INTEGRATED APPROACH FOR STRUCTURAL ENGINEERING FROM CONCEPTUAL DESIGN TO FABRICATION SANJAY KUMAR ARORA MANAGER – CIVIL, PEM, BHARAT HEAVY ELECTRICALS LIMITED NEW DELHI, INDIA

BHEL - AN OVERVIEW

BHEL India’s Largest Engineering & Manufacturing Enterprise for Power Generation, Transmission & Distribution equipments One of the few manufacturer in the world who can supply entire spectrum of products & system for Power Projects from its own manufacturing bases.

BHEL - From just over 1300MW of capacity in the country in 1947 comprising of all imported equipment, we today have over 115,000MW of capacity – 65% of this from BHEL, India.

Power Generation Industry Oil & Gas NCESTransportation Power Transmission OPERATING BUSINESS AREAS SERVING CORE & INFRASTRUCTURE SECTORS OF THE ECONOMY Thermal, Gas, Hydro, Nuclear, DG Sets Switchgear, Transformers, Insulators, Substations, SCADA, HVDC Systems Boilers, Pumps, Heat Exchangers, Valves, Motors, Compressors, Control & Instrumentation Systems, Water de-salination plants Locomotives (electric - AC/DC), Diesel-electrics, EMU's, Traction Electrics On-shore Drilling Rigs, Valves Solar Photo Voltaic Power, Solar Water Heating Systems, Wind Electric Generators, Hybrid Distributed Power Generating Systems

INTEGRATED APPROACH FOR STRUCTURAL ENGINEERING FROM CONCEPTUAL DESIGN TO FABRICATION OBJECTIVE ……

INTEGRATED APPROACH FOR STRUCTURAL ENGINEERING FROM CONCEPTUAL DESIGN TO FABRICATION To eliminate heirarchical structure of (serial) information flow in design To incorporate 3D model based conceptualisation and design To integrate the various stages and build a design chain by utilising intelligent 3D modelling technology and various other design and detailing software

Current practice and information flow Layout Engineer Structural Engineer CONSTRUCTION STAGE

The information management is decentralised. The information is passed, as documents, between the various agencies involved. The correctness of the final result is to be ensured by number of checks and reviews. PROBLEMS WITH CURRENT PRACTICE

Document based communication between various agencies becomes the bottleneck as large amounts of information are not passed, or are passed in a form, which the receiving party cannot readily use for further value addition. This leads to duplication of efforts for drawing work in restoring the same information many times. PROBLEMS WITH CURRENT PRACTICE

BUILDING UP A DESIGN CHAIN BY INTERCONNECTING THE VARIOUS STAGES NAMELY  ANALYSIS AND DESIGN  3D MODELLING  DETAILING SUGGESTED SOLUTION TO PROBLEMS WITH CURRENT PRACTICE

THE DESIGN CHAIN …. GT STRUDL -STRUCTURAL ANALYSIS SOFTWARE By : Case centre, Gtech, USA PDMS -3D MODELLING SOFTWARE By : Aveva Technologies, USA XSTEEL 3D STRUCTURAL STEEL DETAILING SOFTWARE By : Tekla Inc.

Analytical Model (Gtstrudl) Analysis and strl. Design Development of Design chain using 3D modeling technology STAGE - I The space frame analysis and design is to be carried out in normal fashion Final analysis file to be used for generation of 3D model in PDMS environment

Development of Design chain using 3D modeling technology The final analysis file shall be modified by adding certain comment cards Comment augmented analysis file shall be utilised for further step in design chain. All prismatic section profiles in analysis file shall be automatically converted to actual profiles in PDMS environment.

DEVELOPMENT OF INTERFACE BETWEEN GTSTRUDL AND PDMS Transfers all rolled sections as per selected/intended section tables Transfers all built-up members as per selected/intended profiles in parametric form, Parameters can be changed at any stage of further modelling Places all the members in appropriate framework hierarchy corresponding to groups made in analysis input file. Translates the member offset command of analysis file in to actual cut length in 3D model

Analytical Model (Staad Pro or Gtstrudl) Analysis and strl. Design 3D Plant Model in PDMS Interface program #1 Development of Design chain using 3D modeling technology STAGE - II

CUSTOMISATION OF PDMS SOFTWARE TO INCORPORATE ALL TYPES OF ROLLED/BUILTUP SECTIONS IN PARAMETRIC FORM

INTERFERENCE CHECKS IN PDMS ENVIRONMENT GENERATION OF OTHER RELATED INFORMATION IN PDMS SUPERIMPOSTION OF OTHER STREAM DATABASES IN PDMS ENVIRONMENT GENERATION OF PIPING ISOMETRICS GENERATION OF HANGER ASSEMBLY DATA ETC. Benefits of 3D modelling in PDMS

3D model in PDMS enviroment – An overview

Analytical Model (Staad Pro or Gtstrudl) Analysis and strl. Design 3D Plant Model in PDMS Interface program #1 Modification of SDNF link using interface program # 2 Development of Design chain using 3D modeling technology STAGE - III

Analytical Model (Staad Pro or Gtstrudl) Analysi s and strl. Design 3D Plant Model in PDMS Interface program #1 Modification of SDNF link using interface program # 2 Joint Detailing in Xsteel 3D Plant Model in Xsteel Drawing production Design chain using 3D modeling technology

Development of Design chain using 3D modeling technology Analytical Model (Staad Pro or Gtstrudl) Analysis and strl. Design 3D Plant Model in PDMS Interface program #1 Modification of SDNF link using interface program # 2 Joint Detailing in Xsteel 3D Plant Model in Xsteel Drawing production

Benefits of Integrated work approach  Single Point Data Entry  Interference Free Design and Construction  Engineering time cycle reduction  Elimination of errors slipping to site  Reduction in project cost - elimination of rework

The road further  Development of internal interface between GTSTRUDL AND XSTEEL FOR TWO-WAY DATA TRANSFER  INCORPORATION OF BUILTUP MEMBERS IN GTSTRUDL ALONG WITH RELEVENT CODE CHECKING

Layout Modeling Analysis Design Design Drawing Fabrication Drawing Internal Interface Program By Case Centre The road further

Analytical Model (Staad Pro or Gtstrudl) Analysis and strl. Design Joint Detailing in Xsteel Drawing production 3-D Plant Model in Xsteel Interface program The road further