Plant Engineering Services

Gladius Technologies offers comprehensive Plant Engineering Services. The primary aim is to contribute in the growth of sectors like; Oil & Gas, Petrochemical, Refinery, Process, Power, Utility (Water and Waste Water Treatment), Fertilizer, Food & Pharmaceuticals Industries. Our design team involves well trained & experienced professionals (senior design engineers, draughtsman) with an up-to-date knowledge of the latest design codes & standards used worldwide. Major International Codes and Standards used in General Practice but not limited to;

ASME B31.1 / 31.2 / 31.3 / 31.4 / 31.8 / 31.9 l ASME Section VIII, Div.1 / Div.2, API STD-650 / 620 / 2000 l TEMA l PD-5500 l BSEN 10025 l BS5950 l BS8110 l IS456 l ACI 318 l IS800-1984 (WSM) l IS800-2007 (LSM) EURO CODE 3 l AS 4100 l UBC etc.

Reference Books & Various Company Standards

BASIC ENGINEERING DESIGN (BED), FEED, P&ID & PFD

  • Preparation of Process and Instrumentation Diagrams (P&ID), PFD
  • Sizing of Main Equipment Resulting in Process Specifications, Definition of Control and Safety Devices
  • Mechanical Data Sheets of The Main Equipment, Process & Thermal Design (Equipment)
  • Development of Process and Utility Piping and Instrument Diagrams Released for Detail Engineering
  • Development of Detailed Drawings Related to Instrumentation, Electrical Facilities, Civil & Structural Works
  • Plot Plan, Equipment Layout & Piping Study
  • Piping GA Drawings & Piping Routing, Piping Isometrics & Support Drawings
  • 3D Modeling Services-Equipment Modeling, Civil, Structural/Building Modeling, Piping Modeling, Pipe Rack Modeling, Electrical Raceways Modeling, Support Modeling

 

MECHANICAL DESIGN & ENGINEERING

  • Basic Engineering Design (BED), Front Engineering Design (FEED), Preparation of P&ID, PFD
  • Mechanical Design & Engineering
  • Civil & Structural-Design, Analysis & Engineering
  • Electrical & Instrumentation (E&I) Services
  • Piping Stress Analysis (Thermal & Flexibility)
  • 3D Modeling by using Various Software
  • Equipment Design, Analysis, Detailing-Pressure Vessel, API
  • Storage Tanks, Heat exchangers, etc.
  • Skid Design & Engineering, As Built Drawing Preparation
  • Erection & Commissioning Services
  • Staffing Services – Onsite Deputation of Engineers / Draughtsman

 

CIVIL & STRUCTURAL- DESIGN, ANALYSIS & ENGINEERING

  • Static Load, Wind Load, and Seismic Load Analysis
  • Dynamic Analysis of Structure and FEM Analysis
  • Preparation of Load Data, Design of Supporting Structure, Plant, and Process Buildings
  • Engineering for Piping & Ducting Supports, Conveyor & Pipe Rack Supports
  • Design of Steel Chimney, Chimney Foundation, Fan Foundation, Bag Filter, etc.
  • Structural Steel Detail Fabrication Drawing, BOM/MTO
  • Boiler House, Turbine House Buildings, Storage Sheds, PEB Design
  • Reinforced Concrete Framed Structures, Equipment and Machinery Foundations Drawings
  • Concrete Storage Silos, Large Diameter Storage Tank Foundations
  • Cable and Pipe Trenches and Tunnels, Roads, Pavements, Grading Plan and Drainage Systems
  • Gates, Compound Walls, and Fencing

PIPING STRESS ANALYSIS (THERMAL & FLEXIBILITY)
Pipe Stress Analysis for Onshore and Offshore, Power & Process Piping

  • Pipe Stress and Flexibility Analysis for Metallic & Non-Metallic Pipes (Effects of Thermal Loads, Occasional Loads such as Hydrostatic Test, Safety
  • Valve’s Reaction Force, Seismic, Wind & Sustained Loads
  • Vibration Analysis, Steam & Water Hammer, Sea Wave Load Spectrum, Safety Valve Reaction Force
  • Stress Analysis of Piping Connected to Strain Sensitive & Stationary Equipment e.g. Turbine, Pumps, Boilers, Compressors, Tank, Pressure, HP/LP Heaters, Deaerator, Vessels, Drums, Columns etc.
  • Critical Piping Support – Calculation, Designs e.g. Constant and Variable Spring Hangers, Studs, Rod Hangers/Bottom Support
  • Load Calculation for Pipe Support, Spring Hanger Data Sheets, Plates, Inserts & Loading Drawing (Input to Civil)
  • Calculation Of Spring Stiffness, Thrust Force of Expansion, Hydraulic Calculation, Surge Analysis, CAE, CFD & Design Validation
  • FEA – Piping Equipment or Special Fittings, Nozzle Flexibilities, Allowable Nozzle Loads, Stress Intensification Factors, Flange Leakage Calculation

