Ash Handling Group

With the recent trend toward more diversified fuels and combustion technologies, such as coal produced at various overseas and domestic mines, fluidized bed boilers and coal gasification plants, the call for more intense development of new technologies in ash handling systems is growing stronger every day.

Kawasaki is meeting this need, based on its abundant experience as Japan’s leading and most sophisticated ash handling system supplier and boiler manufacturer. To date, Kawasaki has supplied over 80% of the ash handling systems in operation at coal-fired power stations in Japan ranging from 75MW to 1,050MW unit capacities.

Kawasaki custom designs and engineers each ash handling system to fit all the performance requirements for each application by thoroughly evaluating such factors as site, environmental impact, fuel types, unit size, energy availability, economy, plant facilities, ultimate disposal and/ or utilization of ash, and any other items pertinent to the final selection of the optimum ash conveying system.

Whatever your job, whatever your needs, you can be sure there’s a Kawasaki ash handling system that will fit your requirements exactly.

KDT Ash Handling Group provides support and assistance in the preparation of technical drawings, 2D/3D modeling, engineering designs and services to Kawasaki Heavy Industries Plant System, that primarily deals with the design and construction of various types of Ash Handling System Facilities   (Bottom Ash System,  Fly Ash System, Coal Ash Shipping, Reclamation System, etc.), which support various type of Boiler and provides variety of Ash Handling Technologies to meet the various needs of Power plants.

Scope of Work:

• Preparation of 2D/3D modelling using AutoCAD, CATIA & PDMS software.
• Preparation of Planning, Assembly and Fabrication Drawings for Structure & Equipment.
• Preparation of Bill of Materials.
• Preparation of Documentation Works.

Tools:

• AutoCAD
• CATIA V5
• PDMS (Plant Design Management System)
• Excel (for Bill of Materials)

Future Plan Capabilities: 

• Design of Standardized Equipment
• Piping Design Works (Pipe Detailing)
• Site Inspection, Supervision and Monitoring
• Project Commissioning

Sample Projects: 

• Matsuura #1 – (700 MW) – Japan
• Kashima #1 – (500 MW) – Japan
• Hitachinaka #1,2 – (1000 MW) – Japan
• Noshiro #1,2 – (600 MW) – Japan
• Shinko #1,2 – (700 MW) – Japan 

Current Projects:

• Kashima #2 – 645 MW Coal-fired Power Plant, Ibaraki, Japan
• Noshiro #3 – 600 MW Coal-fired Power Plant, Akita, Japan
• Kobe Steel-F Project – 650MW Coal-fired Power Plant, Hyogo, Japan
• Hitachinaka #3 – 650MW Coal-fired Power Plant, Ibaraki, Japan
• Saijo – 500MW Coal-fired Power Plant, Ehime, Japan
• Matsuura #2 – 1000MW Coal-fired Power Plant, Nagasaki, Japan

KDT Piping Group is a part of the Engineering Department of KDT which supports Kawasaki Heavy Industries Plant System, by providing 3D modeling, technical drawings and engineering services of piping facilities for Power and Industrial Plants.

Our team aims to provide the best output of fabrication drawings with utmost quality and efficiency.

Scope of Work:

• Handles the 3D modeling using Plant Design Management System (PDMS) Software, Multi-Discipline Support (MDS) and 2D drawing production of Pipe Supports.
• Creation of 3D Models of Piping and Piping Backgrounds such as Equipment, Structure, Platforms for presentation purposes.
• Preparation of Piping Arrangement Drawing
• Isometric Drawing with Material List
• Pipe support with Material List for Fabrication drawings
• Site Inspection, Field advisory and Supervision at site
• Estimation Projects for Environment and Boiler
• Pipe and pipe support planning

Tools:

• PDMS V12 Software (Plant Design Management System)
• MDS V12 Software (Multi-Discipline Support)
• AutoCAD
• Autodesk Navisworks Manage
• Bentley Autopipe

Future Plan Capabilities:

• PDMS Administration System
• Piping Design Analysis (Auto Pipe Software)
• Material procurement and vendor fabrication inspection

Sample Projects:

