Electrical Design for Process Equipment

NeqSim includes a complete electrical engineering framework that mirrors the existing mechanical design system. After running a process simulation, the electrical design system automatically sizes motors, variable frequency drives (VFDs), power cables, switchgear, transformers, and classifies hazardous areas for every driven equipment item.

Architecture Overview

The electrical design follows the same composition pattern as MechanicalDesign:

ProcessEquipmentInterface
  └── getElectricalDesign() ──► ElectricalDesign (base)
                                    ├── ElectricalMotor
                                    ├── VariableFrequencyDrive
                                    ├── ElectricalCable (power + control)
                                    ├── Switchgear
                                    ├── Transformer
                                    └── HazardousAreaClassification

Equipment-specific subclasses provide additional detail:

Equipment Electrical Design Class Special Features
Compressor CompressorElectricalDesign Auxiliary loads (lube oil, seal gas, cooling), VFD auto-detection
Pump PumpElectricalDesign Auto voltage selection, single-phase for small pumps
Separator SeparatorElectricalDesign Control valve actuators, instrumentation, lighting, optional heat tracing
Heater / Cooler HeatExchangerElectricalDesign Auto-detects type: electric heater (full duty), air cooler (fan motors), shell-and-tube (auxiliary only)
Pipeline PipelineElectricalDesign Electrical heat tracing (W/m × length), cathodic protection, instrumentation
System (plant-wide) SystemElectricalDesign Aggregates all equipment loads, adds utility/UPS, sizes main transformer and emergency generator

Quick Start

// 1. Run process simulation
ProcessSystem process = new ProcessSystem();
// ... add equipment ...
process.run();

// 2. Run all electrical designs
process.runAllElectricalDesigns();

// 3. Get plant-wide load list
ElectricalLoadList loadList = process.getElectricalLoadList();
System.out.println("Total demand: " + loadList.getMaximumDemandKW() + " kW");
System.out.println(loadList.toJson());

// 4. Get individual equipment design
ElectricalDesign compDesign = process.getEquipmentElectricalDesign("1st stage");
System.out.println(compDesign.toJson());

1. Motor Sizing (IEC 60034-30-1)

Standard Motor Selection

Motors are selected from IEC standard power steps (0.37 kW to 10 MW):

\[P_{\text{rated}} = \min \{ P_{\text{std}} \in \text{IEC series} \mid P_{\text{std}} \ge P_{\text{shaft}} \times f_{\text{margin}} \}\]

where $f_{\text{margin}}$ is the sizing margin (default 1.10, i.e. 10%).

Synchronous and Rated Speed

The synchronous speed of an AC induction motor is:

\[n_s = \frac{120 \times f}{p}\]

where $f$ is the supply frequency (Hz) and $p$ is the number of poles. The rated (actual) speed accounts for slip $s$:

\[n_r = n_s \times (1 - s)\]
Power Range Typical Slip
≤ 7.5 kW 5%
7.5–75 kW 3%
75–375 kW 2%
> 375 kW 1.5%

Efficiency Classes (IEC 60034-30-1)

The framework models four efficiency classes with approximate full-load efficiencies for 4-pole, 50 Hz machines:

Power (kW) IE1 (Standard) IE2 (High) IE3 (Premium) IE4 (Super Premium)
≤ 1.1 79.5% 81.0% 82.5% 83.5%
1.1–4 84.7% 86.2% 87.7% 88.7%
4–11 88.0% 89.5% 91.0% 92.0%
11–37 90.3% 91.8% 93.3% 94.3%
37–110 92.0% 93.5% 95.0% 96.0%
110–375 93.0% 94.5% 96.0% 97.0%
> 375 93.5% 95.0% 96.5% 97.5%

Rated Current

The full-load current for a three-phase motor:

\[I_{\text{FL}} = \frac{P_{\text{rated}} \times 1000}{\sqrt{3} \times V \times \eta \times \cos\varphi}\]

where $\eta$ is efficiency and $\cos\varphi$ is the power factor at full load.

