“Fulfilling the requirements of demanding customers is only possible when maximum operating efficiency is achieved and maintained in engineering and design.” This is the recipe for success provided by Štěpán Šmida, Machine Design Department Manager at H&D Engineering (H&D) in the Czech Republic.
As with any recipe,
good tools are required to implement well-crafted plans. For this purpose,
H&D implemented CADMATIC in 2011. Štěpán highlights CADMATIC’s
interoperability and design precision as key value-adding features.
H&D’s reference list of demanding plant design projects in the power sector is indeed impressive: it includes, among others, the recent recirculation of flue gas at the Otrokovice heating plant in the South Eastern region of Moravia.
“It is crucial for us to operate at maximum operating efficiency and with the help of CADMATIC Plant Design we can do this. One concrete example is how it eases communication with our clients. Most of the time we need to be in constant communication with our clients throughout our projects and prepare a lot of ‘preliminary’ documentation based on actual 3D models. The 3D model can be shared easily and quickly with the eBrowser viewer. It also allows us to bring the model to the construction site to communicate efficiently with assembly staff or suppliers,” explains Štěpán.
CADMATIC’s interoperability with other software vendors’ products and technologies is another factor highlighted by Štěpán. According to him H&D’s heating plant project in Otrokovice, Czech Republic is a good example of how this feature boosts efficiency.
The Otrokovice heating plant project in 2015 involved the modernization of two boiler units (K3 and K4) in an existing hall. The entire boiler had to be laser scanned, after which the 3D model was uploaded to CADMATIC to be used as the base for detailed design, space reservation and clash checking.
The recirculation of flue gas at the plant focused on emission reduction and improvement of the coal mill system security. The feasibility of the heating plant was studied and mathematical models were developed to compare the heating plant’s various operations. The modification of the existing brown coal burning boilers was also studied for multi-fuel boilers in order to add coal and biomass to the base fuel.
“This was a very specific project as we wanted to see how CADMATIC would interface with models from other software packages and how the data management would work. Sometimes we do not have time to design complete pieces of equipment like turbines. In such cases we use laser scanning to produce a large 3D model of the existing boiler. On the Otrokovice project, this model was created in AutoCAD® and imported into CADMATIC without any problems regarding data integrity. Our steel engineers then designed the recirculation pipes’ support steel structures, which was also imported into CADMATIC via AutoCAD®, again without any issues,” Štěpán describes the smooth software interfacing.
The next step in the
successful Otrokovice project is already underway. In September 2016 H&D
started the design of new gas boiler in another existing hall near units K3 and
K4. By the end of 2016 the feasibility study of the project had been completed
with documentation for authorities, basic design and most likely detail design
set to follow in 2017.
The Planá nad Lužnicí heating plant project, completed in 2013–2014 illustrates how H&D has smoothly interfaced CADMATIC with Tekla® Structures.
The power plant project was partly a greenfield project and partly a modernization/retrofit of an existing power block. It involved the installation of Rolls Royce cogeneration units with gas engines of 4 x 9175 kW electrical output and HRSG of 4 x 2850 kWth steam and 4 x 4780 kWth hot water. H&D was responsible for the design of the gas pipelines, renovation of the heat distribution system, renovation of existing steam pipelines and reducing and cooling stations, external pipeline systems for boilers, and coal handling. H&D was also responsible for all the civil engineering for the project. In total, the project included more than 185 tons of pipes and more than 200 tons of steel structures.
Tekla® software was used for most of the steel structure design and CADMATIC was used for plant and piping design. Fluent information sharing was ensured by combining the Tekla® structural steel model with the CADMATIC plant design model.
“Our steel structures design department did all the civil engineering for the project in Tekla®. There were some space limitations in the existing machine hall for new pipelines. After doing 3D modelling of the main pipelines in CADMATIC, we conducted pipe stress calculations and shared the results with our steel designers, after which they completed the design of the steel structures accordingly. The interface between CADMATIC and Tekla models meant that all our design departments could identify and solve clashes both in CADMATIC and Tekla.”
Design precision is something that sets H&D apart from the rest. H&D regularly achieves very low percentages of non-conformance reports (NCR) on its projects compared to other companies. How do they do that?
“CADMATIC allows quick, easy and above all precise design. It helps us to reduce the time required for creating final documentation to a minimum. We can easily make layout changes and the management of KKS coding implementation in the documentation and model is straightforward. If the pipe specification feature is used correctly, it cuts out errors completely. Also we have no difficulties with using slopes on big pipes and large distances,” Štěpán concludes.