• Chemical Plant (Turkmenistan- Fertilizer Plant and Gas-to-Gasoline plant, Vietnam –Thai Binh FGD Plant)
• Cryogenic Storage System (Australia – Ichthys LNG Plant)
• Environmental Plant (Japan – Watarinori, Kobe 11, Shijounawate, Chita Nambu, Kagoshima)
• Boiler Plant (Japan – Ubekanda)
• Nuclear Plant (Japan – Oarai Waste Reduction Treatment Facility)
• Estimation Projects (Environment Plant, Japan – Kodaira, Saitama/ Boiler Plant, Japan – Taiheiyo)

Material Handling Group

KDT Materials Handling Group is a part of the Engineering Department of KDT which support KHI Plant System, that primarily deals with design and construction of various types of Bulk Material Handling Facilities (Conveyors, Stacker, Ship Loader, Reclaimer, etc.), Storage Facilities, Part Cargo Facilities (Container Crane etc.), Boarding Bridge, and Aircraft Maintenance Dockyard.

We aim to create accurate fabrication drawings and 3D models to assure that the product will not suffer too much error during fabrications and site installations. We help KHI for making precise drawings and submit according to the deadline.

Scope of Work:

• Handles the 2D design drawing and 3D modeling by the use of CATIA V5 Software.
• Fabrication drawings
• Estimation Materials
• Creation of 3D models in details each part for presentation purposes for clients.
• Site Inspection, Supervision and Monitoring
• Preparation of Bill of materials
• Preparation of Parts List
• Getting the Center of Gravity for Lifting and Site Installation
• Basic Material Strength Calculation
• Transportation Parts List
• Preparation of Kinematic Movement of the Machine
• Clash Checking of the Equipment using 3D software

Tools:

• AutoCAD
• CATIA V5
• MS Excel
• MS Power Point
• MS Word
• Adobe Acrobat
• 3D Composer
• ADAM System
• EVA System

Future Plan Capabilities:

• Structural Analysis using FEA
• Project Commissioning
• Navis Work

Accomplished Projects:

• NSSMC HIROHATA WORKS SR-1 (Japan)
• JFE KEIHIN CY-1STL (Japan)
• NOSHIRO RECLAIMER (Japan)
• SMI WAKAYAMA SR-4 (Japan)
• ANA No.3 DECK (Japan)
• Asahimas Chemical Reclaimer (Indonesia)
• (Philippine Mining Service Corporation) PMSC SL & BC (Cebu, Philippines)
• Shunan Bulk Terminal (Japan)
• Aomi (Marine Boarding Brigde) MBB (Tokyo, Japan)
• JFE Fukuyama (Japan)
• JFE Kurashiki (Japan)
• Kobe Steel Vertical Conveyor (Kobe, Japan)
• Hirohata SR-2 (Japan)
• Jindal RC (India)
• Jindal SR (India)

Current Projects

• Yokosuka Coal Project (Japan)
• Yokosuka Gypsum Project (Japan)
• NS KASHIMA WL-1 (Japan)

Advanced analysis and innovative ideas are needed by anyone who creates great products. We are here to help you realize that goal using our extensive experience and utilizing the advanced methods, software and techniques.

KDT Analysis Group is a part of the Engineering Department of KDT which is dedicated to provide valued engineering services that is cost-effective and with emphasis on quality and integrity. We aim to work responsibly and efficiently to meet and understand our client’s needs and to uphold a high standard of practice in Finite Element Modeling and Analysis.

Our group collaborates with our clients constantly during the course of the project to determine exactly what needs to be done to meet their high expectations and required output. We offer continuous support until the client’s project objectives are satisfied. It is our purpose to become established and trusted partners in the professional services that we provide.

Scope of Work:

• Finite Element Modeling aided by advanced CAE software like Hypermesh and FEMAP
• Structural Analysis using Solvers such as OptiStruct, RADIOSS and Nastran.
• Post-Processing and Report generation with HyperView, MS/Excel, Word and PowerPoint.

