BALAI TEKNOLOGI BAHAN BAKAR DAN REKAYASA DISAIN [BTBRD]

ENGINEERING SERVICES

INTRODUCTION

The BTBRD-BPPT is a technical group specializes in advanced plant design activities .The group provides a wide range of engineering services from conceptual design through to fabrication, construction, operation, maintenance and decommissioning, including:• steel structure analysis and

design• steel structure detailing • equipment analysis and design• piping layout • piping stress analysis and design• electrical system design • instrumentation and control

system design • system modularization• plant data management • 2D/3D Computer Aided Design

To accomplish its engineering tasks and deliver best design results, the group implements a comprehensive state-of-the art computer-aided design /engineering (CAD/CAE) applications integrating 2D and 3D CAD design concept called the SmartPlant Design System (SPDS).

PDS enables multi-disciplinary teams work concurrently to build a detailed digital model of the plant directly into the computer system. Integration features in the systemenable engineers from multiple

disciplines to work on a project simultaneously -- improving design coordination reducing errors and increasing productivity.

During the course of the project SPDS creates and maintains accurate Central Design Data Management database that provides valuable information for regulatory compliancestreamlining operations, maintenance and downstream retrofit projects.

Single point data entry ensures that information entered in the early stages of the project remains live through out the project. By eliminating duplicate data entry, accuracy and consistency of the design data is maintained and preserved throughout design iteration process.

All project deliverables such as engineering drawings, bills of materials reports on any aspect of the design are all are quickly and easily created from the 3D model files and the Central Design Data Management database to produce accurate results first time every time any time.

SPDS provides total drawing integrity as the design changes so drawings can be kept up to date automatically. These intelligent documents ensures that data is always up-to-date throughout the plant life cycle from conceptual design to final implementation and construction through startup and testing and operational life span to decommissioning.

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The Smart Plant Design System consists of integrated 2D and 3D design modules which correspond to basic tasks in the plant design workflow including the following:

2D Computer Aided Design

• The Process Flow Diagram (PFD)module provides interactive tools to create intelligent process flow diagram. 7accepts streamdata from third-party process simulation applications and incorporates the data into the project database.

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SMART PLANT DESIGN SYSTEM

Turbine Building StructureWestinghouse AP600

• The Piping & Instrumentation Diagram (P&ID) module provides interactive tools to create intelligent plant schematics.

• The Instrument Data Manager (IDM) module offers integration with upstream (P&ID) and downstream (electrical) tasks. IDM offers advanced functions such as revision control history files object-to-document relationships wiring connectivity and more.

• The Electrical Data Management (EDM) – WireWorks combines electrical schematic design,

panel layout, cable block diagrams and wiring design with data management and design automation tools.

3D Computer Aided Design

• The Piping module provides interactive tools to route pipelines and place components using an extensive online database.

• the Equipment module provides interactive tools to build equipment by assembling basic 3D elements such as cylinders cones and boxes or models from an extensive library of parametrically defined complex equipment shapes. The composite drawings of the equipment can then be automatically produced from the 3D model.

• The Structural module provides interactive tools to model steel framing floors plates and walls and produce engineering drawings and bill of material. From the 3D model input model geometry can be exported into a structural analysis package such as STAAD PRO V8i for stress analysis and to steel detailing software (TEKLA V19) for producing shop fabrication drawings

• The HVAC/Duct module provides interactive tools to lay out ducts and other HVAC components.

• The Electrical Raceway module provides interactive tools to lay out and model of electrical cable trays conduits wireways

underground duct banks and cable trenches.

• The Interference Checkingmodule identifies hard clashes between design components and pinpoints soft clashes such as insufficient safety clearances or maintenance access.

• The Drawing Manager module allows extraction management and annotation of orthographic drawings to be done semi-automatically and later update the model information changes automatically.

• The Design Review Module provides interactive tools dynamically visualize and simulate the 3D CAD models generated from SPDS. Using Design Review's model animation and motion path facilities specific routes can be stored for future playback providing invaluable information to design teams or for use in operator training and plant maintenance. Plant equipment removal and installation sequencing can be simulated. With the benefit of on-line clash detection optimum routes can be established within the CAD model preventing costly mistakes on site. Where space is at a premium or operator safety is in question Design Review provides the ideal medium to pin-point potential problem areas enabling design alternatives to be considered much earlier in the design cycle.

• The Steel Detailing - TEKLA/Pro-Steel package provides interactive tools to create detailed joint and connection to produce shop fabrication drawings.

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SMART PLANT DESIGN SYSTEM

Analysis and Engineering Design

• Process Analysis and Simulationpackage such as GateCycle,ChemCAD provides a detailed steady-state design and off-design analysis of thermal power systems. A variety of analyses can be performed such as analyzing an overall cycle for a proposed power system or cogeneration station, simulating the performance of existing system at “off-design” operating condition, analyzing advanced gas turbine design, predicting the effect of proposed changes or enhancements to existing plant.

