Precise Engineering Experts in Micro Engineering Models

Transcription

1 Showcasing Power Industry through Micro-modeling Version 1.2 An Application Note Series Precise Engineering Experts in Micro Engineering Models Copyrights 2005, CVMark Consulting, All rights reserved.

2 Learn how organizations are reducing time to market for large and complex, engineering products and structures by using Micro-modeling as a new Presentation Tool. For suppliers, buyers, employees, consultants and contractors; micro-modeling offers a very strong proposition for faster decision making by offering better visualization. You can now Showcase your large Machinery and Systems in a better way Speedup design review and process reengineering Speedup training of interns and recruits Speedup visual training of employees on your plant/system Resolve logistic problems in presenting large machinery and system in an exhibition center Carry replica of your large and complex products with you, any where Sell and consult your system design better Copyrights 2005, CVMark Consulting, All rights reserved. 2 of 9

3 Introduction After telecom sector, it is the time for power sector to seek major re-organization to meet the challenges of globalization and liberalization. Consider e.g., India has introduced an APDRP (Accelerated Power Development and Reform Program) and the Indian Electricity Act 2003, to provide for sweeping changes in its power sector. Together, they have resulted in the rollout of several green field as well as brown field projects, where government as well as private sector organizations have pledged strong commitments. Although, there is a surge in demands for power related products and systems, the maturity of the power industry makes it a very competitive market place. A large number of players, domestic as well as from outside participate in this industry. These include consulting, product, systems, EPC and several intermediaries. The products could be as small as a domestic electric switch and as large as an HV transformer that will stand several meters tall. Larger part of the market is in power infrastructural projects like substation, distribution system and power plant construction, for which bidding is normally in the range of millions of dollars. These projects are very complex, spatially large and have a large cycle time. Although, large cycle time has been considered as a given thing in the execution of these projects, organizations remain in constant look out for new ways to drastically reduce time to market, as the ensuing benefits are large. Issues in dealing with Complex Products Products and systems in power projects being large, bulky and complex, have their own disadvantages from process point of view. During various phases of the project, various people involved in the project need a very high level of visualization of the project to be. Today, these visualizations are supported by sketches, drawings, descriptions and historical project details. Use of these aids, although, essential from an engineering point of view, have their own limitations in terms of the offered visualization of the project to be. It would perhaps be of great help, if it were possible for the project team to have a physical replica of the project to be on their desk. Just imagine, how simple it would be for you, as a marketing team of an EPC company, to impress upon your design concepts of power plant, if you have a miniaturized engineering model of your plant that could be carried to the customer desk. Similarly, imagine, if you have a physical model of a rural electrification project, then how easy it would be for the engineering and operations team to discuss implementation strategy. Figure 1: Power Engineering Products and System 1.High Voltage Reactor, MVA Transformer 3. Special substation Copyrights 2005, CVMark Consulting, All rights reserved. 3 of 9