EQUIPMENT / TANK- DESIGN, ANALYSIS & DETAILING

  • Mechanical Design of Pressure Vessels, Tanks, Distillation Columns, etc. includes – Design Pressure Vessels (ASME SEC VIII Div 1 & 2, PD5500 etc.) & Design Tanks (API 650, 620, etc.)
  • Thermal & Mechanical Design of Heat Exchanger, Mechanical Data Sheet Preparation, GA Drawing
  • Strength Calculation by using In-House Programs/ PV ELITE
  • Detail Design Calculations for Process Equipment for Industries
  • Preparation Detailed/Fabrication Drawings, BOM, CFD Analysis, Finite Element Analysis (FEA)
  • Pressure Vessel & Tank FEA
  • FEA as Per ASME-Section VIII-2, FEA Analysis in Hydrostatic Loading
  • Buckling Simulation
  • Structural Integrity as per API/IS
  • FEM Analysis of Welded Structures & Silo
  • Design of Mounded Bullets, Agitators, Filters
  • Heat Exchangers (Shell and Tube Type): As per ASME Sec VIII Div 1-part UHX, TEMA, EN- 13445 & PD -5500
  • Underground and Above Ground (Single Wall Double Wall) Horizontal Storage Tanks as per UL- 58, EN 12285-1 & EN 12285-2
  • Design and Detailing of Flare Steel Stack: ASME Sec VIII Div.1 + STS 2000

3D MODELING USING VARIOUS SOFTWARE

  • 360-degree views for Piping, Equipments, Cable Trays, Steel, Concrete Structures, Pipe Rack, Electrical Raceways, Supports for Interfering/Clashing Detection & Mitigation
  • Robust 3D Designs to Optimize Project Schedule with High Accuracy of Detailed Engineering
  • Multiple Software Tools Available
  • Animated Walkthroughs to Help Communicate & Visualize Design for End Customers
  • Reviews are Performed i.e. Typically at 30%, 60% & 90% with Clash Detection Report to Resolve Clashes & Exact Views of Plant for Operation, Safety & Maintenance
  • Higher Quality Control Across All Disciplines

 

SKID DESIGN & ENGINEERING

  • High-Quality Engineering Services for Complete Skid Design, Detailing, Stress Analysis, Structural Analysis
  • Complete Fabrication Drawings for Skid Structure, Piping Spools, Piping Supports, MTO Specifications for Hanger Type Supports (If Required by Piping Stress Analysis)
  • Optimize Skid Costs, By Reducing Unnecessary Costs & Ensure Sufficient Stiffness (At Key Locations) to Avoid Vibration Problems for Components Mounted on The Skids
  • Overall Skid Layout to Minimize Site Erection Time and Cost
  • Layout Optimization for Proper Access & Operation with Equipment/Fittings Engineering to Suit Skid Mounting and Operation
  • Skid Environmental Load & Transportation Analysis
  • Skid Optimization, Skid Dynamic Analysis
  • FEA Analysis of Skid Stress
  • Skid Mounted & Modular Pilot Plant Design, Detailing, Analysis
  • Skid Design will Comply with International Standards (ABS, API, AISC) & Customer Specifications
  • Ensure Safe Lifting, Transportation & Operation
  • Manufacturing Support

 

ELECTRICAL & INSTRUMENTATION SERVICES

  • Preparation of Project Specification, Load Flow Studies, Motor Specifications & Datasheets, Plant – Wide Power Distribution Drawings
  • Cable Tray/Trench Layouts, Earthing Layouts, Cable Routing Layouts, Lighting (Indoor/Outdoor) Layouts, Motor Control Centre Design
  • Complete Electrical Projects Design, Detailing and Execution, Installation, Testing and Commissioning Work
  • Instrument – Schedule / List, Specifications & Datasheets
  • Plant Operation & Control Philosophy, PLC/DCS Control Loop Narrative
  • Control System (PLC / DCS) Design & Execution, Block Logic Diagrams
  • Interlocks List, Alarms & Trip Schedule, Instrument Hook-up & Standard Installation Drawings, Cable Schedule, Instrument Locations
  • Design, Detail Engineering, Supply, Erection & Commissioning of DCS, PLC & SCADA based Automation as per Consultant/Customer Requirement

AS BUILT DRAWING SERVICES

Complete Range of As-Built 3D Modeling Services for Piping, Structures, Equipment, HVAC, Electrical & Instrumentation.

  • Creating Intelligent “As-Built” 3D Models from the Physical Plant using 3D Laser Scanning Services
  • As-Built Drawing Documentation provides the ability to review & upgrade facilities without physically visiting the location
  • Capturing Construction Deviation from Construction Documents
  • Generate Photo-Realistic Rendered 3D Models with Walkthrough Animation
  • As-Built Drawing through Actual Measurement of Construction

 

PMC, ERECTION & COMMISSIONING SERVICES

Through our Specialized & Experienced Indian / Overseas Associates having Team of Welders & Fabricators along with Engineers ensure successful

  • Erection & Commissioning of Equipment, Storage Tanks
  • In-house & On-Site Fabrication, Erection & Installation of all kinds of Piping: Industrial, Commercial, IBR, Non-IBR & all Utility Piping
  • Erection, Testing & Commissioning & Handing Over Of HP/LP Piping for Power Plant
  • Erection, Commissioning of Pressure Parts, Economizer Elements & Complete Economizer
  • PEB & Steel Erection Services
  • Erection of Chimney, Buffer Tanks & Day Tanks, Structural, Ducting, etc.
  • Fabrication, Erection & Installation of all kinds of Structures, Buildings, Scaffolding
  • Insulation & Cladding Works
  • Heavy Structural Steel Fabrication & Erection work, Like Column, Tie Beams, Bracing
  • Installation of Crane Girder for TG building, Coal Bunker, Boiler etc.
  • Installation of Equipment for Thermal Power Plant and Sugar Plant
  • Erection & Commissioning of Turbine
  • PMC Services for Power, Process, Oil & Gas and Water & Waste Water Plants