Product Engineering / Fossil Boilers

Design Automation
 Layouts
Structures
Buckstays
Ducts
Fuel systems
Pressure Parts
Salient Features of 3D model based Boiler engineering using PDMS

 Best tool to arrive at optimum Layout.

 Multi-user environment enabling concurrent Engineering / cycle
time reduction / total engineering automation.
 Clash detection & head room clearance identification facilities to
avoid site complaints.
 Catalogue driven components enabling user to select based on
the rationalized list of components.
 Single point solution covering P & ID, structural, ducting, piping,
hangers & supports, equipments and drafting modules enabling
2D drawing extraction from the model.
 The 3D models of structural, ducting and piping created in PDMS
can be exported to the analysis/ detailing software(yet to be
explored).
 3D BASED BOILER ENGINEERING-PIPAVAV 600MW
Phase I - GA DRAWING

INITIAL GA IN 2D COLUMN, DUCTS & AMALGAMATION REVIEW PRELIMINARY 3D FINAL 3D

FOR IMPORTANT BRACING LOCATION OF LO & PPA MODEL MODEL
DECISIONS IN PDMS

INITIAL PPA IN 2D PPA-3D CONVERSION

FOR IMPORTANT AutoCAD TO PDMS
DECISIONS MODEL GA DRAWINGS
IN 2D

FUEL FIRING
CLASH CHECK UPDATION (PIPE ROUTING)

COMPLETED
BOILER
CLASH CHECK UPDATION MOUNTING
(PIPE ROUTING)
PROGRESS

DUCTING
CLASH CHECK UPDATION (SUPPORTS)
YET TO BE
STARTED

SUPPORTING
CLASH CHECK UPDATION STRUCTURES
(SIZING) Pilot
Project in
2010-11
SNAPSHOTS TAKEN FROM THE PIPAVAV MODEL
 EXTRACTED DRAWING
SIDE ELEVATION

SIDE VIEW OF MODEL

 EXTRACTED VIEW
FRONT VIEW OF MODEL
FRONT ELEVATION
 EXTRACTED DRAWING
PLAN VIEW OF MODEL
PLAN VIEW
Deliverables from the model

-Complete set of Layout drawings ( 40 Nos. / Contract) are

planned to be extracted from the model.

-If seamless transfer of model between PDMS & the analysis/

detailing software s are established then

 Structural model can be used for analysis / detailing .

Ducting models can be used for analysis / detailing.
Entire piping model can be used for analysis / detailing.

-Non conformities like – SAR/ CAR / Head room clearances can be

indentified at the design stage itself enabling error free drawings.

-Interface activities can be done through model easily rather than

the conventional method.

-Walk thro animation.

STRUCTURES & BUCKSTAY AUTOMATION

MODULE-WISE
DRUM LIFTING STRUCTURE
COLUMNS
HORIZONTAL BEAMS
VERTICAL BRACING
MBL FLOOR
NON-MBL FLOOR
CEILING STRUCTURE
BOILER ROOF STRUCTURE
POST & HANGERS
STAIRS
ROOF BRACING
FURNACE GUIDES
FAN HANDLING STRUCTURE
AUTOCAD TO STAAD-3DEngine
STAAD TO STRUCAD (interface programs)
BUCKSTAY AUTOMATION
Detailing Of Boiler Main Columns
Base Plate Detailing

Gusset Plate
PLUS I Column

Bolts

Stiffener
Washer
plate Grout
Holes

Stool
Base
plate
Plate

Shear Lug
weld
Detailing Of Boiler Auxiliary Columns
Base Plate Detailing
Box column

Stiffener
Washer plate
plate

Base plate

Stool plate Shear lug

Boiler Column Fabrication Drawing

StruCad generated drwg in spf format

MBL Beams Bolted Connection – 500 MW
Rolled I / Built-up I Beam to PLUS or Box Column

Column

Weld on Rect. Plate

column side

Bolts on
beam side

Built-up I with
greater loads

Seating plate
Vertical Bracing Bolted Connection 500MW
Vertical bracing connected to Beam
Gusset
plate
stiffeners