4 Project in a Box Today, when engineering organizations have to participate in large industry exhibitions, they have stupendous task in show casing their mainline products and systems like, HV switchgear, power transformer, substation, large generators etc.; owing to sheer logistic and cost consideration. Most often, they have to be content with shipping of one or two products and a large number of postures and marketing brochures. Imagine, the extent to which exhibition can be made more fruitful, if you were to have all your products however complex and however large, scaled down with all technical complexity intact (e.g. scale, fittings, contours, finish, color, components etc.), in such a way that they could be individually carried from place to place in a box. This will be a big boon for an organization like BHEL and ABB, for whom it is next to impossible to showcase an integrated value of all the offerings they have to make to the world. With such an offering to customers in an exhibition is possible, it would not only make sense to conduct a multilevel discussions on design, layout, footprint, material flow and construction of the project but will also save significant space and cost at the exhibition. The enhanced visualization aid that micro models provides in an exhibition center, finds applications for various activities that need products or projects, as points of discussions. These discussions could be for strategic, training, customer related, marketing, sales, process re-engineering or showcasing. The point to remember is that if you have a physical replica of your to be products or systems ready, you are in a position to not only market your products and systems to individual needs of the customers, but also showcase your capability to fulfill needs of enterprise level customers. Further, you can place your products as point of discussion for various stakeholders. Micro-modeling already a buzzword Have a look at the exhibits in this whitepaper. They are not photographs taken at the site. The are photographs of the miniaturized models that organizations are using for various applications. Figure-2, shows the miniaturized model of a 6 MW bio-generation plant that AREVA, a multinational conglomerate has showcased in a large power exhibition. AREVA is a world leader in building power generation plants and wishes to show case its expertise and commitment to renewable energy and sustainable development. Like other companies, it could, perhaps, have given massive advertisements that would have led to a multimillion dollar expensive campaign to project its business. It rather, chose to have a micro-model built in Bangalore, and in its first sojourn, shipped it to an exhibition held at New Delhi. The model developed to the scale of 1:200, is an awe-striking replica of the original model that is operating at Guntur, in state of Andhra Pradesh. Figure 2. Different views of Bio Mass Power Generation Plant Copyrights 2005, CVMark Consulting, All rights reserved. 4 of 9

5 Micro-modeling is doing great wonders for many organizations. For large organizations, who manufacture a range of products over many domains and who provide large industrial solutions, it is inconceivable to showcase their complete range of products to enterprise customers in one place and market an integrated value. Micro-modeling of products and systems, and presentation of these in a well knit cluster offers the only best solution to such organizations. ABB, a world leader in industrial automation and power technology, supplying a wide ranging products and systems had no place on the earth, where it could demonstrate its contribution across the value chain. It has now built a world class demonstration center in India, that is a combination of Micro-modeling of large systems and actual but smaller products, to weave a story that tells at one location- what is ABB. The demonstration center is used to showcase ABB s mind-boggling presence across the value chain in power and automation technology to its customers. The same model of representation has now been replicated in its Corporate Research Center in Sweden. Fig. 3(a) Micro models used in ABB Corporate Research Demonstration Center, Bangalore, India Figure 3(b): Power system micro structures, ABB Corporate Research, Vasteras, Sweden Copyrights 2005, CVMark Consulting, All rights reserved. 5 of 9

6 Micro-modeling along with site layout, finds significant use in showcasing infrastructural projects during formal and social occasions including, project inauguration ceremony, corporate presentation, memorabilia, layout tour, schematic presentation, project overview, map etc. These miniatures could be founded on site, in corporate office, office entrance, training room, design engineering room and industrial museum. Figure- 4, is an onsite built Micro-model of 1000 MW Hydro Electric Power Generation Station, over the river Narmada in Bhopal. Look at the fineness, the precision and the contours that match one to one in details to the actual dam. Visitors to the dam, first study this layout before they actually visit the dam, as it gives them a great deal of vividness and realism, and they carry along the memory of the engineering marvel that the Hydro Electric Plant is. Figure 4: On site Micro Landscaping of 1000MW, Hydro Plant at Bhopal over Narmada river GE a multi-domain and a multi-product conglomerate, conducts its product development in a distributed way. Product concept, design, manufacturing, sourcing and service, probably all take place at different locations. It takes a great deal of co-ordination to have various places visualizing the same thing in the same way. It found miniaturized models of its products as a great aid for visualization during training and design phase. Figure-5(a), shows, cut-section miniaturized model of Motorized Drive for off-highway vehicles from GE, that helped its team in enhanced visualization and productive engineering practice. Figure 5(a). Micro Cut-section Model of Motorized Drive for engineering modeling and product training Examples of exploiting benefits of Micro-modeling are numerous, however, more astonishing are the different utilities that users are finding out of Micro-modeling. Almost every body in the supply chain of power industry, has one or more utility attached to it. Whether it is design, consulting, engineering, marketing, sales, operations, training, process reengineering or corporate communication team. Figure 5(b): 16 segment, Micro Cut-section Model of a large Gas Turbine Rotor for training design and maintenance engineers Copyrights 2005, CVMark Consulting, All rights reserved. 6 of 9