Capabilities:

• FEA Linear Static Analysis (Stress and Deformation)
• FEA Dynamic Analysis (Modal Analysis)
• FEA Yield Stress and Buckling Analysis (HCSR)
• FEA Surface Modelling (VA One)

Future Plan Capabilities:

• Optimization Analysis (Shape & Size Optimization)
• FEA Nonlinear Analysis (Elasto-Plastic Analysis)
• Fatigue Analysis
• Noise and Vibration Analysis
• Other Analysis services as the need arises

Sample Projects:

Marine

• Liquefied Petroleum Gas (LPG) Carriers
• Liquefied Natural Gas (LNG) Carriers
• Very Large Crude Oil Carriers (VLCC)
• Pure Car Carriers (PCC)
• Bulk Carriers
• Oil Tankers

Rail

• High Speed Bullet Trains
• Rapid Transit Passenger Trains
• Double Deck Rail Car Body
• Subway Cars

Air

• Embraer 190/195 Passenger Airplane
• Helicopter

Construction

• Hard Rock Tunnel Boring Machines (TBM)
• Slurry Shield Machines

Industrial Equipment

• Components for various applications

The KDT Ship-System Group is the product of the merger between the Ship Macro Team and the System Group of KDT. Offering valued engineering services with emphasis on quality and integrity, the Ship-System Group was established to become the company’s solutions provider of software automation and application development needs. The group’s expertise also includes macro creation, modification and maintenance of AVEVA Marine PML forms, functions and objects for Kawasaki Shipbuilding Corporation (KSC) in Japan. Our proven capabilities and products are currently utilized by our clients for greater work efficiency and productivity.

Scope of Work:

• Macro Programming
• Software Automation
• Application Development

Programming Language:

• Visual Basic Application
• Visual Basic
• Batch File
• Python
• C#
• XML
• PML
• SQL

Software Proficiency:

• Microsoft Visual Studio Professional 2017
• PDMS – Aveva Marine
• Tribon M3
• AutoCAD
• CATIA
• Excel

Sample Works / Projects:

• Automated Job Manhour Recording and Report Generation
• Automation of Support Fabrication Drawings and Material Take-off (MTO)
• Software (Token Flex) License Management Tool
• Quick Response (QR) Code Generator
• Automated Bill of Material (BOM)
• Mesh Adjustment Tool (CATIA)
• Tubing Symmetry Tool (CATIA)
• Macro Library (CATIA)
• Aveva Marine Macros
• PDMS Macros

Ship Production Design and Modeling of Superstructure

Ship Outfitting Design and Modeling of Pipe, Pipe Band Support and Structures

Ship Machinery and Equipment Modeling

Future Plan Capabilities:

• AutoCAD – LISP and VBA
• Arduino – KDT messaging system
• Hypermesh customization

We are a specialized group in the KDT Engineering Department focusing mainly in the detail design and engineering of mill and other equipment’s for use in Industrial Plants. Since our inception in 1998, we have worked closely with KHI Industrial Plant Department’s Mill Group to complete several of these equipment’s. Primarily KHI’s version of vertical mill, the CK Mill. With the benefit of our design experience, using both 2D and 3D systems, we were able to fulfil our Mother Company’s design and engineering needs.

Scope of Work:

• Planning and Design of General Assembly of Equipment.
• Planning of Mill Grinding Section Arrangement.
• Planning of Mill Piping Arrangement.
• Provide 3D modelling using AutoCAD & CATIA
• 3D Animation (i.e. Mill Erection & Installation)
• Preparation of Drawings listed below:
  • Outline drawings
  • Flow Sheet
  • Arrangement drawings
  • Assembly drawings
  • Foundation drawings
  • Details/Fabrication drawing with Material list

Tools:

• AutoCAD
• MS Word, MS Excel
• Adobe Acrobat
• CATIA, CATIA Composer
• PDMS

Future Plan Capabilities:

• Mill Design
• Mill Plant Engineering
• Use of other 3D Softwares
• Development of new concept Mill
• Grindability Test of Raw Materials with Test Mill
• Support of Sales Activities for CK Mill Project in Philippines.
• Site Inspection, Supervision and Monitoring
• Project Commissioning

Sample Projects:

Below are the list of KHI Projects in which KDT Mill Group has collaboration with.

