#1510 - Mechanical Design of Process Plant Equipment
Course Objective
Upon completion of this course, attendees will be able to:
- Apply the requirements of the relevant industry standards to the mechanical design of pressure vessels, heat exchangers, piping systems, and aboveground atmospheric storage tanks.
- Review equipment supplier and contractor proposals for performing the mechanical design of these items.
- Evaluate the mechanical design details for these equipment items that have been prepared by others.
- Apply mechanical design requirements, as necessary, in the fitness-for-service assessment of existing equipment.
Who Should Attend?
Engineers, managers, and others who are responsible for the mechanical design or design review of pressure vessels, heat exchangers, aboveground atmospheric storage tanks and piping systems in process plant applications. Project engineers and project managers who are responsible for capital projects in process plants. Engineers who are responsible for fitness-for-service evaluations.
Course Description
Pressure vessels, heat exchangers, aboveground atmospheric storage tanks, and piping systems typically represent over half the capital investment in a process plant. Mechanical engineers at end-user locations or in central engineering organizations are often responsible for evaluating the mechanical designs prepared by others for all these items, not just one or two. To perform these evaluations, these engineers must understand how these items should be designed. Engineers at contractors and equipment suppliers are also often responsible for the design of more that one of these items as well. Fitness-for-service assessments of existing equipment and piping systems can only be done by engineers who understand how these items are designed.
This course is unique in that it discusses all these items in a single course. It begins by discussing the fundamentals of materials selection for process plant applications, which is not discussed in the industry standards. This material is covered by concentrating only on the most commonly applied topics in each case, rather than attempting to discuss everything. Therefore, attendees receive broad, practical training in a single course rather than having to attend multiple courses. This maximizes their learning in a relatively short time. Those that require additional training for a particular item or topic may take a specialized course that covers it in more detail.
The material presented demonstrates some concepts that are not always shown or described in textbooks. The course emphasis is on developing a practical understanding of the mechanical design of fixed equipment and piping systems in process plant applications. Sample problems and participant exercises are included throughout the course to illustrate the concepts discussed and provide the attendees with practice in applying them.
Course Outline
Material Selection Considerations (Approximately ½ day)
- Material Selection Factors
- Material Types
- Mechanical Properties
- Environmental Effects
- Fabricability
- Cost Availability
- Process Contamination
- Reliability
- Metallurgy and Application of Alloys
- Alloy Classes
- Carbon Steel
- Low Alloy Steels
- Stainless Steels
- Typical Product Forms
- Typical Material Selections
- Material Standards and Specifications
- Industry Standards
- Carbon Steel Selection
- Low-Alloy Steel Selection
- Stainless Steel Selection
- Non-Ferrous Materials
- Fracture Toughness
- Special Design Considerations
- Elevated Temperature Service
- Hydrogen Resistance
- Fracture Toughness and Impact Requirements
- Joining Dissimilar Metals
- Refractory Linings
Pressure Vessels (Approximately 1 day)
- Basic Pressure Vessel Concepts
- Main Pressure Vessel Components
- Primary Pressure Vessel Process Functions
- ASME Code Section VIII
- Division Scopes
- Structure of Division 1
- Materials of Construction
- Fracture Toughness Considerations
- Maximum Allowable Stress
- Specifying Design Requirements
- Design Conditions
- Other Loadings and Design Parameters
- Design Calculations for Pressure-Containing Components
- Pressure Vessel Supports
- Fabrication, Inspection, and Testing
- Glossary
Heat Exchangers (Approximately 1/2 day)
- Introduction
- Main Heat Exchanger Types
- Shell-and-Tube (TEMA Type)
- Air-Cooled
- Applications and Limitations of Shell-and-Tube and A Cooled Heat Exchangers
- Specifying Design Requirements
- Primary Shell-and-Tube Heat Exchanger Components
- Girth Flanges
- Pass Partition Gaskets
- Flat Channel Cover
- Tubesheets
- Internal Floating Head
- Tubes
- Pass Partition Plates
- Nonpressure-Containing Parts
- Vibration Considerations for Shell-and-Tube He Exchangers
- Causes of Vibration
- Possible Types of Damage
- Parameters That Affect Vibration
- Potential Solutions to Vibration Problems
- Primary Air-Cooled Heat Exchanger Components
- Tube Bundle
- Header Box
- Nozzles
Above ground Atmospheric Storage Tanks (Approximately 1 day)
- Introduction
- Scope of API 650
- Primary Tank Components
- Material Selection
- Fracture Toughness Considerations
- Allowable Stress
- Mechanical Design of Primary Components
- Mechanical Design Parameters
- Shell Thickness
- Wind Girders
- Bottom
- Fixed Roof
- External Floating Roof
- Internal Floating Roof
- Fabrication Details
- Inspection and Testing
- Vents and Fire Protection Systems
- Glossary
Piping Systems (Approximately 1 day)
- Introduction
- Scope of ASME B31.3
- Design Conditions, Loads, and Stresses
- Material Selection
- Fracture Toughness Considerations
- Allowable Stress
- Fittings
- Flanges
- Gaskets
- Pressure Design of Components
- Straight Pipe
- Miters
- Branch Connections
- System Layout Considerations
- Typical Supports and Restraints
- Piping Stress Analysis
- Piping Flexibility
- Design Information Required for Analysis
- Equipment Nozzle Load Criteria
- System Design Considerations
- Valve Functions, Types, and Selection Process
- Fabrication and Erection
- Inspection and Testing
- Glossary
Sample problems are included where appropriate throughout the course to illustrate specific solution techniques and provide planned opportunities for group discussion. Written exercises are included for the participants to practice what has been taught and to demonstrate their knowledge.
