tecno cad service engineering · mechanics plant sector 12 machine skid modeling 12 gas skid...

Tecno Cad Service Engineering S.n.c. © 2016

2017

Tecno Cad Service Engineering

INDUSTRIAL

PLANT DESIGN

CIVIL

MECHANIC

ELECTRICAL

INSTRUMENTAL

CONTROL SYSTEMS

Tecno Cad Service Engineering S.n.c. © 2016 1

SUMMARY

Introduction 2

References 2

Contacts 2

How to reach us 2

General Information 3

About Us 3

Main activities 3

Development tools 3

Structure 3

Organizational structure 4

Working Areas 5

CIVIL SECTOR 5

Foundations and Earthmoving 5

Industrial buldings 6

GLASS COMPOSITION SECTOR 7

ELECTRO-INSTRUMENTAL SECTOR 8

Documentation example 8

CONTROL SYSTEMS SECTOR 9

Basic engineering of control panels 9

Main Partners 11

MECHANICS PLANT SECTOR 12

Machine Skid modeling 12

Gas Skid modeling 13

Skid Dimensioning 14

Piping stress analysis 16

Structural verification 18

Structural verification: under pressure equipment 19

Structures calculation and check 20

Metallic carpentry 22

Special test bench design 23

AVEVA PDMS/E3D 24

Finite Element analysis (FEM) 26

FEM analysis on alternative compressors 27

Mechanical equipment and components 28

REFERENCES 29


INTRODUCTION

References

Tecno Cad Service Engineering S.n.c.

Via Del Polo Tecnologico, 10 - 57023 Cecina (LI) - Italy

VAT 01139810491

Contacts

Tel: 0586 630128 - 0586 631067

Fax: 0586 632761

e-mail: [email protected]

Website: www.tecnocadservice.com

How to reach us

TCS is situated in Cecina, Via del Polo Tecnologico within an area that includes the “Polo Tecnologico Magona” run by the University of Pisa, Department of Chemical Engineering.

If you're looking at this document in pdf format, you can click on the map below to switch the display on Google Maps.

TCS is 50 km from Pisa International Airport (40 minutes driving) and 30 km from the city of Livorno.

Traveling from the North it is easily accessible along the highway Genova Livorno southbound until “Cecina centro” exit.

www.tecnocadservice.com

https://goo.gl/maps/BScbaHTXbBT2

https://goo.gl/maps/8w1XFvHNes92

https://goo.gl/maps/Vdx4nmuvYKx


GENERAL INFORMATION

About Us

TCS was founded in 1995 by a group of four technicians, as a pure design company, mainly in the field plant mechanical and electro-instrumental. Over the years, it has been significantly developed, with the inclusion of dedicated teams, becoming a company capable of developing multidisciplinary activities, up to reach a staff of over 50 employees. Both total turnover and number of employees are constantly growing even in a period of general crisis in the market.

TCS has a certified economic strength from its budget in surplus continuously.

TCS offices cover an area of about 600 m² where can be hosted any group of customer technicians who would interface with the committed team.

Main activities

Basic and detailed engineering for the following sectors: petroleum, chemical, power generation, heavy industry (glass, steel, concrete).

We are specialized to support our customers who intend to build or modify the production sites, planning for them the infrastructure, services and process plants starting from P&ID developed by the customer.

In some sectors such as glass, Energy, Oil & Gas TCS has experienced staff able to provide the customer with an important support also on process aspects.

Development tools

TCS uses the most modern and powerful calculation tools to address the increasingly complex issues that arise.

Basic and detailed engineering with Unigraphics NX6, PDMS, AutoCad modeling.

Stress analysis, structures sizing, FEM analysis (static, dynamic, harmonic, fatigue, thermal) by SAP, Caesar II, Ansys, Hypermesh.

Electrical: Ampère and other software designed for the classification of Atex areas and protection against lightning.

Instrumentation: Software for sizing control valves.

Control systems: development systems for PLC/DCS Siemens, ABB.

Structure

TCS organizational chart is shown on the next page. TCS has a flexible structure aimed at meeting customers and contracts that vary from year to year both in size and production times. In case of important multidisciplinary engineering orders a technical team is formed and it is overseen by a project manager who coordinates all activities involved in the specific project. A special area for the team can be also reserved.


