EPC of Thermal Power Projects – “A Concept of Virtual Design”

Date: 19th February 2009Speaker: Dr.Sanjay Gambhir

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Agenda:

• Doosan

• Doosan & Doosan Babcock Engineering

• Concept of Virtual Design

• Advantages

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Doosan Corporation

Infrastructure support businesses

Oricom

Consumer goods / Non-heavy industries

Others

Doosan Infracore

• Construction equipment• Industrial vehicle• Defense system• Machine tools

Doosan Heavy Industries and Construction

• Thermal & nuclear power plant• Desalination plant• Material handling•Casting & Forging

Doosan Engine

• Ship engines

• Advertising• Integrated MarketingCommunication Services

•Holding company withdiversified businesses in industrial facilities and consumer goods

– Liquor– Techpack(bottles)– Publishing– Fashion– Electro-materials– Magazine, etc.

• Resorts• Sports, etc

DoosanConstruction

and Engineering

• Civil engineering• General construction

Doosan Mecatec

• Chemical process equipment• Steel Bridge• Plant engineering• Factory automation

BUSINESS PORTFOLIO OF DOOSAN GROUP

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A Panoramic View of DOOSAN Changwon Plant

DOOSAN Changwon Plant- Ground Area : 4,429,000 m2

- Roofed Area : 425,000 m2

Manufacturing Shops• Boiler & Piping• NSSS• Turbine• Generator• Rotor• Blade• Heavy Fabrication

• Foundry• Forging• Work roll• Gas Turbine• Defense Industries• I&C

• Main Office• Dock Facilities• R&D Center• NDE and Laboratory• Balancing Test• Guest House

Facilities

Main Office

Quay (Loading & Unloading)

R&D Center

Balancing TestFactory

Boiler EquipmentFactory

Bending/Welding Factory

Turbine & Gen. Equipment Factory

Casting FactoryForging Factory

I&C Factory

Nuclear Equipment FactoryDesalination Evaporatorassembly Field

Dormitory

Guest House

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DOOSAN HAS ESTABLISHED EXTENSIVE GLOBAL NETWORK FOR MARKET EXPANSION & TECHNOLOGY DEVELOPMENT

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Vietnam• Vina, Desalination &

HRSG plant of Doosan Heavy

• Steel structure production plant of Doosan Heavy

Belgium• Excavator/forklift

production plant of Doosan Infracore

Yantai, China• Construction

equipment plant, Doosan Infracore

Korea• Doosan Infracore

• Incheon• Changwon #1, #2

• Doosan Heavy Industries and Construction

• Changwon

Bucharest, Romania• Casting & forging plant

of Doosan Heavy●Doosan GroupSubsidiariesBranchesDealersDoosan Heavy/InfracoreMfg. plant Major plant projects

Texas, USA• HF Controls, an

instrument & control system company

• Doosan Heavy

Florida, USA• DHT, a

desalination company of Doosan Heavy

India• DBES

Papua New Guinea• Power plant of Doosan

Heavy

Sri Lanka• Steel plant of Doosan

Heavy

Beijing, China• China Holding Co. of

Doosan Fujian, China• Engine JV of Doosan

Infracore

Dubai, UAE• R&D Center of

Doosan Heavy

Renfrew, UK• Babcock, a boiler

technology company of Doosan Heavy

Luxemburg• European Holding Co.

of Doosan Heavy

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DOOSAN Heavy offers World’s best Power and Water Solutions

Global leader in power & water solutions• Desalination global No.1

–40% global market share• HRSG(1) global No.1

–30% global market share• Crankshafts global No.3

–23% global market share• Casting & Forging : Global # 1• Nuclear Power Plants global No.5

–Dominant player in Korea

Pioneer in heavy industries• Korean renewable energy market leader

–sea wind power plant (’06)• Pioneer of RO(2) water market

–acquired AES of USA (’05)

Power

DesalinationCasting &

forging

Industrial facilities Construction

DHIBusiness Portfolio

(1) Heat recovery steam generator; (2) Reverse Osmosis

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DHIC BRANCHES AND SUBSIDIARIES

Branches (19)Subsidiaries (15)

New Jersey

Bangkok

Dubai

FrankfurtWindsor

Schenectady

Taipei

Beijing

RiyadhHANVICO(Vietnam)

DB E&S

CHICO(Sri Lanka)

SHADA(Saudi Arabia)

HPL(Papua New Guinea)

