The Heris HRSG is one of the biggest systems installed in Iran and all other countries in that region.
The operational weight of the HRSG is around 5,000 tons and this system is installed in a region with severe seismic activity (spectrum plateau at 0.75 g). Moreover, the plant is at a high level over the sea and subject to snow and high-speed winds (182 km/h of wind base speed).
CUBE srl work covers all the design process of main and secondary structures starting from a general arrangement of the customer, writing the design criteria, modeling all parts through to shop drawings of them.
As our standard workflow, the Tekla database is at the center of the process. Information from the calculation team is immediately checked in the model but also some significant components, as structural nodes, are initially modelled in Tekla, with the aid of the structural engineer, and then verified with codes and eventually re-modeled, if necessary.
We continuously exchange data and models with the contractor through a large set of ifc, dgn, tczip files.
Special challenges
Together with our client, we defined the design criteria and then realized a gross model in SAP2000 for studying structural solutions for this critical system. Proceeding at the same time with a Tekla model, we checked constructive issues of the calculation model. In fact, forces were very high, about 1,700 tons in each diagonal element, but mass budget and geometrical constraints were really restrictive.
Another remarkable point is the high level of detail requested compared to the overall dimension of the system.
For the first time, we decided to model each single part of the internal system including thermal insulation components and also pins, studs, and each small component installed inside. That means thousands and thousands of parts.
What made the project successful?
The remarkable point is about the high level of detail requested compared to the overall dimension of the system. We realized a Tekla model with more than 115,000 parts. Each external and internal detail has been modeled and checked in order to prevent interferences and also installation problems. Each phase involved a structural engineer for estimating the consequences of choices and we sent a weekly bill of materials and 3D models to the contractor which had continuous control and information about the status of the work.
At this time, HRSG casing is under construction and we have received only some comments about annotations style or general notes.
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