development of engineering infrastructure in pakistan ...infrastructure development goals and...
TRANSCRIPT
Development of Engineering Infrastructure in Pakistan Atomic Energy Commission
National Conference Organized by SASSI “Application of Nuclear Science & Technology in Pakistan”
(July 12-13, 2012)
Waqar M. Butt Member (Engineering), PAEC (member.engg@ gmail.com)
Infrastructure Development Goals and Objectives
To meet the design, manufacturing and testing requirements of
► Operating plants/facilities
► New Plants/ Projects
Objectives
► Life time engineering support for O/M of Plants/ facilities
► Minimize dependence on vendors
► Enhance role in future plants/ facilities
► Offer services to National/International Industry
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Infrastructure Development (Capacity and Capability Building)
Design and Manufacture of Plant Equipment
Testing and Inspection
Specialized Training
Computer, Control and Instrumentation Design & Engineering
Interface with industry
Infrastructure Development Program got boost after international embargo in
mid 70’s
Safe and continued operation of KANUPP after embargo was a major challenge
for PAEC
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Major Infrastructure Facilities
Scientific and Engineering Services (SES)
Heavy Mechanical Complex-3 (HMC-3)
National Centre for Non-Destructive Testing (NCNDT)
Pakistan Welding Institute (PWI)
Informatics complex (ICCC)
HMC-3 NCNDT PWI ICCC
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Design and Manufacture of Plant Equipment
Process equipment design
Manufacture of plant equipment
Replacement equipment support throughout plant design
life and beyond
Major equipment maintenance services
► Ageing management ► Decommissioning
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Applicable Codes and Standards
Codes / Stds. Description
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
AISC American Institute of Steel Construction
AWS American Welding Society
API American Petroleum Institute
BS EN British Standard / European Standard
DIN Deutche Industrial Norman
FEM Federation Europeene De La Manutention
GB Chinese Standards
ISO International Standard Organization
TEMA Tubular Exchanger Manufacturers Association
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Engineering Software In-house capability of using following software
Software Description
ANSYS Design and analysis
Autodesk Inventor Suite 2008 with MDT
3D Modeling and design Software
Catia 3D Modeling and design software
Solid Works 3D Modeling and design software
Pro-E (Wildfire4) 3D Modeling and design software
Auto Plant 2004 Creation of 3D piping models
PV Elite 2008 Comprehensive Software for design of pressure vessels and heat exchangers
STADD Pro 2006 Structural engineering software
Chem CAD 6.0.1 (CC Therm) Software for thermal design of heat exchangers
Fire CAD Design software for Boilers
E-Tank 2000 1.8.0 Software for design of tanks as per API 620, 650 & 653. 6/41
Certification
International Standards Organization ISO 9001: 2008 Certified for Design & Manufacture of Engineering Products for Heavy and Medium Industries
The National Board
of Boiler and
Pressure Vessel
Inspectors
R Repair / Alteration
as per ANSI 23 / NB
Pakistan Nuclear Regulatory
Authority
HMC-3 is the first engineering
organization that has been certified to
produce Nuclear Safety Class-I
equipment and components in Pakistan.
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ASME: Certification
American Society of Mechanical
Engineers
Stamps
A Assembly of Power Boiler
S Power Boiler Design and Fabrication
as per ASME Section-I
PP Power Piping as per ASME B.31.1
U Pressure Vessel as per ASME-VIII Div-I
U2 Pressure Vessel as per ASME-VIII Div-II
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API: Certification
American Petroleum
Institute
Monogram Licensing for
Specifications:
12D Field Welded Steel
Storage Tanks
12F Shop Welded Steel
Storage Tanks
12J Oil & Gas Separators
or / and Oil Gas Water
Separators
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Design & Engineering
Fabrication
Heat Exchanger
Dish Head Forming
Thick Plate Rolling
Pipe and Section Bending
Welding, All Types
Narrow Gap Welding
Plasma Cutting
CNC Machining
Heat Treatment
NDE
Destructive Testing
Hydrostatic
Pneumatic
Vacuum
Quality Assurance & Control
Major Manufacturing Facilities
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Major Manufacturing Facilities
250mm Plate Edge Preparation
Machine
Plasma Cutting Machine (100mm)
250 mm Plate Bending & Rolling
Mill
4m Dia Dish Making Line
Fabrication
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8m CNC Milling & Boring Machine
X, Y, W & Z Stroke:
8.5, 2.0, 1.0 & 1.2 m
respectively.
Positioning Accuracy:
0.015mm/1.0m.
Repeatability Accuracy:
0.01mm.
Machining
Major Manufacturing Facilities
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16m CNC Vertical Boring & Turn Mill
Jobs Size, Maximum:
Diameter 16,000 mm.
Height 6,500 mm.
Weight 320 tons.
Positioning Accuracy:
0.012mm/1.0m.
Repeatability:
0.008mm.
Machining
Major Manufacturing Facilities
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Working Range: 8m in Horizontal & Vertical Planes. Welding: Up to 350mm thick steel plates. Roller supporters: 500 tones
Narrow Gap Welding Machine
Welding
Major Manufacturing Facilities
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Major Equipment Manufactured
Pressure Vessels
Chemical Vessels
Water and Steam Drums
Heat Exchangers
Air Pre-Heaters
Condensers
Heating Furnaces
Vacuum Furnaces
Welding Positioners
Water Treatment Plants
Food irradiation Plants
Desalination Plant Equipment
Chemical Reactors
Boiler Drums
HP Heaters
EOHT, Gantry Cranes (upto 100 tons)
Heavy Steel Structure
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Evaporator for Desalination Plant
Dia = 3,216 mm Length = 16,400 mm Weight = 50 ton Capacity = 1,600 m3/day
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Testing and Inspections
Systematic testing and inspection program
throughout manufacture, construction,
commissioning and operation phases.
