industrial structures
The services of structural engineering for industrial plants have distinct features compared to other branches of the construction industry. In this field, the process engineering and the mechanical equipment which brings this process to life are the main players of the project. The structural engineer has to take into account very demanding requirements in terms of tolerances, huge dead loads, dynamic live loads and corrosive environments. Moreover, every industry (oil, gas, mining, cement, chemical,‌) has its own standards and specific rules which obliges the structural engineer to adapt his design philosophy to the own design framework of the Client/Project. FHECOR Ingenieros Consultores designs all types of structural typologies in all structural materials, adapting the structural concept to the specific requirements of the plant, and always thinking of maintenance and environmental friendly solutions.
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INDUSTRIAL PROJECTS DEVELOPMENT PROCESS BIM Plant Initial Model
Structural Concept
to develop
Preliminary Design
Client
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FHECOR
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BIM INITIAL MODEL reception from the client, including basic structural concept and preliminary main mechanical equipment.
STRUCTURAL CONCEPT development from the initial model, considering the main mechanical equipment supplied.
Structural data extraction from the BIM model, regardless of the mechanical information.
Sending of the Structural Concept to the Client for approval (together with the plant Owner).
BIM Model and Drawings to develop Basic Design
Client
Basic Structural Design
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Reception of comments on the Structural Concept as well as an updated model completed by the GENERAL ARRANGEMENT DRAWINGS (including definitive main equipment and secondary preliminary equipment).
FHECOR
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STRUCTURAL BASIC DESIGN (foundations and superstructure concrete formwork, steel floors and frames). Structural model and drawings sending for the final revision by the Client to get his definitive approval.
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INDUSTRIAL PROJECTS DEVELOPMENT PROCESS BIM Model and Drawings to develop Detailed Design
Client
Detailed Structural Design
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Reception of comments about the structural basic design. Reception of BIM DEFINITIVE MODEL and FINAL MECHANICAL DRAWINGS, including the main and secondary mechanical equipment.
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FHECOR
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DETAILED STRUCTURAL DESIGN (reinforcement re-bars for the concrete structure, connection details between concrete and steel structure,...) considering the technical information sent by the Client in the previous stage. Realization of the DRAWINGS and/or STRUCTURAL DETAILS MODEL (concrete reinforcement and steel joints).
Construction
Contractor
Technical Support to on-site Works
FHECOR
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FHECOR can also supply technical support to the Contractor/Client during the construction development to guarantee the accuracy of the structure erection works, and to optimize the construction procedures.
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BIM Methodology Application The BIM approach to the project development is essential in the industrial plants new projects due to the strong linkage between the different engineering disciplines and the main role that the clashes between the structure and the mechanical equipment play in the design of the buildings. Also, the plant maintenance cost along the years (a big part of the OPEX) can be reduced if the BIM model is well built and managed, and the structural part of the model is not foreign to this focus.
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FHECOR Ingenieros Consultores can manage BIM models coming from the most known Plant Engineering Design software packages of the market (Smart® 3D, AutoPlant®, AVEVA PDMS®, AVEVA Everything® 3D, SolidPlant® 3D, AutoCAD Plant® 3D) and then, importing this models via .ifc files to Tekla Structures, we can perform the initial design of the structure, go back to the plant designer to check the clashes and accuracy of the geometry. Afterwards, once the plant designer has given his approval to the structural concept, we develop the structural calculation and the structure final design.