Organizational structure

ADMINISTRATION – BUSINESS CORE

DE MASTRO, PANTANI, BINI

BUSINESS & TECHNICAL ACTIVITIES

CAPPELLI, CARDUCCI

SUPPORT

AMIDEI, MECCARIELLO

PIPING STRESS ANALYSIS – CALCULATION – PROGRAMMING

ROSSI, FRANCHI, CARDELLI, BARTOLINI

MECHANICAL PLANTS – VESTIZIONE MACCHINE

MANCINI

SERVICE: RIBECHINI, BULLERI, VOLTERRANI, TUCI

MT/CO: SAMARITANI, FANFANO, FANTI, RIGHI

DE SANTIS

TU/WA: CRECCHI, BARSOTTI, BELLONI, LACETRA

PDMS ADMIN: SCARCIOLLA, AGOSTINI, CONFORTI, CARLOTTI

MECHANICS FF

LESSI M., MANCIULLI, MNUTI, PRETOLANI, LESSI L.

MULTIDISCIPLINARY PLANT DESIGN

CARDUCCI, GUERRIERI, PIGHETTI, MINIATI, TADDEI, VALENTI, BASSI, PRIORESCHI

FEA ANSYS

PANICCIA, PUCCINELLI, BRUNORI, ACERRA

AUTOMATION & CONTROL

DI PIETRO, BACCIARELLI

FGS & SGP ROSI

PO/CE: MARCACCI, FUSAROLI, PANTANI

SA.PO. FGS: CORSI, GHILLI, ZUCCHI

SGP: LAGHI, SOLARI, STANCULESCU R., CAROTENUTO

ELECTRO-INSTRUMENTAL CORSINI

SERVICE: STANCULESCU D., ORIGGI, SARDEGNOLI

CO/AL: BERNARDINI, CACCAVALE, GROSSO

EM/ST: DE LUCA, LONI

SYSTEM

ZINIO, MANFREDINI, FALASCHI, CLEMENTI, FAVILLA


WORKING AREAS

CIVIL SECTOR

FOUNDATIONS AND EARTHMOVING

Industrial halls designing both with pre-stressed concrete structures and steel.

Earthmoving design and definitions.

Geotechnical study.

Foundation works in reiforced concrete.

Concrete structures.

Steel structures.

Architectural design of buildings or industrial infrastructure.

C I V I L S E C T O R


INDUSTRIAL BULDINGS

Biomass Storage Buildings.

Buildings for turbines installation.


GLASS COMPOSITION SECTOR

New weighing chamber of F400A Saint Gobain line (Saint Roch – Belgium), realized during 2006.

WEIGHING CHAMBER LAYOUT


ELECTRO-INSTRUMENTAL SECTOR

DOCUMENTATION EXAMPLE

Protections and electrical cables sizing.

Electrical interconnections.

Cable racks/Cables routing.

Electrical and pneumatic connections (primary and secondary).

Instruments and cabin layout.

Materials list and documentation.

Specifications & Data sheet.

I / O List.

Dimensioning of CV / PSV / FE.

Safety Loop.

Field Bus / Profibus architecture.

Automation function diagrams.

Cabin Engineering.

Electrical Planning, BT and DL. 37/08 verification.

Planning with SMART PLANT Instrumentation (INTOOLS).

Materials list.

Purchase specifications.

RDO & suppliers follow-up.

Feasibility studies.

Specialists in the use of software such as SPAC Automation, EPLAN Electric.


CONTROL SYSTEMS SECTOR

BASIC ENGINEERING OF CONTROL PANELS

Steam turbines + Centrifugal compressor or electric generator.

Electric motor + Centrifugal or reciprocating compressor.

Turbo-expander + Centrifugal compressor or generator.

The basic definition of a control panel (UCS, Unit Control System) is divided through the following main activities:

Schematic Realization (AutoCAD or Visio) that defines the main components of the control system and their interconnections, which is serial hardwired (Control System Schematic).

Unit Control System Layout: CAD drawing for the definition of size, access, carpentry and positioning of the components inside the control panel.

UCS I/O List: signal list from/to field customer systems (DCS, ESD, CCM, etc .) and cabin internal signals for I/O cards sizing of the PLC.

Definition of the vibration monitoring system and overspeed protection and its specific purchasing.

C O N T R O L S Y S T E M S S E C T O R


Basic engineering of control panels (cont.)

Functional Description: textual description of the control system operation.

Cause&Effects chart: creation of a table showing the effects on the control system by certain causes, such as interlock of pressures or temperatures that cause pumps or heaters activation.

Definition of the interconnections between the control framework in the field and junction boxes and other account executives (DCS, MMC, ESD) and relative cables list.

Considering the results of the activities described above, the logic of PLC programming dedicated to the control of the system through functional logic diagrams are defined (sequences start, normal stop, emergency shutdown, auxiliary sequences, turbine speed regulators, anti-pumping compressor controllers, machine vibration monitoring, alarms sequences and blocks).

C O N T R O L S Y S T E M S S E C T O R


MAIN PARTNERS

C O N T R O L B U I L D E R F & P L U S

T I A P O R T A L


MECHANICS PLANT SECTOR

ENGINEERING SERVICES FOR OIL FIELDS, CHEMICAL/PETROCHEMICAL AND POWER GENERATION

3D Unigraphics NX6 WORKS

MACHINE SKID MODELING

Centrifugal compressors.

