40AVEVA World Magazine 2012|Issue 2How AVEVA technology is helping to meet the energy demands of this vibrant economyEnergetic IndiaThe Kauther Gas plant in north Oman was designed and built by Petrofac for Petroleum Development Oman using AVEVA Plant. The project involved the engineering, procurement, construction, commissioning and initial operation of a 20 million standard cubic metres processing facility. Photograph courtesy of Petrofac.AVEVA India has played a significant role in bringing in front-line technologies to enhance the quality and efficiency of the power and marine sectors. Its head office in Mumbai consists of a highly skilled sales and technical team to support the growing demand for customer deployments and new project inquiries. Both offices in Mumbai and Hyderabad are fully staffed to support the growing customer base involved in complex planning, procurement, design and engineering projects. AVEVA's powerful matrix organisational structure provides a very strong local presence in combination with specialised global resources to meet the needs of demanding multinational customers.Meeting the energy challengeThe Desein Indure group of companies is a good example of the way Indian engineering is meeting the energy challenge. A recognised leader in the country's energy industry, the group's activities include consultancy and EPC (engineering, procurement and construction) services for the energy sector, both in India and abroad. Its services range from feasibility studies and multi-discipline engineering projects to complete turnkey projects, including planning, engineering, construction, commissioning and operational and maintenance support.Upgrading to AVEVA PlantTo meet rapidly increasing demand for its services, the company recently upgraded to AVEVA Plant. The General Manager of Desein Indure's newly created 3D Plant Design division, Rohit Nath, explained why. 'The company realised that, in order to achieve a considerable increase in production, we needed to move from our existing 2D design system to a 3D solution for planning, design and construction. We had often been hampered by 2D technology's limitations in clash detection, and by incomplete information for fabrication and construction. This frequently led to late design modifications, incurring costly on-site rework. We needed a more sophisticated engineering system.'With its massive population and increasing industrialisation, energy demand in India is growing strongly. Fortunately, the country is blessed with substantial hydrocarbon reserves - principally coal - and world-class engineering skills. Add to this some world-class engineering technology from AVEVA and you have a recipe for some exciting economic development.AVEVA PDMS model of an ash handling power plant. Image courtesy of Desein Indure.
AVEVA World Magazine 2012|Issue 241System performance, cost and vendor support were considered important criteria in selecting a system and, after thoroughly evaluating several systems, the AVEVA Plant solution was chosen. AVEVA PDMS was implemented in March 2011. 'Staff from AVEVA's Mumbai office provided very effective training,' said Mr Nath. 'Our engineers picked up the new tool very quickly.'To compare the achievable project performance of the new 3D PDMS system with the original 2D system, two teams worked in parallel on part of a design project for a new power plant.'The pilot exercise confirmed all our expectations,' said Mr Nath. 'With PDMS we were able to detect several major clashes very early, avoiding potentially huge costs and delays in on-site rework. Design reviews were easily performed with all engineering groups. The PDMS models allow the engineers to "walk through" the whole virtual plant, so we can quickly detect and eliminate potential design problems long before fabrication has even begun,' he concluded.Comprehensive and accurate deliverables The company greatly values the ability of PDMS to generate comprehensive and accurate deliverables, overcoming another major shortcoming of its old 2D system. All types of construction drawings, such as piping isometrics and arrangement drawings, together with Material Take Offs (MTOs) and Bills of Quantity (BOQs) for all disciplines are now easily generated directly from the PDMS models. 'We now generate all our own production deliverables,' explained Mr Nath. 'Previously, we had to use subcontractors to create many of these.'Desein Indure's engineers also quickly discovered the benefit of being able to import suppliers' equipment models in PDMS. 'Several of our suppliers of boilers and turbines also use PDMS, so they can provide us with accurate 3D models,' commented Mr Nath. 'This saves us even more design time.'It has successfully completed a number of power plants, and many more are currently under development, including a 2 x 525 MW project at Angul in Orissa. Early successes with PDMS led the company to use it on several other power projects. At the time of writing, it plans to execute an entire new power plant project in late 2012, using PDMS right from the start, from the first plant layout and through all stages of layout and detailed design, including piping, ducting, equipment, electrical, instrumentation and structural disciplines.Outstanding ability'Moving from 2D to 3D has considerably shortened our design times and greatly improved the quality of our design and construction information,' said Mr Nath. 'PDMS's ability to generate clash-free designs is outstanding; it saves us a lot of time and money in construction. We have been able to further increase efficiency in the design process, with more concurrent working between the different design disciplines, and the ability to handle much larger quantities of data. Besides, to collaborate on large international projects, it is essential to be using an engineering and design technology that is both state of the art and extensively used in the industry worldwide,' Rohit Nath concluded.AVEVA is one of many international companies which take advantage of India's high levels of skills to improve their own competitiveness. It is particularly pleasing to be able to return the compliment by helping India's own industries to reach their full potential with the best available tools. We look forward to a long and successful involvement with this dynamic country.About the Desein Indure groupThe Group has over 1,800 staff, consisting of specialists, engineers, CAD technicians and other supporting staff, covering all engineering disciplines, with extensive experience in planning, engineering, procurement, project management, construction, commissioning, and operation and maintenance of power plants to international standards.The Indure Private Limited, incorporated in 1970, is the contracting and manufacturing arm of the Desein-lndure Group. The company is a world leader in the manufacture and supply of complete ash handling systems, having completed more than 230 turnkey ash handling projects for power plants in India and abroad, with a total capacity of over 70,000 MW.Indure is also a leading EPC contractor for complete power plants and balance of plant packages, as well as coal and material handling systems for power and other sectors. The company also offers EPC solutions for solar thermal and PV power plants in association with well-known international technology providers and EPC contractors. With two large manufacturing units, the company provides a one-stop-shop service, comprising pattern shop, fully automatic foundry with induction furnaces, CNC-based machine shop, fabrication shop with CNC plasma cutting machine and assembly shop, all under one roof.Desein Private Limited, an IS0-9001:2008 certified company, has been providing specialised engineering services for fossil fuel-based power plants in India and abroad for over four and a half decades. The company provides total engineering, procurement and construction from concept to commissioning for unit sizes up to 800 MW, both super- and subcritical - Rankine Cycle for steam turbines and Brayton Cycle for gas turbines in combined cycle mode. It has, to date, undertaken more than 140 engineering assignments with a total power generation figure of over 32,000 MW.Desein is currently providing complete operation and maintenance services to five power stations, including the first coal-fired power plant in the UAE. The company also carries out environmental impact assessment studies and suggests measures to contain, within permissible limits for environmental protection, pollution arising out of new projects.Desein provides multi-disciplinary engineering skills to bring together civil, structural, architectural, mechanical, electrical, instrumentation and controls and environmental engineering to provide a composite deliverable. Visit www.desein.com for more information.Rohit Nath, General Manager for the 3D Plant Design Division of Desein Indure speaking at the 2011 AVEVA World Summit in Singapore.www.aveva.com/45years