Post on 15-Feb-2017
Engineering Capability Presentation
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Overview
• Engineering team• Process Engineering• Piping Engineering• Mechanical Engineering• Project and Systems Engineering• Welding Engineering• General Services
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Engineering Team
Management of projects and the design and construction and servicing of energy and process plant facilities throughout Africa. Expertise encompasses major power utility projects, owner-
operator facilities and construction projects
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Process Engineering
Manager: Juan Gerber Pr.EngEmail: juan.gerber@babcock.co.zaOffice: 011 601 1016Cell: 083 678 8222
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Babcock Process Engineering• Boiler and steam plant thermal engineering
• Boiler thermal design and analysis:• Pre-feasibility and feasibility, FEED, concept, basic and detail
design.• Combustion, boiler, airheater, mills, fans, pumps, valves.• Coal, biomass, waste, liquid fuel, etc.• Pulverised fuel, stoker, bubbling fluid bed, waste heat.
• Boiler performance modelling: Validation/Calibration, sensitivity analysis, Monte Carlo simulation.
• CFD & Flownex• Full boiler 3D CFD to detailed component 3D CFD.• System simulations with Flownex, such as complete CW system
simulation.
• Data analysis• Coal history statistics.• DCS data event identification, statistics and consolidation.• Start-up, shutdown and load change assessment.
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Main presentation titlecan sit on two linesWith a further description underneath
Main presentation titlecan sit on two linesWith a further description underneath
Main presentation titlecan sit on two linesWith a further description underneath
Main presentation titlecan sit on two linesWith a further description underneath
Piping Engineering
Manager: Elbert Cilliers Pr.EngEmail: elbert.cilliers@babcock.co.zaOffice: 011 601 1104Cell: 083 554 2097
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Babcock Piping Engineering• Boiler and steam plant piping design engineering
• 3D Scanning, Piping Layout and Routing• Line sizing (pressure drop calculations)• Valve specifications• Pressure part design to international standards (EN and ASME)• Isometric, layout, general arrangement and detail drawings
• Stress Analysis• Stress and flexibility analysis for code compliance• Incident investigations (Steam/Water Hammer, harmonic, etc…)• Cold pull simulation• Restraint and balance erection analysis• Support sizing
• Maintenance• Construction method statements, rigging studies and simulations• Restraint and balanced erection engineering• Support and elevation surveys• Plant life extension studies
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Babcock Piping Engineering• Project Example for Boiler and steam plant piping design
engineering• Matimba main steam system redesign and replacement
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Babcock Piping Engineering• Project example for Stress Analysis
• GNPower (Philippines) – Main condensate line vibration analysis
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Babcock Piping Engineering• Project Example for Maintenance
• Support and Elevation surveys
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Mechanical Engineering
Managed by: Madoda Ndembe Pr.Tech.EngEmail: Madoda.ndembe@babcock.co.zaOffice: 011 601 1025Cell: 083 206 4456
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Mechanical Engineering• Mechanical Design
• Boiler pressure parts to ASME and BS EN• General Arrangement and detailed fabrication drawings• Refurbishment of boiler plants & pressure vessels
• Hot and Cold Structures• Flues, Buckstays, Boiler casings• Boiler supporting structures, Bins, Ducts, Platforms• Structural & Boiler Inspections• Boiler life study
• FEA• Life prediction regarding creep fatigue life• Design by analysis • Design taking in consideration fatigue and creep.
• 3D Scanning• Accurate capturing plant geometry• 3D Modelling• Construction Simulations• Reverse engineering : Create drawings from 3D scanning
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Mechanical Engineering• Project Examples
Sec Reheater Design by Analysis Sec Reheater Design by code
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Mechanical Engineering
Lethabo Maintenance Ducting
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Mechanical Engineering
Hendrina PF Piping
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Mechanical Engineering
Hendrina Burner Manipulation scan
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Project & Systems Engineering
Manager: Etienne Wannenburg Pr.Tech.EngEmail: etienne.wannenburg@babcock.co.zaOffice: 011 601 1186Cell: 082 210 1331
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Project & Systems Engineering
• Lifecycle of the project• Subsystems and system as a
whole• User requirements and
specification• Planning and management
• Critical components• Risks• Interfaces• Concurrent Engineering
• Design Reviews and Technical Audits
• Engineering contracts
Concept and Feasibility
Basic Design
Detail Design
Fabrication and Supply
Construction and erection
Commissioning and optimisation
Inspections and Testing
Maintenance, repair, overhaul
and asset management
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Welding Engineering
Manager: Uvesh Gajoo IWEEmail: Uvesh.Gajoo@babcock.co.zaOffice: 011 601 1034Cell: 083 318 6693
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Welding
• Welder Qualification and Training• Development and qualification of weld procedures
• Exotic materials• Repair methodologies• Construction methodologies
• Lethabo Steam Penetrations• Matimba Main Steam Replacement
• SAIW support during construction and outage work
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Welding
21CrMoV5-7
X10CrMoVNb9-1
14MoV6-3
1
2
3
4
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Welding
• Welder Qualification and Training• Development and qualification of weld procedures
• Exotic materials• Repair methodologies• Construction methodologies
• Lethabo Steam Penetrations• Matimba Main Steam Replacement
• SAIW support during construction and outage work
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Welding• Research and Development
• Orbital Welding• Big Bore• Small Bore
• Voice activated welding equipment• Rice paper alternatives• Smaller TIG Torches• Specifically designed grinding media for Matla and Lethabo scale removal
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General Services
Service delivery projects include ........
• EPC contracts• Life Extension Studies• Efficiency improvements• Technology and Capacity upgrades• Emission reduction• Control system audits and upgrades• Maintenance repair and overhaul• Boiler inspections• Boiler orientation models