When it comes to steam generation, Babcock offers a broad base engineering expertise which covers the entire engineering cycle from technical process definition and design, through detailed engineering in mechanical, electrical and instrumentation disciplines enabling us to deliver a comprehensive design and engineering service tailored to our customers’ business requirements.
Our design and engineering team operate in conjunction with our manufacturing, fabrication, construction, project and site implementation teams via integrated management processes to offer an assured solution. We also have sophisticated database packages for collating, processing and managing technical data for applications such as inspection strategies, maintenance planning, risk based asset management, relocation projects and configuration management applications in general.
Project management, design, erection and commissioning of new industrial steam generation plant up to 100MW (electrical):
Babcock can either tender to a customers enquiry specification or develop the project from inception, with services such as;
- Overall project management
- Development of detailed owner or user specifications
- Concept and feasibility studies
- Speciality process analyses
- Process and detailed engineering design of industrial steam generating plant and ancillary plant
- Local and offshore procurement
- Site erection
- Plant commissioning
- Integrated project risk management, including safety risk assessments to plant, equipment and personnel
- Weld specification and qualification
- Technical manuals (Operating and Maintenance)
Babcock is a specialist in the design of boilers that can combust multiple and different fuels in its Bubbling fluidized bed furnaces.
Repair and maintenance of steam generation plant and ancillaries:
Babcock performs the following services on a wide range of boiler types and capacities
- Plant inspections
- Scope of work determinations
- Plant wear predictions
- Analysis and balancing of High Pressure pipe systems
- Refurbishment and repair to damaged and worn components
- Speciality and high integrity welding
- Management of plant shut downs
- Safety risk assessments to plant ,equipment and personnel
- Quality assured services
Refurbishment and life extension of steam generation plant and ancillaries:
Babcock carry out specialised analysis, inspect the plant, assess and scope the refurbishment and life extension work in conjunction with, or on behalf of its customers. Babcock has the ability to manage an entire project for the customer with services such as;
- Overall project management of the project
- Development of detailed owner or user specifications
- Identification of plant performance and capacity upgrades
- Concept and feasibility studies
- Speciality process analyses
- Process and detailed engineering design of industrial steam generating plant and ancillary plant
- Local and offshore procurement
- Site erection
- Plant commissioning
- Integrated project risk management, including safety risk assessments to plant, equipment and personnel
- Weld specification and qualification
Manufacture and supply of spares to steam generating plant and ancillaries:
Babcock retains the propriety ownership of all of its boiler plant and can specify and supply all spare part components to customers. Spares are manufactured to original technical specifications.
Specialised steam generation process, engineering analyses and other engineering services:
Our engineers employ a wide range of in-house and proprietary computational and analytical tools such as Caesar 2 pipe stress analysis software, Master Series structural steelwork design package, FlowNex 1D Fluid/Thermal flow calculation software, EFD Lab for 3D Computational Fluid/Thermal flow calculations, etc. Draughting services are catered for by AutoCAD Inventor, CadWorxs and ProEngineer software packages.
These analytical tools can be applied to ad hoc assessment of existing plant performance and condition as well as new supply or plant modification projects.
Operator Training and Development:
Boiler inspection, reports and recommendations
Independent Power projects as Engineering Procurement Construction (EPC) or Developer on Build, Own, Operate and Transfer (BOOT) basis:
Babcock has the experience to package an outsourced power island solution to customers wishing to be independent of the national electricity utility. The solution can be one of several economic models such as EPC, BOO or BOOT. Babcock will work in partnership with financial organisations and other reputed plant OEMs to provide an optimum techno-economic package for customers. Services can include;
- Fuel identification and assessment
- Integrated technical design, supply erection and commissioning
- Participation in environmental permitry or responsibility for such permitry
- Facilitation or responsibility of financial arrangements
- Operating and maintenance contracts
- Negotiation of Energy Purchase agreements
- Negotiation of fuel supply contracts
- Negotiation of waste disposal contacts
Mechanical construction:
Babcock has a long track record in mechanical construction and mechanical maintenance in the petrochemical and metallurgical industries. Babcock also participates in the refinery shut-down projects.
Relocation of decommissioned plant:
Babcock has been involved in 3 major process plant relocations, where the countries of dismantling and re-erection were different. Most recently Babcock dismantled one of its retired boilers and relocated and re-commissioned the plant with the required replacement of obsolete components, refurbishment and life extension that was required. The process includes:
- Overall project execution plan
- Compilation of the plant configuration documentation package
- Process descriptions
- Drawings
- Specifications and part references
- Plant dismantling plan
- Component identification and tracking system
- Scrap and salvage management
- Transportation to new site (if local) or to port of export (if off-shore)
- Erection and commissioning where required