CK Mill

• CK-490 Raw Mill, CK-490 Cement Mill & CK-490 Slag Mill (China)
• CK-450 Raw Mill, CK-450 Cement Mill & CK-450 Slag Mill (China)
• CK-410 Raw Mill & CK-410 Slag Mill (China)
• CK-390 Raw Mill (Vietnam)
• CK-370 Raw Mill, CK-370 Cement Mill & CK-370 Slag Mill (China)
• CK-370 Cement Mill (Tanzania)
• CK-340 Raw Mill (China)
• CK-340 Slag Mill (Korea)
• CK-280 Slag Mill (Japan)
• CK-250 Coal Mill (China)
• CK-240 Coal Mill (Myanmar)
• CK-170 Coal Mill (Indonesia)

Tube Mill

• 7000kW Ø5.3×16.0mL Cement Mill (Vietnam)
• 4800kW Ø4.7×14.0mL Cement Mill (Myanmar)

Others

• Tetracyclone for Raw Grinding (Vietnam)
• Tetracyclone for Raw Grinding and Cement Grinding (Vietnam)
• KRF-21 Rotary Feeder, KRF-19 Rotary Feeder (China)

Energy Group

Kawasaki started its boiler business in Japan in 1878 and accumulated huge experience in this field over so many years. Kawasaki is one of the leading boiler manufacturer in the world and supplied equipment as totalized thermal plant a combination of advanced technologies of boiler, steam turbine, environmental control system, coal handling system and ash handling system. After 20 years Kawasaki provided a total of 132 boilers in different countries like USA, Brazil, China, Philippines, Thailand etc. Kawasaki engineering, project management and aftermarket services include design of HRSG, modification, circulation analysis, thermal-efficiency improvements, time life studies, engineered solutions, fields services including boiler inspections, failure analysis, repair procedures, performance testing, inspections and more depending on the need of the customers.

KDT Boiler Group is a part of the Engineering Department of KDT which helps KHI attain its goal through constant support in preparing different kind of drawings, calculations and engineering documents which are required in designing different kinds of boilers.

KDT Boiler Group is continuously working KHI in preparing drawings, calculations and documents of different kind of boiler and Power Plant products like;

Power Plants

• Combined Cycle Power Plant (CCPP)
• Conventional Fossil Fuel Power Plant
• Cement Waste Heat Recovery Power Plant (Cement WHRPP)

Boilers

• Internal Circulation Fluidized Bed Boiler (ICFB)
• Heat Recovery Steam Generator (HRSG)
• Cement Waste Heat Recovery Boiler
• Waste Incineration Heat Recovery Boiler
• U-KACC Boiler
• Marine Boiler

Scope of Work:

Scope of work in Energy group is divided into two categories, which is mainly classified by the type of work being prepared.

Boiler Detail Design Work

• Preparing detail drawings  of boiler pressure and non-pressure parts (e.g. Header, Steam Drum, Water Wall Tubes, Buckstay, Wallbox, Refractory Studs, etc.)
• Preparing Calculation Documents (e.g. Piping Pressure Loss, Boiler Drum Internal Parts Dimensions, Safety Valve Specifications, etc.)
• Preparation of 3D Model of Boiler pressure and non-pressure parts using CATIA Software.

Boiler Process Design Work

• Preparing Piping and Instrumentation Diagram Drawings (PID) for different processes of the    power plant area
• Preparation of engineering documents, and calculations sheets required in a project.
• Checking specifications of purchased equipment and instruments.
• Assist in commissioning works at site for each assigned project
• Project communication and management with other KHI Business Unit’s (Electrical, Piping, Construction, etc.)
• Modelling of piping based on the PID diagram and producing isometric drawings.
• Assist in commissioning works at site for each assigned project.