Bridge
plate

Vertical
bracings

Beam
Vertical Bracing Bolted Connection 500MW
Vertical bracing connected to Base Plate

column
Bracing

Gusset
plate
Ear plate

Extended
flange
GA DRAWING
Customization of Floor Arrangement
Detailing of Floor Beam connections
FLOOR GENERAL
ARRANGEMENT
Customization of Roof Structure
BARH Ceiling Arrangement
Ceiling Connections
 Interface Program to transfer floor arrangement information
from AUTOCAD to STAAD

Floor Transmittal in Autocad

Staad analysis output
with LOAD
 Interface Program to import 3D Model from
Staad – Pro to Strucad
STAAD INPUTMODEL STRUCAD OUTPUT MODEL
 Du Despatch Monitoring System

Du Despatch Monitoring System is developed for the purpose of monitoring the

actual status of DU's pertaining to Boiler supporting structures
 BUCKSTAY AUTOMATION

1. INPUT 2. AFTER COMPLETION OF INPUT

OUT PUT:

2. PRODUCTION DRG.
1. ERECTION DRG.
 Automation in Ducting

I. Module wise automation

*Straight duct
*Elbow duct
*Transition duct

II. Automation of Wind box connecting duct through 3D parametric solid modeling in
Unigraphics NX 5 (210/250/270MW).

III. Online duct erection manual in dynamic 3D pdf format.

IV. Automation of Aerofoil duct (both single & split design).

 2D MODULE WISE AUTOMATION OF STRAIGHT DUCT

Features:

1. Developed in VBA-Autocad.
2. All drawings are true-scale drawing.
3. Generate Straight duct detailed drawing for 60MW-800MW
Boilers.
4. Automatic selection of stiffener spacing & sizing for all four walls.
5. Automatic selection of internal truss pattern based on duct size.
6. Includes all variations like opening, corner construction, end connection
detailed, splicing.
7. Cycle time reduction.

Deliverables:

 All deliverable drawings are to-scale drawing

 Detailed drawing of Straight duct which covers bill of materials
table, flange details table, despatch table, cutting plate details
& excel file for SAP uploading.
 Generates error free drawings.
 2D MODULE WISE AUTOMATION OF ELBOW DUCT

Features:

1. Developed in VBA-Autocad.
2. All drawings are true-scale drawing.
3. Generate Elbow duct detailed drawing for 60MW-800MW
Boilers.
4. Automatic selection of stiffener spacing & sizing for all walls.
5. Automatic selection of internal truss pattern based on duct size.
6. Includes all variations like opening, corner construction, end connection
detailed, splicing.
7. Cycle time reduction.

Deliverables:

 All deliverable drawings are to-scale drawing

 Detailed drawing of Elbow duct which covers bill of materials
table, flange details table, despatch table, cutting plate details
& excel file for SAP uploading.
 Generates error free drawings.
 2D MODULE WISE AUTOMATION OF TRANSITION DUCT

Features:

1. Developed in VBA-Autocad.
2. All drawings are true-scale drawing.
3. Generate Transition duct detailed drawing for 60MW-270MW
Boilers.
4. Automatic selection of stiffener spacing & sizing for all walls.
5. Includes all variations like corner construction, end connection detailed,
splicing.
7. Cycle time reduction.

Deliverables:

 All deliverable drawings are to-scale drawing

 Detailed drawing of Transition duct which covers bill of materials
table, flange details table, despatch table, cutting plate
details & excel file for SAP uploading.
 Generates error free drawings.
 WIND BOX CONNECTING DUCT AUTOMATION in UG NX (3D solid modeling package)
(210/250/270MW)

Features:
1.Design rules & programming in Knowledge Fusion(KF).

2.Creation of parts, sub-assemblies, main-assembly and controlling them

using NX parametric expressions.

3.Introduction of Conditional Suppression concept in assembly.

4.Usage of array concept in case of stiffeners in assembly.

Deliverables:

*Isometric view of the 3D model

* Detailed drawing of WBCD
* Erection drawing of WBCD
* Omega and U-type expn. Jts. Drg.

* BOM and DU table.

