Mechanical Static Design

Module 1 – Introduction

  • Introduction about process Industry and EPC (Engineering, Procurement, Construction) industry.
  • List of Equipment’s used in Industries, their introduction, applications.
  • Relevant Codes and Standards used in Industry

Module 2 – Material Technology related to Pressure Vessel Design and Engineering

  • Basics on Material Technology related to Pressure Vessel Design.
  • Stress strain Diagrams, Types of Materials, Commonly used carbon steels, Stainless steels, Low and High alloy steels, ASM Code properties for different materials and Engineering properties related to materials.
  • Factors governing choice of materials, criteria for material selection for process equipment.
  • Materials for Different temperature requirements (High and Low Temperature), NACE requirements, Hydrogen Requirements, Petrochemical Requirements, Sour gas service requirements cryogenic services.
  • Types of Gaskets , Gasket material selection , Role of gaskets in Pressure Vessel Design

Module 3 – ASME Codes and its relation to Pressure Vessel Design

  • Introduction of Various Standards of Different Consulting and Engineering Companies
  • Codes related to Pressure Vessels & Process Equipment’s, (ASME Sec.VIII Div.1-Latest issue, ASME Sec II, TEMA and API 650 etc.)
  • Code philosophy understanding requirements of codes.- ie conditions/clauses governing pressure vessel design under ASME Sec VIII Div 1.
  • Pressure vessel categories & code rules for design of Pressure Vessel Design.

Module 4 – Mechanical Design of Pressure Vessels

  • Design and Analysis of Pressure Vessels & Component & Coded
  • Design of Pressure Vessels (ASME Section VIII Division 1).
  • Internal and External Pressure Design, Design of cylindrical vessels, various types of dished heads, flat heads.
  • Design of Jacketed vessels, Limpet Coils, Horizontal equipment’s with saddle support.
  • Various Types of Supports & Attachments: Leg, Skirt, Bracket Supports.
  • Lifting attachments, Design of Anchor Bolts, Safe Loads for Ropes and Chains.
  • Nozzle openings and reinforcements, Nozzle Local Load Analysis.
  • Welded joints, Butt welded joints of unequal Thicknesses, Application of Welding Symbols.
  • Role of MAP, MAWP, Design Pressure, Design Temperatures, Allowable Stresses, Corrosion Allowance and Loadings as per ASME in Pressure Vessel Design.
  • Impact Testing, PWHT along with heating rates and cooling rates, Hydro test pressure, Stamping of Vessels.

Module 5 – Pressure Vessel/Column/Reactor Design Calculation: (ASME SEC VIII, DIV.1)

  • Maximum Allowable Stress Values ( UG-23)
  • Shell Design for Internal Pressure ( UG-16, UG-27,Appendix 1-2)
  • Dished End Design For Internal Pressure ( UG-32)
  • Shell Design for External Pressure (UG-28, UG-29,UG-30)
  • Dished End Design For External Pressure ( UG-33)
  • Hydro test Pressure/Pneumatic Test ( UG-99,UG-100)
  • Wind Load ( IS-875, Pt-3)
  • Seismic Load ( IS-1893, Pt-1 & 4)
  • Combined Loading Effect
  • Conical & Toriconical Section Analysis (UG-32,33, Appendix 1-5 & 1-8)
  • Weight Calculation
  • Opening ( Nozzles) ( UG-36 ~ UG-45)
  • Local Load ( WRC 107 & 297)
  • MDMT & Impact Test Enigma ( UCS-66)
  • Lifting & Tailing Lug analysis
  • Support Analysis ( Skirt, Leg, Saddle ,Lug ) & Anchor Bolt Design
  • Joint Efficiency, MAWP, MAP, SR of DE for Forming Operation
  • PWHT (UCS-56).
  • Types of Gaskets, Gasket material selection, Role of gaskets in Pressure Vessel Design.
  • Mechanical Design of Non Standard Flanges as per Appendix 2 .
  • Mechanical Design of Jacketed Vessels and Limpet Coils.

Module 6 – Fabrication of Pressure Vessels

  • Plate rolling, Plate Bending, Welding methodologies (STAW, GTAW, GMAW, SMAW) , welding symbols , fabrication sequences , fabrication schedules, plate forming, cutting etc.
  • Hydro testing of pressure vessels, pneumatic testing of pressure vessels.
  • Painting and coating for corrosion protection, surface preparation, pickling & passivation of process equipment’s.

Module 7 – Column & Tower Internals

  • Types of Internals
  • Functions of Internals
  • Process aspect of these internals
  • Specialized manufacturers of internals.
  • Scope and design of the internals

Module 8 – Design & Analysis of Heat Exchangers

  • Heat Exchanger Types, Classifications , TEMA types, classifications,
  • Design of Shell, Channel, Shell Bonnet, Channel Cover, Selection of Girth Flanges.
  • Limitations in the use of heat exchangers.
  • Components of Heat Exchangers
  • Design aspects in the design of Heat Exchangers.
  • Tube sheet Design: Fixed Tube sheet, Floating Tube sheet , U – Tube sheet
  • Design of tube sheet as per TEMA as per Bending and Shear Loading.
  • Limiting cases in the design of heat exchangers.
  • Testing of Heat Exchangers

Introduction to the following types of heat exchangers:

  • Condensers
  • Evaporators
  • Reboilers
  • Plate Heat Exchangers

Module 9 – Detail Engineering Aspects of Process Equipment’s

  • Understanding the BASIC ENGINEERING PACKAGE, Tender requirements of Clients, Engineering Design Basis, Understanding the Client and Project requirements, Issues co agreed between client and the Consultant.
  • Preparation of Technical Specifications: Process Data Sheets and Mechanical Data Sheets.
  • Information flow between Process and Mechanical and other relevant data required to prepare the Technical Specification.
  • Understanding the scope of supply between mechanical, civil& process.
  • Enquiry Stage design , drawings and other relevant calculations
  • Preparation of General Arrangement Drawings & Fabrication Drawings of Process Equipment’s.
  • Evaluation of Vendor Offers, Preparation of Technical Queries, Technical Bid Evaluation, Technical Recommendation to be given to the Client.

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