Babcock Ntuthuko Generation_Engineering_Capability

Engineering Capability Presentation

Main presentation titlecan sit on two linesWith a further description underneath

Overview

• Engineering team• Process Engineering• Piping Engineering• Mechanical Engineering• Project and Systems Engineering• Welding Engineering• General Services


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


Process Engineering

Manager: Juan Gerber Pr.EngEmail: [email protected]: 011 601 1016Cell: 083 678 8222


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.


Piping Engineering

Manager: Elbert Cilliers Pr.EngEmail: [email protected]: 011 601 1104Cell: 083 554 2097


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


Babcock Piping Engineering• Project Example for Boiler and steam plant piping design

engineering• Matimba main steam system redesign and replacement


Babcock Piping Engineering• Project example for Stress Analysis

• GNPower (Philippines) – Main condensate line vibration analysis


Babcock Piping Engineering• Project Example for Maintenance

• Support and Elevation surveys


Mechanical Engineering

Managed by: Madoda Ndembe Pr.Tech.EngEmail: [email protected]: 011 601 1025Cell: 083 206 4456


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


Mechanical Engineering• Project Examples

Sec Reheater Design by Analysis Sec Reheater Design by code



Lethabo Maintenance Ducting



Hendrina PF Piping



Hendrina Burner Manipulation scan


Project & Systems Engineering

Manager: Etienne Wannenburg Pr.Tech.EngEmail: [email protected]: 011 601 1186Cell: 082 210 1331


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


Welding Engineering

Manager: Uvesh Gajoo IWEEmail: [email protected]: 011 601 1034Cell: 083 318 6693


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


Welding

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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


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


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

Babcock Ntuthuko Generation_Engineering_Capability

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