 Online duct erection manual in dynamic 3D pdf format

Features of online duct erection manual in dynamic 3D format:

* Basically a pdf file containing 2D erection welding detail drawings with isometric 3D view of welding details.
* Hyper-links to dynamic 3D models of the respective erection drawings.
*3D dynamic PDF files of the parts that are to be welded on site can be rotated, zoomed in/out and cut to view the
minute details.
*System requirements : Acrobat reader 8 or above. Memory needed -25MB
* Hosted in our QUEST website

Sample 3D dynamic pdf model of the hyper-linked reference which

Sample Indexed page of duct erection welding details with
can be rotated, zoomed in/out and section view can be created.
hyper-link to dynamic 3D model (Flange connection with
(Flange connection with non-metallic expansion joints)
non-metallic expansion joints)
Automation of Aerofoil (Both single & split design)
Features:
•Both single & split design
•Program will decide the single or split option
based on duct dimensions
•Cycle time reduction 30 man days to 3 man days
•Error free design
•Deliverables- 2D drawing, GMS for SAP

Split options:

Horizontal Vertical Multi-

Split. Split. Split.
Design Automation in Fuel Systems
• Automation in System Design
– Generation of P&IDs and valve schedule for Fuel oil
system
– General Arrangement of Raw coal Bunker to Mill
– Loading Plan of pulverized coal piping

• Automation in Detail Engineering

– All products from Bunker outlet to mill inlet
– Pulverized coal piping system
– Tilting tangential Burner Assembly

Product Engineering (FB)

 Automation of P&IDs - Fuel oil system

• Integrated sizing and pressure drop

calculations
• Guides Fuel oil Atomizer selection
• Estimation of utility requirements
• Any combination of the number of
pumps and heaters is possible
• Takes care of FSSS and C&I requirements
• P&ID’s & valve schedule for all
Megawatt ratings of boilers created
automatically

Product Engineering (FB)

 Automation of Bunker to Mill system
• Input data captured from Technical
Specification, BPP transmittals and Boiler
GA drawings.
• Drawing generation through VBA and
AutoCAD.
• Knowledge based ‘Built-in Logics’ for
checking correctness of user input data
(to eliminate any design errors)
• Total drawings generated = 120 A4
equivalent

Product Engineering (FB)

 Automation of Pulverized Coal piping
 Automated flow balancing of coal
piping
 Generates data & drawings of
straight pipes, pipe bends, ceramic
bends, ceramic orifices, ceramic
pipes from 2D coal piping layout
 Prepares erection sequence of
various piping components for site
 Automated Loading Plan & Detail
engineering of coal pipe supports
 Generates 190 A4 equivalent
drawings

Product Engineering (FB)

 Automation of Tilting Tangential Burner Assembly

 Complete detail engineering package for

tilting tangential burners using VB & AutoCAD
 Handles around 500 components in the detail
engineering process
 Creates around 300 equivalent A4 drawings
with BOM
 Uses standardized 250 equivalent A4
drawings
 SAP compatible BOM
 Open for future up gradation – data centric
approach

Product Engineering (FB)

AUTOMATION & 3D APPROACH FOR PRESSURE PARTS ENGINEERING

SYSTEM DESIGN:

AUTOMATION OF WATER AND STEAM SCHEMES (P&ID)

AUTOMATION OF GENERAL ARRANGEMENT -PPA DRAWING

GENERAL ARRANGEMENT (PPA) DRAWING EXTRACTION FROM 3D MODEL

LIVE DESIGN / MANUFACTURING STATUS (SAP) MONITOR

DETAILED DESIGN:

AUTOMATION OF IBR – CODE CALCULATIONS

AUTOMATION OF DETAILED DRAWING GENERATION (WW PANELS)

AUTOMATION OF DETAILED DRAWING GENERATION (HORIZONTAL COILS)

AUTOMATION OF SPIRAL BURNER PANEL DETAIL DRAWING EXTRACTION

ASSEMBLY DRAWING EXTRACTION (PP HANGERS) FROM 3D MODEL

 Product Automation Plan
Area: Pressure Parts
Applicability
Product/ 660/800
S.No. Remarks
Arrangement Industri- 110/120/1 210/250/ 500/600 MW OTSG
al Boilers 50 MW 270 MW MW
design

#Material specifications,
Fin welded attachments, shape
1 √ √ √ √ #
panels changes of panel to be
altered for OTSG design.

