Since its foundation in 1990, Kraftszer Ltd has become a well-known participant in the Hungarian industrial and power engineering market. Kraftszer is part of German GAH, a member of the Alpiq-group (formerly Atel-group). The company’s expertise areas cover power plants, industrial energy services and engineering. Since 2009 the company has successfully been using CADMATIC software for the implementation of demanding design projects.
At the end of 2009 Kraftszer implemented CADMATIC Plant Design Software for the piping design of the BOP (Balance of Plant) systems of a gas turbine combined cycle installation in Hungary at the Dunamenti power plant. The extensive and complex piping work required for the project necessitated the selection of software that could generate the isometric drawings with several modifications.
The CADMATIC solution was selected by Kraftszer based on its pipe design capabilities and the possibility to import elements from other 3D software packages. The openness of the software was crucial since the client used Microstation-based 3D software and supplied DGN files for the steel structure and vendors’ equipment. The design environment model was also distributed with AutoCAD DWG files.
After gaining experience in using CADMATIC in 2009 on the BOP project, Kraftszer used the software for a demanding new biomass fired steam boiler installation at the Dalkia-owned Pécs power plant in Hungary. The design project was started in the autumn of 2010.
The boiler is a straw fired, 4-pass water tube boiler – installed in an existing boiler room in place of previously demolished coal boilers. The new biomass boiler produces max. 146 t/h steam at 100 bar and a superheating temperature of 540°C. The boiler’s overall dimensions are rather impressive: the width is 16,5 m, the length 25 m, the height 30 m and the gross weight is 1500 tons. A twin-nave bale storage hall has been built next to the boiler house.
The design comprises the installation of the boiler body, steam piping, feed water supply, combustion air ducting with pre-heater, exhaust gas ducting with exhaust gas filters and ventilation, automatic straw bale handling from the storage hall to the boiler, slag handling system and other auxiliary systems such as compressed air and fire fighting piping systems etc. The amount of separate systems is 22 in all.
Due to a lack of design resources Kraftszer distributed the steam boiler project environment from the very start of the project.
“This type of work was unfamiliar to us, but we recognized its effectiveness very quickly. Now we can cooperate with different companies that are using CADMATIC, both in Hungary and abroad. This enables us to manage the available resources in design work and in project administration”,
explains Kraftszer’s Design Department Head, Mr István Tömösközi.
CADMATIC software was used from the beginning of the project to prepare the basic P&I drawings with the Diagram module, where it provided a direct connection between the P&I and the 3D model.
“This connection facilitated the consistent pipe and valve coding in P&I drawings and 3D model. Code repetition suppression was another important matter provided by the diagram module. By using the P&I module we were able to generate several lists (e.g. equipment, valves, instruments) from the database. In some cases it needed SQL database handling”
, Mr Tömösközi continues.
CADMATIC was used for the construction design phase of the project as well. The boiler body was imported from the boiler manufacturer’s 3D model. The existing boiler house was laser-scanned and the point cloud was used to generate a 3D AutoCAD model. This AutoCAD DWG file was imported into CADMATIC and used for design and collision checks. The other equipment, steel structures, pipes, valves, fittings, ducts, pipe supports, and cable trays were modelled entirely with CADMATIC.
“During the construction design many arrangement and section drawings, nearly a thousand isometric drawings and hundreds of pipe support drawings were generated from the 3D model. The drawings were created almost fully automatically, only the annotations were positioned manually”
, Mr Tömösközi concludes.
The above-mentioned documentation was created by eight engineers with the support of four foreign engineers working in different towns and countries.