Tools

These are the software that are being utilized by the group in preparing drawings, 3D models and structure analysis:

• AutoCAD PID
• AutoCAD
• CATIA
• STAAD
• PDMS

Future Plan Capabilities:

KDT Boiler Group envisions its members to be able to fully support KHI in preparing engineering works by continuous education and training on fields such as;

• Design of Piping and Instrumentation Diagrams
• Calculation and Design of Boiler pressure and non-pressure parts
• Site Inspection, Supervision and Monitoring
• Continuous Commissioning work assistance

Sample Projects:

• HRSG, Rio De Janeiro Brazil
• HRSG, Chiba Japan
• ICFB, South Korea
• Marine Boiler, Shell FLNG-Prelude Project Australia
• Conventional Fossil Fuel Power Plant, Steag State Power, Mindanao Philippines
• Cement WHRPP, Souryu Project, South Korea
• Cement WHRPP, Sungshin Project, Japan
• Municipal WHRB, Shijonawate, Japan
• Municipal WHRB, Miyakonojo, Japan

Tunneling Equipment Group

SCOPE OF WORKS

• 3D modelling of various types of shield and tunnel boring machines and other miscellaneous equipment.
• 3D/2D Planning and preparation of the detail drawings such as the Working Platforms, Trailer Trucks, Cutter Bit Holder, Device for Reaction, Device for Conveyance and etc.
• Providing technical assistance to the Japanese engineers assigned in KDT
• 3D/2D Planning and preparation of Piping and Tubing
• Preparation of Transportation Assembly (2D/3D models and Bill of Materials)
• Providing Engineers/Supervisors at Site (particularly in Singapore’s Jurong Project)
• Providing surface and solid model for Analysis using CATIA

Tools:

• CATIA V5 (Mechanical Design 2 with Piping and Tubing Licenses and SA2, FMD, FMS CATIA Analysis Licences)

COMPLETED and ON-GOING PROJECTS

• 6.9m Slurry Type TBM

- Conversion of drawings from client standard to KDT standards.

- Modification of Fabrication drawing

• 12.20m Mud Pressure Shield Machine

- Conversion of drawings from MicroCADAM to AutoCAD, applying KDT standards.

- Modification of Fabrication drawings

• 16.1m Mud Pressure Shield Machine

- 3D modelling of Cutter Bit and Cutter Head

- Planning and Fabrication drawings

- Making of Procedure for Cutter Replacing

• 6.63m Slurry Type TBM

- 3D modelling of Cutter Head

• 5.85×11.79m Shield Machine

- 3D modelling of Front, Middle, Rear Body, Cutter Head and Accessories

- Fabrication drawings of Trailer Truck

• 6.88m Slurry Type TBM

- 3D modelling of Center Cutter Holder with single and double roller cutter

• 15.28m Earth Pressure Balanced Type Shield Machine

- 3D modelling of the whole machine

Cutter Head / Cutter Drum / Bulk Head / Front, Middle, Rear Body / Screw Conveyor / Front Deck / Rear Deck / Shield Jack / Articulation Jack / Piping / Tubing / Accessories

- Transportation Assembly of the whole machine

- Planning and Fabrication drawings

• 13.94m Earth Pressure Balanced Type Shield Machine

- 3D modelling of the whole machine

Cutter Head / Cutter Drum / Bulk Head / Front, Middle, Rear Body / Screw Conveyor / Front Deck / Rear Deck / Shield Jack / Articulation Jack / Piping / Tubing / Accessories

- Planning and Fabrication drawings of Piping and Tubing

- Transportation Assembly of the whole machine

• 6.58m Earth Pressure Balanced Type Tunnel Boring Machine

- 3D modelling of the whole machine

Cutter Head / Cutter Drum / Bulk Head / Erector / Front, Middle, Rear Body / Screw Conveyor / Belt Conveyor / Shield Jack / Articulation Jack / Trailer Truck / Accessories

- Transportation Assembly of the whole machine

• 3.62m Tunnel Boring Machine

- Fabrication drawings of trailer truck

- 3D modelling of Cutter Head / Cutter Drum / Bulk Head / Front, Middle, Rear Body / Belt Conveyor Outline

• 3.34m x 2.89m H&V Type Tunnel Boring Machine

- 3D Planning of Trailer Truck

- 3D modelling of the whole machine

Cutter Head / Cutter Drum / Bulk Head / Erector / Front, Middle, Rear Body / Shield Jack / Articulation Jack / Trailer Truck / Piping / Tubing / Accessories