1/2 Coil
#Configuration and Panto
Economiser
2
with Panto
# √ √ NA NA supports to be modified for LEGEND:
Industrial boilers.
type supports
Completed
Fusion welded
3 NA √ √ √ NA _
panels
Yet to be taken
3/4/6 Element #Support design to be
4 NA √ √ √ #
Horizontal coils modified for OTSG design.
P In progress
#Tappings, attachments to
5 Downcomers NA √ √ √ # be incorporated for OTSG
design.
Pilot Project under
6 Headers P P P P P progress (Solid Modeling
Approach)
#New programs to be
7 Radiant roof NA # √ √ #
developed.
#New code to be
Pendant Platen
8 # P P P # developed for
coils
configuration changes.
Pendant RH #New code to be
9 coils for single NA # P P # developed for
stage configuration changes.
 Product Automation Plan
Area: Pressure Parts
Applicability
Product/ 660/800
S.No. Industrial 110/120/1 210/250/2 500/600 Remarks
Arrangement MW OTSG
Boilers 50 MW 70 MW MW
design

Pendant spaced #New code to be developed for

9 # √ P NA #
SH coils configuration changes.

#New code to be developed for

10 Lines & Links # # P √ #
configuration changes.

General #New code to be developed for

11 # # # √ #
arrangement of PP configuration changes.
LEGEND:

Arrangement of Completed
Downcomer, #New code to be developed for
12 # # # √ #
Circulating pump configuration changes.
& Discharge line
Yet to be taken

Pressure parts
expansion #New code to be developed for P In progress
13 # √ √ √ #
movement configuration changes.
diagram

A program has been developed to

input the Autocad 3D model into
PDMS environment & tube
Burner Panel
14 NA NA NA NA P manufacturing drawings have been
automation
extracted in line with practice of
Shangai Boiler Works as given for
Barh Unit I

#New program to be develped for

15 P&ID NA √ √ √ #
OTSG design.
 AUTOMATION OF WATER AND STEAM SCHEMES (P&ID)
FOR 500 /600 MW & 250 / 270 MW
Outputs
 Schemes of Water And Steam, SH & RH steam,
Boiler Water Circulating Pump and Soot
Blower piping system (4 schemes)
 Valve Schedule
 Valve report in xls format to Valves Dept to
book valves and to upload into SAP for
GMS generation

Salient benefits
 Error free Schemes generated
 Generation of KKS coding for both OLD
and NEW system
 Valve schedule generation -No
manual intervention for valves
selection.
 Overall cycle time reduction from
30 days to 4 days
 PPA- General Arrangement Drawing automation

• BCR Drawing for customer submission

• Input for other engineering activities and

to be released at the early stage of
contract

System capacity –500 / 600 MW

All design variants of 500 / 600 MW
Subcritical drum type design including

Single and double stage Re-Heater .

Salient benefits
Engineering cycle time reduction
Error-free Generation of drawings.
Drawing stored in data form – information /
data can be retrieved at any point of time for
further design usage.
 SENEGAL 125 MW
• Modeling of pressure part components (Headers, Links and Tubes)
• Extraction of 2D drawing from 3D model
• Completed in a short span of 42 days
Design / Manufacturing
Status review

Live data from SAP

Pictorial Representation
 Automation of IBR Calculations

Single Window for all products covered

• Shells, Headers and Drums
•Pipes
•Tubes
•End Covers

Output Generated for SHELLS Output Generated for TUBES

Excel Output – fit enough for submission; Calculations are locked for editing
 Automation of Water Wall Panels for Utility Boilers
Input Form

Generated Panel drawing

Data Flow Diagram

Design Automation of Horizontal Coils
Design Automation of Horizontal Coils
Output – Assy Drawing Output – BOM in Excel

Output – Circuit Drawing

Output – Text File for Welding Data.

Burner Panel – PDMS Model
Drawing generated through in-house applications
3D Model as received from ALSTOM for BARH- II Pressure Parts Hangers
2D Assembly drawing extracted and annotated in AutoCAD
(Header and Pipe supports – Super critical design)