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CASE STUDIES
Boiler Shell Layout Design Automation for Global Boiler Manufacturing
Giant
Design Automation proved a Game Changer in Time and cost reductions
Client Background
The Client has been in the business of building steam engineering and control instrumentation solutions that work for process industry. Started with steam generation solutions 50 years ago, today it has partnered with the world technology leaders in respective fields, manufacturing products that cover the entire spectrum of energy generation, energy efficiency, control and instrumentation for the process and power industry.
Pre-implementation Status
One of the client’s product varieties include “Shell tube Boiler” which are heavy and giant Industrial Boilers.
The design process of these huge structures involve various complex logics and calculations such as Sinking time calculations, Steam space calculations, Shell Design Calculations, Tube Plates thickness calculations, 1st Pass Tubes & 2nd Pass Tube calculations, etc.
Carrying out entire design process manually was challenging as it required optimizing the Boiler shell diameter and layout as there are several shell tubes and other components that goes inside a boiler shell.
Need Analysis
Product Complexity:
The client manufactures Shell Tube Boilers, which are large-scale industrial boilers used for various applications.
Due to their heavy-duty nature, these boilers require precise engineering to ensure optimal functionality and durability.
Challenges in Optimization:
The Boiler Shell Diameter and layout configuration posed significant design challenges.
The boiler shell houses numerous tubes and internal components, requiring strategic arrangement to maximize efficiency.
Manual iterations in layout design resulted in inefficiencies, leading to delays and increased labor costs.
Need for an Automated Solution:
To eliminate manual iterations, an automated design solution was required for boiler shell layout optimization.
The automation process would ensure precise calculations, reducing errors and improving overall design accuracy.
A well-integrated system would enhance efficiency, allowing faster production and improved operational performance.management.
PARAM Team analyzed the design process at the Client’s plant, and with its proven ability, proposed a Software Solution for Design Automation of Boiler Shell Layout.
Our Solution: GA Layout & Base Frame Drawing Automation
PARAM developed a customized Design Automation Solution for Boiler Shell Layout Optimization which does all the complex calculations based on the Design logic, optimizes the Boiler Shell Layout Diameter, and even produces variety of critical Design Outputs such as Excel BOM, SAP Ready BOM, Tube Placement, Boiler Shell Elevation showing all accessories connected on it, Weldment Drawings, etc.
Process Flow:
Automated Calculations for Shell Layout:
Sinking time calculations
Steam space calculations
Shell design calculations
Tube plate thickness calculations
1st pass & 2nd pass tube calculations
Determination of Initial Shell Diameter:
The software computes the initial boiler shell diameter based on the above calculations.
Optimization & Validation Process:
The PARAM Team’s logic is applied to strategically place the required number of tubes within the boiler shell.
The software optimizes the shell diameter and verifies water head and volume for the given diameter.
If parameters do not align, the shell diameter is recomputed until optimal results are achieved.
Software Outputs:
Drawings: Optimized boiler shell layout, tube placement, boiler shell elevation, and weldment drawings.
BOM: AutoCAD BOM, Excel BOM, and SAP-ready BOM in CSV format.
OUR SUCCESS STORY
Time Savings: Significant reduction in design time.
Cost Efficiency: Optimized shell diameter reduces raw material costs.
Productivity Boost: Faster design order cycle time enables handling more projects and increasing business.