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Overview
• Engineering team
• Process Engineering
• Piping Engineering
• Mechanical Engineering
• Project and Systems Engineering
• Welding Engineering
• General Services
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Engineering Team
Management of projects and the design and construction and servicing of energy and process
plant facilities throughout Africa. Expertise encompasses major power utility projects, owner-
operator facilities and construction projects
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Process Engineering
Manager: Juan Gerber Pr.Eng
Email: juan.gerber@babcock.co.za
Office: 011 601 1016
Cell: 083 678 8222
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Babcock Process Engineering
• Boiler and steam plant thermal engineering
• Boiler thermal design and analysis:
• Pre-feasibility and feasibility, FEED, concept, basic and detail
design.
• Combustion, boiler, airheater, mills, fans, pumps, valves.
• Coal, biomass, waste, liquid fuel, etc.
• Pulverised fuel, stoker, bubbling fluid bed, waste heat.
• Boiler performance modelling: Validation/Calibration, sensitivity
analysis, Monte Carlo simulation.
• CFD & Flownex
• Full boiler 3D CFD to detailed component 3D CFD.
• System simulations with Flownex, such as complete CW system
simulation.
• Data analysis
• Coal history statistics.
• DCS data event identification, statistics and consolidation.
• Start-up, shutdown and load change assessment.
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Piping Engineering
Manager: Elbert Cilliers Pr.Eng
Email: elbert.cilliers@babcock.co.za
Office: 011 601 1104
Cell: 083 554 2097
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Babcock Piping Engineering
• Boiler and steam plant piping design engineering
• 3D Scanning, Piping Layout and Routing
• Line sizing (pressure drop calculations)
• Valve specifications
• Pressure part design to international standards (EN and ASME)
• Isometric, layout, general arrangement and detail drawings
• Stress Analysis
• Stress and flexibility analysis for code compliance
• Incident investigations (Steam/Water Hammer, harmonic, etc…)
• Cold pull simulation
• Restraint and balance erection analysis
• Support sizing
• Maintenance
• Construction method statements, rigging studies and simulations
• Restraint and balanced erection engineering
• Support and elevation surveys
• Plant life extension studies
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Babcock Piping Engineering
• Project Example for Boiler and steam plant piping design
engineering
• Matimba main steam system redesign and replacement
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Babcock Piping Engineering
• Project example for Stress Analysis
• GNPower (Philippines) – Main condensate line vibration analysis
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Babcock Piping Engineering
• Project Example for Maintenance
• Support and Elevation surveys
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Mechanical Engineering
Managed by: Madoda Ndembe Pr.Tech.Eng
Email: Madoda.ndembe@babcock.co.za
Office: 011 601 1025
Cell: 083 206 4456
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Mechanical Engineering
• Mechanical Design
• Boiler pressure parts to ASME and BS EN
• General Arrangement and detailed fabrication drawings
• Refurbishment of boiler plants & pressure vessels
• Hot and Cold Structures
• Flues, Buckstays, Boiler casings
• Boiler supporting structures, Bins, Ducts, Platforms
• Structural & Boiler Inspections
• Boiler life study
• FEA
• Life prediction regarding creep fatigue life
• Design by analysis
• Design taking in consideration fatigue and creep.
• 3D Scanning
• Accurate capturing plant geometry
• 3D Modelling
• Construction Simulations
• Reverse engineering : Create drawings from 3D scanning
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Mechanical Engineering
• Project Examples
Sec Reheater Design by Analysis Sec Reheater Design by code
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Mechanical Engineering
Lethabo Maintenance Ducting
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Mechanical Engineering
Hendrina PF Piping
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Mechanical Engineering
Hendrina Burner Manipulation scan
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Project & Systems Engineering
Manager: Etienne Wannenburg Pr.Tech.Eng
Email: etienne.wannenburg@babcock.co.za
Office: 011 601 1186
Cell: 082 210 1331
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Project & Systems Engineering
• Lifecycle of the project
• Subsystems and system as a
whole
• User requirements and
specification
• Planning and management
• Critical components
• Risks
• Interfaces
• Concurrent Engineering
• Design Reviews and Technical
Audits
• Engineering contracts
Concept and
Feasibility
Basic Design
Detail Design
Fabrication and
Supply
Construction and
erection
Commissioning
and optimisation
Inspections and
Testing
Maintenance,
repair, overhaul
and asset
management
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Welding Engineering
Manager: Uvesh Gajoo IWE
Email: Uvesh.Gajoo@babcock.co.za
Office: 011 601 1034
Cell: 083 318 6693
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Welding
• Welder Qualification and Training
• Development and qualification of weld procedures
• Exotic materials
• Repair methodologies
• Construction methodologies
• Lethabo Steam Penetrations
• Matimba Main Steam Replacement
• SAIW support during construction and outage work
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Welding
21CrMoV5-7
X10CrMoVNb9-1
14MoV6-3
1
2
3
4
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Welding
• Welder Qualification and Training
• Development and qualification of weld procedures
• Exotic materials
• Repair methodologies
• Construction methodologies
• Lethabo Steam Penetrations
• Matimba Main Steam Replacement
• SAIW support during construction and outage work
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Welding
• Research and Development
• Orbital Welding
• Big Bore
• Small Bore
• Voice activated welding equipment
• Rice paper alternatives
• Smaller TIG Torches
• Specifically designed grinding media for Matla and Lethabo scale removal
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General Services
Service delivery projects include ........
• EPC contracts
• Life Extension Studies
• Efficiency improvements
• Technology and Capacity upgrades
• Emission reduction
• Control system audits and upgrades
• Maintenance repair and overhaul
• Boiler inspections
• Boiler orientation models