Strong NDT/NDE program
Training and re-training of NDT/NDE inspectors and enhancement of
testing facilities.
National center for Non-destructive Testing (NCNDT) of PAEC has
necessary facilities and expertise to meet the inspection & testing
requirements of nuclear plants and offer these services to local
industry.
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Pressure up to 40 MPa & Flow up to 1.08 m3/hour.
Hydrostatic Testing
The Industrial Boroscopy Equipment can undertake normal as well as irradiated jobs. It can work on Tubes of minimum dia 7 mm and length up to 7.5 m.
Boroscopy
Inspection and Testing
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• Size (X- Y- Z travels)
3000 x 1500 x 1500 (mm)
• Loading Capacity
3,637 kg
Coordinate Measuring Machine (CMM) Profile Projector
CMM can be used for testing the machined
and assembled magnets.
Inspection and Testing
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► NDE/ NDT
► Welding technology
► Industrial/Fire safety
Regular Training Courses for
PAEC and local industry.
Specialized Training Program
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NDT Courses for Industry
NDT Appreciation Course for Managers
NDT & Fracture Mechanics
Basic Concept on Acoustic Emmission
Introductory Course on NDT of Concrete
Theoretical Aspects of RT, UT & ET
Radiation Safety
Ultrasonic Thickness & Crack Depth Measurement
Phased Array & Time of Flight Diffraction (TOFD) Techniques
Ultrasonic Defect Detection with Digital/Analog Equipment
Understanding of Ultrasonic Testing in ASME Code Section -V
Interpretation of Radiographs
Ultrasonic Sizing of Defects
Introductory Course on NDT of Concrete
Theoretical Aspects of UT,RT & ET
Eddy Current Testing
Ultrasonic Flaw Detection in Welds
Specialized Training
Courses are also arranged
on industry request.
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Welding Courses for Industry
National Course on
Welding Technology for Engineers
Appreciation Course for Executives
Orientation Course on International Standard
Welding Inspectors Level-I & Level-II
TIG Welding for Welders
Gas Tungsten ARC Welding of Carbon & Alloy Steels
SMAW for Pipe Welders (Mat Carbon Steel)
GTAW Process for TIG Welders (Stainless Steel)
Welding Inspection and Quality Control
Weldability of Metals
Gas metal Arc Welding for Welders
Stainless Steel Pipe Welding for Welders
Welding of Cast Iron for Engineers
Stainless Steel Pipe Welding for GTAW / SMAW Welders
Specialized Courses / Training
Programs are also arranged
on industry request.
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Design and Engineering of Computer, control and Instrumentation
Control System for Process/Chemical Plants
Data acquisition Systems
Electronic Instruments and Software
Training Simulator and testing aids
Control Room modification/up-gradation
Specialized equipment development
Telephone Exchanges
Cargo Scanners
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Full Scope Training Simulators
Simulators for operator training.
Soft Panel based Simulators
Similar simulators for
conventional Power
plants can be
developed
for the industry for
training
purposes.
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• Gamma Rays Cargo Scanner
for vehicle inspection.
Radiation Monitors
• Pedestrian Portal
monitors and Hand & Foot
Contamination monitors.
Gamma Rays Cargo Scanner
•Medium Frequency
Inverters and Automatic Control
Systems up to 250 KW
PCR Machines
• Based upon Polymerase Chain Reaction
technique. Used in medical & biological
research labs for variety of applications
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I & C for Vacuum Induction Furnaces
Telephone Exchanges
• Indigenous development of
telephone exchanges up to
1000 lines including ISDN
services & Executive
telephone sets.
Fermenter
• For batch/continuous
culture & bio-processes
capacity of 1, 10 & 100 liters 27/41
Interface with Industry
Manufacturing services
NDT/NDE Services
Specialized Training Programs
NATIONAL REFINERY
PAKISTAN REFINERY
PAKISTAN STEEL
PEOPLES STEEL MILLS
PPL
OGDC
SNGPL
Engineering Services offered to Industry
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CERN, Switzerland
SESAME
Chinese Vendors
Nuclear Power Plants
MARUBINI, Japan
FUJI ELECTRIC, JAPAN
VOITH, GERMANY
KAPCO
WAPDA
KESC
Welded from 140 mm thick Carbon steel plates.
All joints 100% Ultrasonic tested.
Machining of Top Plate with an angular accuracy of 1 minute.
Final Dimensions: 2986 x 2972 x 2500 mm.
Magnet Supports for CERN
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Back view of YE±4 Shielding Wall in horizontal
position
YE+4 SHIELDING WALL for CERN
Front view of YE±4 Shielding Wall in
horizontal position
Diameter : 13910 mm.
Height : 15745 mm with supports.
Flatness : ±3 mm.
Flatness of each sector : ±2 mm.
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Collaboration in Piping works at CERN
Collaboration in Piping works with ALICE: ~ 96 Man-months.
Work involved welding, installation & pressure testing of
Multilayer pipes of OD 25 mm to 40 mm.
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Vacuum Vessels for CERN
Vacuum Vessels for PETS Dia. 400 x 1360 (L) mm - 2Nos.
Material : A240-304L.
Positioning accuracy of inner plate ± 0.5 mm and parallelism
± 0.3 mm.
The leak tightness value < .10-9 mbar*lit/sec and vacuum
value is 10-8 mbar.
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Turbine Blade Carrier for Power Plant
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Machining of Flange of Main Shaft,
L = 5 m, Weight = 22 T,
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