkey capability that includes engineering, procurement and erection services. The firm carries the credit and financial ratings and bonding necessary for turnkey projects.
Information about Farnham and Pfile is available at

About IBM

IBM is an information technology company, with 80 years of experience. IBM Sales & Distribution, which supports more than a dozen key industries worldwide, works with companies of all sizes around the world to deploy the full range of IBM technologies.

The fastest way to get more information about IBM is through the IBM home page at

About Dassault Systemes

Dassault Systemes is a global software developer for the CAD/CAM/CAE/PLM market, providing companies with e-business solutions to implement their digital enterprise, thus creating and simulating the entire product life cycle from initial concept to product in service.

Information about Dassault Systemes is available at

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