• 4.0m Bedrock Mud Boring Machine

- 3D model of Front Body for FEM Analysis

- 3D model of Cutter Head / Cutter Drum / Bulk Head / Erector / Front, Middle, Rear Body / Shield Jack / Articulation Jack / Slurry Pipe

• 14.04m Mud Pressure Boring Machine

- 2D/3D Planning of Machine 1 (No Articulation)

- 2D/3D Planning of Machine 2 (With Articulation)

- Fabrication Drawings of Cutter Head and Rear Deck

- 3D modelling of the whole machine

Cutter Head / Cutter Drum / Bulk Head / Erector / Front, Middle, Rear Body / Pillar / Segment Retainer / Screw Conveyor / Shield Jack / Articulation Jack / Front Deck / Rear Deck / Trailer Truck / / Piping / Tubing / Accessories

Future Plan and Capabilities:

– TBM 3D model animation using NAVIS Works

KDT Environmental Group acknowledges that the quality of the environment has a deep impact to the health and well-being of the people that live in it; and to keep the environment healthy, a good Waste Management System is necessary. One of the popular methods applied especially in developed countries is through the use of an Incineration Plant. Incineration introduces a disposal method where the solid organic wastes are subjected to combustion to convert them into residue and gaseous products. Incinerators convert waste materials into heat, gas, steam and ash.

In collaboration with KHI Japan’s Environmental Group, our group have put into practice the Waste-To-Energy Concept wherein solid organic wastes are collected and subjected to combustion and the heat produced is utilized through heat recovery boiler and power generator to generate electric power which is then used by the different Electric Companies. Furthermore, it ensures the prevention of flue gas pollution by using appropriate treatment systems.

Our KDT Environmental Group has two (2) main jobs, namely:

• Equipment Detail Design Job – deals with the design of equipment being used in KHI Environmental Group projects especially in Incineration Plants. AutoCAD is the main engineering tool used in these jobs.
• PDMS Modeling Job – deals with 3D modeling of equipment using PDMS software as an engineering tool to provide proficient means of detecting possible interference/clash between structures and for better visualization of various KHI incineration plants.

Scope of Work:

• Mechanical Equipment Design of various Incineration Plants.
• Prepare Detail drawings for various Incineration Plant equipment such as Incinerator, Gas Quenching Tower, Ducts, various Tanks, Structural, Deck and Handrails
• Prepare Detail drawings for various Recycling Plant Equipment.
• Integrate the Material List to the drawings automatically using BOM System.
• Checking of all drawings thoroughly to ensure that the designs are completed on time, of high-quality and to meet the target on profitable and cost-controlled manner.
• 3D modeling of steel and concrete structures, mechanical equipment, ducts, building utility piping and cable racks. Clash checking of structures, equipment, ducts and piping spools.

Tools:

• AutoCAD
• PDMS 12.0 SP6
• CATIA V5
• Autodesk Navisworks Manage
• MS Office
• Adobe Acrobat

Future Plan Capabilities:

• Main Mechanical Equipment Designs
• Site Inspection, Supervision and Monitoring
• Project Commissioning

Sample Projects:

• Planning and Design of General Assembly of Equipment.
• Hofu Incineration and Recycling Plant (Japan)
• Miyakonojo Incineration Plant (Japan)
• Matsusaka Incineration and Recycling Plant (Japan)
• Saikai Incineration Plant (Japan)
• Kobe 11^th Incineration Plant (Japan)
• Watari-natori Incineration and Recycling Plant (Japan)
• Shijonawate-Katano Incineration and Recycling Plant (Japan)
• Takatsuki Incineration Plant (Japan)
• Kusatsu Incineration and Recycling Plant (Japan)
• Komatsu Incineration Plant (Japan)
• Sukagawa Incineration Plant (Japan)
• Fuji Incineration and Recycling Plant (Japan)
• Kagoshima Incineration Plant (Japan)
• Chita-nanbu Incineration and Recycling Plant (Japan)