PHS(Malaysia) LKPPL

HFC(Dallas)

SeoulTripoli New Delhi

Doosan Hydro(Tampa)

IMGB(Bucharest)

Babcock(Crawley)

Doosan-Vina (Vietnam)

Hanoi

Shanghai

M.E Operation Center

R&D Center

Kuwait

Mumbai

New JerseyD E&S

Tokyo

Abu Dhabi

October 2008

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MAJOR EXPERIENCE RECORD IN OVERSEAS– POWER PLANT

Project Capacity CountryClient

• Gheco-one• Cirebon TPP• Mundra UMPP• Qatalum• JBL M1 • Amman East PP• Barka Ph2 IWPP• Sipat TPP

• Thailand• Indonesia• India• Qatar• U.A.E• Jordan• Oman• India

• GHECO• PT Cirebon Electric Power• AED• QP, Norsk Hydro• DEWA• AES/MItsui• SMN Barka Power Co.• NTPC

• 700MW(TPP)• 695MW(TPP)• 4,000MW(Boiler)• 1,200MW(CCPP)• 1,330 MW (CCPP)• 387 MW (CCPP)• 685MW (CCPP)• 1,980MW (Boiler)

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MAJOR EXPERIENCE RECORD – NUCLEAR POWER PLANT

Project

Levy County #1,2*V.C. Summer #2,3*Vogtle #3,4*Sanmen, Haiyang*Shin-Kori #3,4Shin-Kori #1,2Shin-WolsungUlchin #3~6Wolsong #2~4

Capacity

2000MW(AP 1000)2000MW(AP 1000)2000MW(AP 1000)2000MW(AP 1000)2800MW(APR 1400)2000MW(OPR 1000)2000MW(OPR 1000)4000MW(OPR 1000)2100MW(Candu)

Country

USAUSAUSAChinaKoreaKoreaKoreaKorea Korea

Client

WECWECWECWECKHNPKHNPKHNPKHNPKHNP

* Order intake in 2007&2008

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KEY ORDER INTAKES IN ‘07

Shanmen/Haiyang#1,2 NSSS

Amman east 370MW

Jebel Ali M #1,21330MW+670MW

Qatalum1400MW

Al Taweelah A10220MW

Mundra4000MW

British Energy Engineering Service

Barka680MW

Glow 110MW

800MWX5World biggest TPP PJT

Became 1st main equipment provider ofAP1000 reactor of WEC

First order of CFB Boiler

World biggestCCPP PJT

Shuaiba Exp RO33MIGD

Eng’ service to 9 power Plants till 2013( 1,200 bil KRW)

World 2nd biggest RO Desal. plant

Enter into North Africa& Oil-fired Plant market

Tripoli West1,400MW

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About Doosan Babcock Engineering & Services India

• Incorporated on 14th November 2005 as “Doosan Engineering & Services”, A 100% Subsidiary of

Doosan Heavy Industries & Construction of South Korea

• Global Engineering Centre at Gurgaon, India for EPC of Power Projects.

• Established capabilities for Design & Engineering of Combined Cycle Power Plants and Coal

Based Thermal Power Plants.

• Renamed as Doosan Babcock Engineering & Services (DBES) on 1st January 2009 as part of the

restructuring for Indian Operation with offices at Gurgaon & Chennai.

• Already completed many HRSG, Boiler and EPC Projects in addition to Proposal Engineering.

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DBES GurgaonDBES Gurgaon

Electrical EngineeringElectrical Engineering

PSE, MEDPSE, MEDCivil & ArchitecturalEngineering

Civil & ArchitecturalEngineering

Instrumentation & Control

Instrumentation & Control

Plant Design & Piping Department

Plant Design & Piping Department

ORGANIZATION STRUCTURE- DBES Gurgaon

EngineeringManagementEngineeringManagement

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Some EPC Projects at Doosan Babcock Engineering & Services India

TPP

TPP

TPP

TPP

CCPP (1HRSGX1GTX1ST)

CCPP (3HRSGX3GTX2ST)

Type of Power Plant

Engineering & Construction is on.

Thailand1X700 MWGHECO6

Engineering & Construction is on.

Philippines2X100 MWCebu5

Engineering & Construction is on.

Thailand1X115 MWGlow4

Engineering & Construction is on.

Indonesia1X660 MWCirebon3

Engineering Completed. Construction is on.

Pakistan1X175 MWDaharki2

Engineering Completed. Construction is on.