SMART PLANT DESIGN SYSTEM

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• Pipe Stress Analysis and Designpackage such asCAESARII, provides stress analysis for pipe and piping components based on Finite Element Method (FEM). The acquired results are checked against the required design criterion, e.g. ASME B31.1, B31.3, ASME Boiler and Pressure Vessel Section III, etc. Piping layout model input data are imported from Pipe Module 3d CAD tools.

Main Steam Reheater AreaWestinghouse AP600

SMART PLANT DESIGN SYSTEM

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generator interactively or through Structure Module 3D CAD tools.

• Pressure Vessel Analysis and Design package such as APV (Advance Pressure Vessel), provides an assistance in the design of pressure vessels in accordance with the ASME Boiler and Pressure Vessel Code Section VIII division 1. Included in this package are Zick and Saddle design, Leg and Lugs design for seismic (in accordance with UBC), and Vessel construction and repair estimator.

• Structural Analysis and Design package such as STAAD-Pro V8i, provides a design analysis of steel and concrete structures. Analysis and Design processes can be performed in one execution, i.e. after the analytical process has been performed, a design calculation in accordance with the chosen design criterion (e.g. AISC/ASD, AISC/LRFD, API, AASHTO etc) are evaluated. Results of design analysis processcan be viewed interactively using STAAD-POST graphical Post-processing for verification of the structure. Model input data can be generated through STAAD-PRE graphics input

OUTPUT DELIVERABLES

• Plot Plans• General

Arrangements & Layout

• Process Flow & Instrumentation Diagram

• Flow & System Calculations

• Piping Stress Analysis Report

• Piping Isometrics • Ventilation System

Drawings and Lists of Equipment

• Electrical System Drawings, Diagrams and Lists

• Instrumentation and Control Drawings, Diagrams and Lists

• Structural Stress Analysis Report

• Structural Steel Fabrication Drawings

• Bill of Material Reports

• Modularization

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Piping Isometric

Westinghouse AP600

Structural Analysis of Feed Water ModuleWestinghouse AP600

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RESOURCES

25%

28%11%

7%

11%

11%7%

Human Resources

Process

Mechanical

Electrical Eng

Instrumentation & Control

Civil and structure

Informatics

Chemical

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RESOURCES - SOFTWARE

Analysis

Drawing

Smart Plant Design

• Process Flow Diagram• Process & Instrumentation

Diagram• Instrumentation Data

Management• Wire Works• Control Builder/Control Logic

Diagram• Frame Work Plus

• ModelDraft• Equipment Modelling• Piping Designer• Cable Raceway Designer• Interference Checker• Isometric Manager• Drawing Manager• TEKLA v.19

• Gate Cycle• Advanced Pressure Vessel• CAESAR II

• STAAD PRO V8i• STAAD PRO Foundation• RAM Connection

• Microstation• AutoCAD

PROJECT EXPERIENCE/ CASE STUDIES

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BIODIESEL PLANT -- Local Gov of RiauProcess, Engineering, Procurement and Construction of 8 tones/day Biodiesel plant with CPO pond as the feed stock.

BIODIESEL PLANT -- PT. Padasa Enam UtamaDesign and Engineering Biodiesel plant, 3 tones/day to supply internal fuel for the diesel generator in a palm oil mill.

South Pars, SOHAR, Tangguh ( Gas Onshore) Project in Tangguh IrianJaya, Indonesia -- PT Pertafiniki Engineering, Jakarta Indonesia• Equipment 3D Cad Modeling• Structure 3D Cad Modeling• Isometric production and checking• Piping MTO• Structure MTO

Plant Model and DuctingKF Pharmaceutical Salt Factory

PROJECT EXPERIENCE

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MADURA “BD” DEVELOPMENT PROJECT -- PT PAL Indonesia • Process and Instrumentation Diagram (P&ID)• Instrument Data Manager• Piping 3D modeling for main deck and cellar deck.• Equipment 3D and Structure 3D Modeling• Isometric production, checking and Piping MTO• Structure MTO

WESTINGHOUSE AP600 NUCLEAR PASSIVE REACTOR -- Westinghouse Electric Corporation, Pittsburgh, Pa. USA• Plant layout in the south end Turbine Building

and auxiliary Building which include: a. Piping modeling and build in printb. Equipment modeling and build in printc. Ducting (HVAC) modeling andd. Support and structures modeling and build

in pribuild in printnte. Cable trays modeling and build in printf. Access path, cranes and other related

commodities• Isometric production and MTO reporting for

piping and equipment, • Clash Detection and its report• Modularization (Modeling and as build drawing

production)• Pipe stress analysis• Structural analysis• Control Logic Diagram

Plant Design System Training -- PT. Rekayasa Industri EC BPPT conducted a 55 days Plant Design System training for PT. Rekayasa Industri Engineers. That Includes : • Piping & Instrumentation Diagram• Instrument Data Manager• Piping Modeling• Equipment Modeling• Interference/Clash Detection• Structural Modeling• Composite Drawing• Isometric Detection• Pipe spec writing