Part-Load Performance

Motor efficiency varies with load. Peak efficiency occurs around 75% load:

\[\eta(L) = \begin{cases} \eta_{\text{FL}} - 20 \times (0.25 - L) & \text{if } L < 0.25 \\ \eta_{\text{FL}} & \text{if } 0.25 \le L \le 1.0 \\ \eta_{\text{FL}} - 5 \times (L - 1.0) & \text{if } L > 1.0 \end{cases}\]

Power factor at part load drops more steeply:

\[\cos\varphi(L) = \begin{cases} \cos\varphi_{\text{FL}} - 0.25 & \text{if } L < 0.25 \\ \cos\varphi_{\text{FL}} - 0.12 & \text{if } 0.25 \le L < 0.50 \\ \cos\varphi_{\text{FL}} - 0.05 & \text{if } 0.50 \le L < 0.75 \\ \cos\varphi_{\text{FL}} & \text{if } L \ge 0.75 \end{cases}\]

API Usage

ElectricalMotor motor = new ElectricalMotor();
motor.setEfficiencyClass("IE3");
motor.setPoles(4);
motor.sizeMotor(250.0, 1.10, "IEC");  // 250 kW shaft, 10% margin

// Read results
System.out.println("Rated: " + motor.getRatedPowerKW() + " kW");
System.out.println("Speed: " + motor.getRatedSpeedRPM() + " RPM");
System.out.println("Efficiency: " + motor.getEfficiencyPercent() + " %");
System.out.println("Current: " + motor.getRatedCurrentA() + " A");
System.out.println("Frame: " + motor.getFrameSize());
System.out.println("Weight: " + motor.getWeightKg() + " kg");

// Part-load performance
double eff_50 = motor.getEfficiencyAtLoad(0.50);
double pf_50 = motor.getPowerFactorAtLoad(0.50);

2. Variable Frequency Drive — VFD (IEEE 519)

Topology Selection

The VFD topology is automatically selected based on voltage and power:

Voltage Power Topology Pulse Config THD Active Rectifier
≤ 690 V ≤ 250 kW 2-level 6-pulse 35% No
≤ 690 V > 250 kW 2-level AFE 5% Yes
690–3300 V ≤ 2000 kW 3-level 12-pulse 10% No
> 3300 V > 2000 kW Multi-level AFE 3% Yes

VFD Electrical Input

The VFD adds its own losses on top of the motor input:

\[P_{\text{input,VFD}} = \frac{P_{\text{input,motor}}}{\eta_{\text{VFD}}}\] \[P_{\text{input,motor}} = \frac{P_{\text{shaft}}}{\eta_{\text{motor}}}\]

Therefore the total electrical input from the bus:

\[P_{\text{electrical}} = \frac{P_{\text{shaft}}}{\eta_{\text{motor}} \times \eta_{\text{VFD}}}\]

VFD Efficiency at Part Load

VFD efficiency degrades at low load and low speed:

\[\eta_{\text{VFD}}(L, s) = \eta_{\text{rated}} - \Delta\eta_L - \Delta\eta_s\]

where:

\[\Delta\eta_L = \begin{cases} 5\% & \text{if } L < 0.25 \\ 2\% & \text{if } 0.25 \le L < 0.5 \\ 0 & \text{otherwise} \end{cases}\] \[\Delta\eta_s = \begin{cases} 2\% & \text{if } s < 0.3 \\ 0 & \text{otherwise} \end{cases}\]

Heat Dissipation and Cooling

\[Q_{\text{heat}} = P_{\text{rated}} \times \left(1 - \frac{\eta_{\text{VFD}}}{100}\right)\]
Condition Cooling Method
$P > 500$ kW or $V > 3300$ V Water cooling
Otherwise Air cooling

Harmonic Distortion (IEEE 519)

The Total Harmonic Distortion (THD) in current is defined as:

\[\text{THD}_I = \frac{\sqrt{\sum_{h=2}^{\infty} I_h^2}}{I_1} \times 100\%\]

IEEE 519 limits for general systems are typically 5–8% THD at the PCC (Point of Common Coupling). The framework flags THD levels and automatically selects input filters or active front-end (AFE) rectifiers when THD exceeds limits.

API Usage

VariableFrequencyDrive vfd = new VariableFrequencyDrive();
vfd.sizeVFD(motor);  // motor already sized

System.out.println("Topology: " + vfd.getTopologyType());
System.out.println("THD: " + vfd.getThdCurrentPercent() + " %");
System.out.println("Efficiency: " + vfd.getEfficiencyPercent() + " %");
System.out.println("Cooling: " + vfd.getCoolingMethod());
System.out.println("Heat dissipation: " + vfd.getHeatDissipationKW() + " kW");

3. Cable Sizing (IEC 60502 / IEC 60364)

Ampacity Selection

Cables are sized to carry the derated load current. The required base ampacity:

\[I_{\text{base,required}} = \frac{I_{\text{load}}}{f_{\text{temp}} \times f_{\text{group}} \times f_{\text{depth}}}\]

The cable cross-section is selected from the IEC 60228 standard series (1.5 mm² to 630 mm²) such that the base ampacity of the cable equals or exceeds $I_{\text{base,required}}$.