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ITER, Cadarache, France In southern France, 35 nations are collaborating to build the world’s largest tokamak, a magnetic fusion device that has been designed to prove the feasibility of fusion as a large-scale and carbon-free source of energy based on the same principle that powers our sun and stars. ITER will be the first fusion device to produce net energy. ITER will be the first fusion device to maintain fusion for long periods of time. And ITER will be the first fusion device to test the integrated technologies, materials, and physics regimes necessary for the commercial production of fusion-based electricity. The requirements that all the buildings of the ITER complex have to satisfy are between the most demanding of the construction industry. FHECOR Ingenieros Consultores has designed the structural systems for most of the buildings of the ITER complex, including: • • • • • •
Assembly Hall RF Heating Building Site Services Building Control Building FD-SN Resistors Building Reactive Power Control Building
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Silo design and refurbishment Storage silos and bins are essential structures to store bulk solids for a wide spectrum of industrial plants: cement, mining, food, fertiliser, etc. The quantities of the materials stored can range from a few tonnes to hundreds or thousands of them. Silos and bins can be constructed of steel or reinforced/prestressed concrete and may discharge by gravity flow or by mechanical means. Bins and silos design involves the properties of the bulk material stored, the geometry of the silo/bin and also the discharge mode. In the last years it has been a fact that silos and bins designed and constructed following the requirements of the old standards (previous to Eurocode EN 1991-4) fail with a frequency that is much higher than almost any other industrial equipment. The major causes of silo failures are design errors, construction errors and utilization errors. FHECOR Ingenieros Consultores has developed refurbishment projects for a wide variety of silos and bins, proposing optimal technical solutions that permitted to extend the life of the damaged structures.
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ALLIANCE Refinery, Khabarovsk, Russia The Khabarovsk Refinery Hydroprocessing Project consisted of a major expansion of the existing Khabarovsk refinery, to increase plant capacity, improve performance and address both Russian and international requirements for the reduction of the sulphur content of kerosene and diesel products. FHECOR Ingenieros Consultores was the structural advisor for the expansion Project of the plant that included the installation of a new combined Hydrocracking, Hydrotreating and Hydrogen Units. The work also included associated utilities and offsites, together with the associated upgrades and infrastructure modifications and interconnecting pipe racks.
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LNG tanks, Mugardos, Spain Storage tanks are a significant part of any LNG project cost. There are several basic designs including single containment (with an inner container made of 9% Ni steel able to withstand cryogenic temperatures), double containment (in which an outer container made of concrete provides a second barrier to contain the leaks), and full containment tanks (in which an outer layer made of pre-stressed concrete completely encases the tank to provide a second containment system). FHECOR Ingeneros Consultores designed two double containment tanks with a capacity of 150.000 m3 according to API620 standard, for a LNG storage installation in Mugardos (La CoruĂąa, Spain). In addition, all the foundations and structures related to the process plant were also designed by FHECOR.
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INITEC CEPSA REPSOL Acciona Industrial FCC Cementos Portland Valderrivas Fusion for Energy Adveo/Unipapel
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offices projects
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A team committed to high quality engineering The most important differential value of our work is what our professionals provide. Professional technicians, willing to continue learning every day and eager to always find the best solutions to increasingly demanding challenges. To support them, FHECOR promotes permanent training, maintains close links with universities and professional associations and devotes a significant part of its resources to technical protocols and work policies to guarantee project quality. Senior engineers are actively involved in project development and monitoring, accompanying clients in key decisions.
Fhecor has an Integrated Management System accredited by several international seals: ISO 9001, ISO 14001 and OHSAS 18001
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Three-dimensional project visualization is simplified through the use of new virtual reality tools that are compatible with user-friendly management hardware.
Creating better conditions for all Both civil engineering and architecture share the privilege of being able to contribute to creating better social living conditions. In addition, projects are developed that are environmentally-friendly and create adequate working conditions for all. At FHECOR we are committed to the NGO, Bridges to Prosperity (B2P), with which we have collaborated in the construction of footbridges in Nicaragua by contributing our technical and human resources.
credits cover page 5 page 7 pages 8-9 pages 10-11 page 12 page 13
image SIEMENS photos ITER Organization photos ITER Organization photo ITER Organization photos ITER Organization photos REGANOSA photo Pablo Cinza Blanco
Calle Barquillo 23, 2ยบ 28004 Madrid, Spain P: +34 917 014 460 F: +34 915 327 864 f h e co r @ f h e co r. e s www.fhecor.com
edition v4 - april 2019