Rescheduling of the exhaust air system of a production area at Novelis Sheet Ingot GmbH

Overview

Location: Nachterstedt plant, Saxony-Anhalt, Germany
Project duration: 12 months
Focus: Inventory, 3D scan, piping redesign, system planning, project management

HÖRMANN Rawema Engineering & Consulting GmbH implemented the redesign of the exhaust air system of a production area at the Nachterstedt plant with the aim of measurably improving flow behavior, safety functions and reliability and ensuring implementation through to final acceptance.

Project content

Exhaust air system analysis and improvements

Analysis of the existing exhaust air system and derivation of targeted improvements in terms of flow behavior, safety functions and reliability. Reliable basis for replanning and implementation.

3D laser scan of existing ducts

Inventory of the ductwork using 3D laser scanning. Precise recording of geometries and interfaces as a basis for planning and collision checks.

CFD flow calculation

Calculation of flow resistances using computational fluid dynamics (CFD). Evaluation of pressure losses and power reserves for designing the new pipe routing.

3D pipeline redesign

Redesign of the pipeline routing in 3D. Optimized routes, cross-sections and installations to improve throughput and operational reliability.

Specification of measures and supplier selection

Specification of the conversion measures with clear descriptions of services and interfaces. Structured supplier selection and support through to commissioning.

On-site planning and monitoring

Planning and monitoring of the conversion measures on site. Schedule, quality and interface coordination through to functional approval.

Final acceptance and documentation

Execution of the final acceptance with proof of performance. Complete documentation as a basis for operation, maintenance and subsequent adjustments.

Advantages of our solution

• Flow efficiency: CFD-supported design reduces flow resistance and stabilizes exhaust air performance.
• Operational safety: Improved safety functions and quality-assured implementation increase reliability and availability.
• Transparency: 3D scanning and 3D replanning make pipe routing, installations and interfaces clearly comprehensible.
• On-time implementation: Precise specification of measures, supplier management and on-site monitoring reduce risks and rework.
• Documentation clarity: Final acceptance and complete documentation provide evidence and auditability for operation.
   

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