Gas turbines.

Steam turbines.

Oil units.

Basements, piping, structures, equipment, civil.

2D drafting.

Piping plant development.

Supports plants development.

Isometrics.

Materials list.

Valves list.

Stress Analysis.

M E C H A N I C S P L A N T S E C T O R


GAS SKID MODELING

Basements, piping, structures, equipment, civil.

2D drafting.

Piping plant development.

Supports plant development.

Isometrics.

Materials list.

Valves list.

Stress Analysis.

Structural Analysis.

Lifting check.



SKID DIMENSIONING

Skid mounted pipes Stress Analysis.

Carpentry check.

Foundations tie-rods check.

COMPRESSOR SKID GENERAL ARRANGEMENT



Skid dimensioning (cont.)



PIPING STRESS ANALYSIS

A first-level analysis on the entire pipe is performed by the CAESAR II calculation tool.

A second-level analysis is performed by the Fem Ansys simulator within the most critical points for the calculated voltages.

It is reported in example a piping line and the detail of Fem analysis performed on a flange .



Stress analysis su piping (continua)

Plant piping systems analysis.

Piping systems analysis “on board”

Standard and special supports planning.

Underground and on-rack piping design.

Static analysis (natural gas pipe, HP vapour, chemical and petrochemical plants) according to ASME B31.x regulations.

Dynamic analysis (earthquake, hammer hit, etc.).

API617 verifications (loads on nozzles of centrifugal compressors).

API610 verifications (loads on nozzles of pumps).

ITK21305 verifications.

Seal check of flanged couplings (Kellogs, ASME).

Software used Coade CaesarII v.4.40 → v.5.10

(Algor pipepack v.8, v.16)

(Bentley Autopipe 2004, XM)



STRUCTURAL VERIFICATION

Structural inspections and dimensioning of civil and industrial carpentry.

Analysis by main verification codes.

Optimization of the profiles to minimize weight and cost.

General Arrangement implementation and carpentry.

Assembly drawings.

Feasibility studies.

Workshop brands drawings for installation.

Materials list.

3D MODEL - STRUCTURE OF THE INTAKE DUCT SUPPORT AND FILTER-HOUSE EXHAUST

TRUSS FOR TV RELAY STATIONS



STRUCTURAL VERIFICATION: UNDER PRESSURE EQUIPMENT

Under pressure side sizing.

Tubeless shell or plate heat exchangers sizing.

Structure and under pressure side design for columns, equipment, condensers, recovery systems, pre-heaters, vaporizers.

Atmospheric tanks designing (according to API e BS) and related piping designing (according to ASME/ANSI).



STRUCTURES CALCULATION AND CHECK

Structure analysis (buildings, piping rack, racks) for carpentry.

Analysis of skid lifting.

Design and verification of foundation bolts.

Structural sizing.

Verifications according to UBC regulations.

Verifications according to EUROCODEs regulations.

Audits according to all the italian standards (new standards for construction, UNI 10011, etc.).

Environmental audits according to local regulations (French, English, Arabian states, North African states, etc.).

Software used: CSI SAP2000 v.10, v.11 (Tecnisoft Modest)



Structures calculation and check (cont.)

Dimensioning and optimization of carpentry profiles used to reduce costs.

The preliminary structure is created using 3D structural analysis software (SAP 2000).

The structure then is charged according to the customer’s specifications and reference standards, so the coefficients of exploitation of the individual beams are checked and their profiles are optimized. The overall weight of the structure is reduced.

This reduction of weight results in an optimization of the offer for the ITO phase and in a reduction of costs for the OTR phase.



METALLIC CARPENTRY

Carpentry developing, assembly and workshop drawings.



SPECIAL TEST BENCH DESIGN

SPECIAL TEST BENCH (NP MASSA)



AVEVA PDMS/E3D

Catalogues and specifications management.

Isometrics customization.

2D customization.

Machine base modeling.

Piping modeling.

Supports modeling (MDS).

Plant piping and supports location development.

Supports tables development (ADP/AREA).

Isometric book creation (Spooler).

PACKAGE STEAM TURBINE



AVEVA PDMS/E3D (cont.)

TABLE OF LINES DRAWN FROM PDMS/E3D

STORAGE SILO FOR SODA



FINITE ELEMENT ANALYSIS (FEM)

When the criticality of the service requires it, an harmonic finite element analysis is performed on the structure and collectors connecting cooler to piping system. The analysis is performed using ANSYS.

Depending on the customer requests, it’s possible to realize 3D models of the structures and individual components using solid modelers such as Unigraphics, SolidEdge or SolidWorks.