PROJECT EXPERIENCE

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Bontang LNG Plant Expansion Project –Train H-- PT. IKPT (Inti Karya Persada Teknik) EPC Company, Jakarta, Indonesia• Steel Detailing Drawing • MTO of Steel Detailing Structure

TUNU Development Project -- PT PALAMECEngineering Consultants, Jakarta, Indonesia • Equipment 3D Cad Modeling • Structure 3D Cad modeling• Isometric production and Checking • Piping General Arrangement Drawing• Piping MTO• Structure MTO• Detailed Engineering

Various CPO Mills in Indonesia -- Dit. TAB and Pemprov. Riau Province, Indonesia• Steel Detailing Drawing (in X-Steel)• MTO of Steel Detailing Structure

Sumbagsel Gas CO2 Removal from gas field South Sumatera Area -- PT. Rekayasa Industri EPC Company Jakarta, Indonesia• Equipment 3D Cad Modeling• Piping 3D Modeling• Piping & Instrumentation Diagram PDS 2D using PDS

STATIC CONTROL SYSTEM VAR COMPENSATOR IN EAST JAVA AND BALI INDONESIA -- PT PLN P3JB Region East Java and Bali, Indonesia• Electrical Design• Testing/Simulation• Installation.• Commissioning• Maintenance

Engineering Design for Mobile Oil Recovery (MORS) -- PT. Sayap EnggangPerkasa, Engineering Consulatans, Jakarta, Indonesia• Equipment 3D Cad Modeling• Structure 3D Cad modeling (in Frame Work +)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO

PROJECT EXPERIENCE

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Jacket Structure Drawing Improvement -- PT. BP. Indonesia, Jakarta, Indonesia3-D Re-draw using PDS

Pilot Plant Biodiesel from CPO In Riau Indonesia -- Pemprov. RiauProvince, Indonesia• Equipment 3D Cad Modeling• Structure 3D Cad modeling (in X-Steel)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO• Detailed Engineering• Design Analysis

PIM-2 Fertilizer Plant (Water Treatment Project) in LhokSeumawe, Aceh Indonesia -- Krakatau Engineering Company (KEC), Cilegon, Banten, Indonesia• Equipment 3D Modeling• Structure 3D Modeling (in Frame Work +)• Piping 3D Modeling• Plant view rendering

Paint Upgrading BHP Indonesia Steel Construction Plant in Cilegon, West Java,Indonesia -- PT. Karinda EPC Company, Jakarta, Indonesia• Steel Detailing Drawing (in X-Steel)• 2 MTO of Steel Detailing Structure

CO2 Removal (from Pertamina Gas Field) in Subang, West Java, Indonesia --PT. RekayasaIndustri, EPC company, Jakarta, Indonesia• Equipment 3D Cad Modeling• Structure 3D Cad modeling (in Frame Work +)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO

NH3 PGN (Gas Plant) in East Java, Indonesia PT. Rekayasa Industri EPC company, Jakarta, Indonesia. • Equipment 3D Cad Modeling• Structure 3D Cad modeling (in X-Steel)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO

PROJECT EXPERIENCE

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PLTU Generic 2x7MW In Aceh Indonesia -- PT3KE-ESDM, Jakarta, Indonesia.• Equipment 3D Cad Modeling• Structure 3D Cad modeling (in X-Steel)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO• Design Analysis

PLTP TEG 2MW CIBUNI In Bandung Indonesia -- PT. TEG EPC company, Jakarta, Indonesia. • Equipment 3D Cad Modeling• Structure 3D Cad modeling (in X-Steel)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO• Design Analysis

IGG Bioethanol, In Banyuwangi Indonesia -- PTPN III, Indonesia • Equipment 3D Cad Modeling• Structure 3D Cad modeling (in X-Steel)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO• Design Analysis

Gondorukem, Terpentin In PemalangIndonesia -- PT. PASADENA EngineeringJakarta, Indonesia• Equipment 3D Cad Modeling• Structure 3D Cad modeling (in X-Steel)• Isometric production and Checking• Piping General Arrangement Drawing• Piping MTO• Structure MTO• Detailed Engineering• Design Analysis

BUSINESS AREA

Oil and gas Industry

Power Generation

Renewable Energy

Chemical and Process Industry

Gedung 480, Kawasan Puspiptek,Serpong, Tangerang Selatan, Banten 15314

Tel. 021 7563213 / 17Fax. 021 7563273

e-Mail. sekr-btb2rd@bppt.go.id

btbrd.bppt.go.id