Oman685 MWBarka II1

StatusCountryCapacityName of ProjectS. No.

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Virtual Design Concept: Why?

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Interlinking Between Various Groups: A Complex Phenomena

Shop Fabrication

Procurement

Transport

Electrical

Project Mangement

Site Erection

Proposal Engineering

Plant Layout

I&C

Civil

Architecture

Process

Mechanical

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Let us have a Common Platform: A Virtual Shared Work Space

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Virtual Design Concept: EPC Phases

Engineering Phase I

Engineering Phase II

Engineering Phase III

Engineering & Procurement

Phase IV

EPCPhase V

Virtual Shared Workspace

with Database

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Cable Trays

FW+

PIPING

EQP

Speedikon

E-RWAY

Pelicon Forge

Steel

Equipment

Piping

Pipe Supports

Civil etc.

3D Modell

Design CheckAnalysisInterference CheckDesign Review

DocumentationDrawing ManagerIsoGenReport Manager

Design Check + Documentation

Virtual Design Concept: Engineering Phase I

Every Discipline involvedAutomatic Data Flow

Planning in 3DConcurrent Design

Integration in 3D

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Phase I: Bangpakong 700MW CCPP (HRSG), Taiwan

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Phase I: Bangpakong 700MW CCPP (HRSG), Taiwan(Drum Area)

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Phase I: Barka 685MW CCPP, Oman

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Phase I: Barka 685MW CCPP, Oman (HRSG)

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Phase I: Barka 685MW CCPP, Oman (HRSG Silencer Area)

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Phase I: Barka 685MW CCPP, Oman Gas Turbine Building

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Phase I: Daharki 175MW CCPP, Pakistan

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Phase I: Daharki 175MW CCPP, Pakistan (HRSG)

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Phase I: Daharki 175MW CCPP, Pakistan (Feed Water Pump Area)

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Phase I: Cirebon 660MW TPP, Indonesia

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Phase I: Cirebon 660MW TPP, Indonesia

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Phase I: Cirebon 660MW TPP, Indonesia, (Turbine Building Ground Floor)

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Phase I: Cirebon 660MW TPP, Indonesia, (Turbine Building Mezzanine Floor)

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Phase I: Cirebon 660MW TPP, Indonesia, (Turbine Building Operating Floor)

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What more can be done?

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Cable Trays

FW+

PIPING

EQP

3D M

E-RWAY

Pelicon Forge

Steel

Equipment

Piping

Pipe Supports

Misc.

Let us integrate Process & I&C

3D Modell

Every Discipline involvedAutomatic Data Flow

Planning in 3DConcurrent Design

Integration in 3D

Design CheckAnalysisInterference CheckDesign Review

DocumentationDrawing ManagerIsoGenReport Manager

Design Check + Documentation

Virtual Design Concept: Engineering Phase II

SPP&ID I&C

Addtional Design ConditionsLists like line list, valve list etc.Interface with softwaresAccurace of original data transfer

SpeedikonCivil

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Cable Trays

FW+

PIPING

EQP

3D M

E-RWAY

Pelicon Forge

Steel

Equipment

Piping

Pipe Supports

Misc.

3D Modell

Every Discipline involvedAutomatic Data Flow

Planning in 3DIntegration in 3D

Concurrent Design

Design CheckAnalysisInterference CheckDesign Review

DocumentationDrawing ManagerIsoGenReport Manager

Design Check + Documentation

Virtual Design Concept: Engineering Phase III

SPP&IDI&C

Addtional PDCLists like line list valve list etc.Interface with softwaresAccurace of original data transfer

HBDSpeedikon

Civil

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Virtual Design Concept Integration with Shop Fabrication, Procurement and Tranport

Virtual Design Concept: Engineering & Procurement Phase IV

Virtual Design with Database

Steel Shop Fabrication

Piping Shop Fabrication

Procurement

Transport

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Final Target: Complete Automation with PLM

Virtual Design Concept: EPC Phase V

PLM

Steel Shop Fabrication

Piping Shop Fabrication

Procurement

Transport

Virtual Design with Database

Project Mangement

Site Erection

Proposal Engineering

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Advantages

Higher Customer Satisfaction

Optimized Design

Easy to Visualize

Online Updated Design

Walk Through Before Erection

Project to Product

Coordinated Interdisciplinary Team

Effort

Reduced Site Non-conformance Cost

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Thanks