FEM ANALYSIS ON ALTERNATIVE COMPRESSORS

MODAL ANALYSIS: the results of system’s vibration modes

PRESSURE AND TEMPERATURE: temperature stressed boiler and results



MECHANICAL EQUIPMENT AND COMPONENTS

Modeling and development of mechanical components (pumps, impellers, model tests, etc.).


REFERENCES

SAINT GOBAIN

Branche Vitrage (Plate glass) Since the late 80s through 90s TCS staff has had an ongoing relationship with the International Technical Directorate of Paris (Auberviller) for the design and implementation of all Float lines both new and revamping realized in that period.

Branche Imballage (Hollow glass) TCS staff has participated in the design of the 400 tpd line of Villa Poma, the two Lonigo lines (an oven with a head burners and the other with transverse burners).

In more recent years (2014/15) TCS realized the design of systems related to the furnace cooling circuits and compressors (7 bar) with Verallia Company.

TCS staff participated to the supervision of the electrical and fluid engineering part of the float line in Colombia.

San Galli Vetro TCS staff participated to the design of both float lines, in relation to the basic engineering, for the Manfredonia line (1999) and the complete design of utilities, electrical and control of “San Giorgio di Nogaro” line (2010). It included the assembly oversight and the commissioning direction.

Zignago Vetro (Hollow glass) Field instrumentation design on the Hot End for Oven revamping (Empoli 2014).

AGRIPOWER

TCS staff created and coordinated the design of a biomass plant (15 MW) in collaboration with AET supplier of the boiler. The design includes civil works, mechanical and electrical works.

Ecoespanso TCS staff participated to the design and implementation of an energy power plant (about 2 MW) with heat recovery from the gases emitted from a sludge incinerator (2010).

CEMENTO

TCS staff was a manager at a large italian multinational cement producer for technical direction.

BREDA

Construction and assembly of rail truck and buses.

SARPLAST (Vetroresina, GRP, Prfv)

Piping plant , construction isometrics carrying materials list and supports.

R E F E R E N Z E


SOLVAY CHIMICA ITALIA S.p.A.

Engineering for wastewater sludge treatment.

Leonardo project: loop diagram (Intools).

San Carlo: wagon’s load automation.

ALSTOM FERROVIARIA

Dynamic FEM calculation for investigation on recurring breaking causes of a rail car component.

GENERAL ELECTRIC (Nuovo Pignone)

Firenze, Massa, Bari, Vibo Valentia (continuous collaboration)

Power Generation – basic and detailed engineering

(multidisciplinary: mechanical plant, electro-instrumental and control system)

Turbogas (Gas Turbines + Electric Generator).

Turbo compression (Gas Turbines + centrifugal compressors).

Steam turbines.

Compressors.

Turbo-expander.

Skid gas treatment.

Gas-tight panels.

DANIELI AUTOMATION

Orders DUNAFERR, MMK, SANGAN, MARCEGAGLIA, TEZCAN

Electrical systems engineering for rolling mills and hot dip galvanizing.

DANIELI ENGINEERING

DANIELI ENGINEERING KSC (PDMS) (sub-contract)

Water treatment, compressor room, laboratory, external distribution, fire prevention system.

PDMS modeling.

Caesar II piping stress analysis

DANIELI ENGINEERING - TRIERER STAHLWERK GMBH (PDMS) (sub-contract)

Water treatment, compressor room.

PDMS modeling.

R E F E R E N Z E


T.M.E.

Post water treatment plant for industrial use in Rosignano solvay

Pipe plants, supports and isometric drawings.

Incinerator plants of “Casal Borsetti (RA)”, “Granarolo (BO)” and Lecco

Pipe plants design, supports and isometric drawings.

Water treatment plant of Alon Tabor

Piping layout and supports.

VATECH ESCHER WYSS (sub-contract)

Premadio II plant: hydroelectric plant in cave

Piping plant development and isometrics.

METANO IMPIANTI

Compression Skid gas.

Development of pipelines, isometrics, foundations, MTO, carpentry and metal structures.

TERMOKIMIK

Water treatment plant with piping development, isometrics, supports and relative material lists.

LA TOSCANA IMPIANTI

Audits, design and realization of shop drawings of boiler (pressure vessels, columns, heat exchangers, etc.)

ABB

Gas-pipeline Pedro Duran Farell

Pipelines plants development with associated isometrics and supports.

GPDF gas compressor station - Algeria

SAIPEM

Pipe coupling system “castoro 2”

Pipelines development.

PROCTER AND GAMBLE

Drawings for facility expansion, carpentry and piping.


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Tecnologico, 10 - 57023 Cecina (LI). Content and images included in this

document are the property of Tecno Cad Service S.n.c. and it is not permitted

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