7 Micro-modeling a New Marketing Tool Micro-modeling is an engineering practice that allows representation of real life objects, however large and complex, into smaller scale, to provide utilities that are not readily fulfilled by original objects owing to size, cost or location constraints. More and more organizations are using this technique as a novel marketing/ selling tool to reduce the distance between actual product/site and stakeholders that are involved in decision making through visualization of complex setup like power plant or substation. Micro-models are being used for following high value realization: 1. Showcasing: in exhibition, board room and corporate office e.g. plant structural details, landscaping, process layout, infrastructural layout, complex large products and systems etc. 2. Walk-thru exercise, Workflow simulation, Process re-engineering: through visualization of spatially large systems e.g. power plant, cement plant, automobile factory, steel mill etc. 3. Instructions & Training: to recruits, employees, customers and students, about features and functionalities of products and systems 4. Working demonstration, e.g. movement of conveyor system etc. 5. Mementos Various industry stakeholders, who are using Micro-models include plant owners, suppliers, consultants, contractors, project offices, training institutes and exhibitors. Industries with profiles similar to that of ABB, BHEL, Siemens, AREVA, CPRI, Crompton Greaves, Kirloskar Electric, EMCO, EIL, L&T, Caterpillar, Wartsilla Diesel, Power Grid, NTPC, NHPC, Suzlon, TERI, Reliance Energy and Tata Power will have a lot to gain by adopting miniaturized models of their products and systems. Micro-modeling of Industrial Structures is not the job of a hobbyist or a toy maker, it is an exact engineering practice that involves multidisciplinary engineering approach. It needs expertise in industrial design, knowledge of assembly and precision manufacturing process, adeptness in painting, special carving and cutting process, ability in handling tiny components and special materials, and experience in structural landscaping. In making dynamic (or live) models, e.g. movement of conveyors or rotation of kiln, implementation of advanced industrial automation techniques is required. Hence normally, Micromodeling of a structure like Power Plant, is a an engineering project in itself. It takes time to produce an exact replica with the right scaling, precision and visualization. Derive the Benefits of Micro-modeling So, you may be in any part of the power industry value chain, dealing with products, systems or projects; you now have an excellent way to carryout your discussions with your group, by having the product in front of you, before it is actually made. Further, you could ship your dream project to any destination and could have multiple copies in a very short time at a very less cost, thanks to Micro-modeling!! Further Information For more information on Micro-modeling, log onto and download a white paper on Micro Industrial Models- A new marketing tool. You would probably like to have a look at other industry verticals, by downloading Showcase your Cement Plant through Micro-modeling Copyrights 2005, CVMark Consulting, All rights reserved. 7 of 9

8 Contact Precise Engineering Models Nityanand Mahale Manager- Business Development #247, Laggere Main Road Chowdeshwari Nagar, Bangalore , INDIA Tel: Copyrights 2005, CVMark Consulting, All rights reserved. 8 of 9

9 Disclaimer: CVMark Consulting is an independent niche-technology research agency based out of Bangalore. This report is commissioned by Precise Engineering Models to create market awareness of micro modeling as applied to power industry. CVMark Consulting intends to serve business community through research reports, newsletters, issueoriented reports and other products. No part of this publication may be reproduced, stored in a retrieval system beyond the pur-chaser's computer, posted on an intranet or the Internet, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the express, written permission of CVMark Consulting. Factual material contained herein is obtained from sources believed to be reliable, but the publisher is not responsible for any errors or omissions contained herein. Opinions are those of CVMark and are based on research conducted for this report. CVMark holds no responsibility for decisions made on the basis of content of this report CVMark Consulting info@cvmark.com Bangalore CVM-MM Copyrights 2005, CVMark Consulting, All rights reserved. 9 of 9