Temperature Derating (IEC 60364-5-52)

For XLPE insulated cables rated at 90°C conductor temperature:

\[f_{\text{temp}} = \sqrt{\frac{T_{\text{max}} - T_{\text{ambient}}}{T_{\text{max}} - T_{\text{base}}}}\]

where $T_{\text{max}} = 90°\text{C}$ and $T_{\text{base}} = 30°\text{C}$.

Ambient (°C) Derating Factor
25 1.00
30 1.00
35 0.96
40 0.91
45 0.87
50 0.82

Grouping Derating

Installation Method Factor
Ladder / Open air 1.00
Tray 0.85
Direct burial 0.90
Conduit 0.80

Voltage Drop

Three-phase voltage drop along a cable of length $L$:

\[\Delta V = \sqrt{3} \times I \times L \times (r \cos\varphi + x \sin\varphi)\] \[\Delta V\% = \frac{\Delta V}{V_{\text{system}}} \times 100\]

where:

The maximum allowable voltage drop is 5% (IEC 60364-5-52). If exceeded, the algorithm automatically upsizes the cable.

Short-Circuit Withstand (IEC 60949)

The adiabatic short-circuit withstand current:

\[I_{\text{sc}} = \frac{k \times A}{\sqrt{t}}\]

where $k$ is the material constant ($k_{\text{Cu}} = 143$, $k_{\text{Al}} = 94$ A·√s/mm²), $A$ is the cross-section in mm², and $t$ is the fault duration in seconds.

API Usage

ElectricalCable cable = new ElectricalCable();
cable.setLengthM(100.0);
cable.sizeCable(150.0, 400.0, 100.0, "Tray", 40.0);

System.out.println("Cross-section: " + cable.getCrossSectionMM2() + " mm²");
System.out.println("Ampacity: " + cable.getAmpacityA() + " A");
System.out.println("Voltage drop: " + cable.getVoltageDropPercent() + " %");
System.out.println("SC withstand: " + cable.getShortCircuitWithstandKA() + " kA");

4. Transformer Sizing (IEC 60076)

Rating Selection

Transformers are selected from IEC standard ratings (100 kVA to 25 MVA) with a 15% margin:

\[S_{\text{rated}} = \min \{ S_{\text{std}} \mid S_{\text{std}} \ge S_{\text{load}} \times 1.15 \}\]

Loss Estimation

Loss Type Typical Value Description
No-load (iron) 0.2% of rating Core hysteresis + eddy current
Full-load (copper) 1.0% of rating Winding $I^2R$
\[\eta_{\text{xfmr}} = \left(1 - \frac{P_{\text{NL}} + P_{\text{FL}}}{S_{\text{rated}}}\right) \times 100\%\]

Impedance

Primary Voltage Typical $Z\%$
> 30 kV 10%
10–30 kV 6%
< 10 kV 4%

Cooling Types

Rating Cooling Description
≤ 5 MVA ONAN Oil Natural, Air Natural
5–10 MVA ONAF Oil Natural, Air Forced
> 10 MVA OFAF Oil Forced, Air Forced

5. Switchgear / MCC (IEC 61439)

Starter Type Selection

The starter type is automatically selected based on motor size and VFD usage:

Motor Size With VFD Starter Type
≤ 11 kW No DOL (Direct On Line)
11–200 kW No Star-Delta
> 200 kW No Soft Starter
Any Yes VFD

Circuit Breaker Sizing

\[I_{\text{CB}} = \min \{ I_{\text{std}} \mid I_{\text{std}} \ge 1.25 \times I_{\text{FL}} \}\]

Standard ratings: 100, 160, 250, 400, 630, 800, 1000, 1250, 1600, 2000, 2500, 3150, 4000 A.

Fuse Rating

\[I_{\text{fuse}} = \min \{ I_{\text{std,fuse}} \mid I_{\text{std,fuse}} \ge 1.6 \times I_{\text{FL}} \}\]

Short-Circuit Rating

System Voltage Typical Short-Circuit Rating
> 6 kV 40 kA
1–6 kV 31.5 kA
< 1 kV 25 kA

6. Hazardous Area Classification (IECEx / ATEX)

Zone Classification (IEC 60079-10)

Equipment Type Zone EPL Ex Protection
Compressor, Pump, Separator Zone 1 Gb Ex d
Heat Exchanger, Cooler, Pipeline Zone 2 Gc Ex e
Non-hydrocarbon service Safe area — None

Temperature Classes (IEC 60079-20-1)

Class Max Surface Temp (°C) Typical Gas
T1 450 Hydrogen
T2 300 Ethylene
T3 200 Gasoline, Hexane
T4 135 Acetaldehyde
T5 100 Carbon disulphide
T6 85 —

Ex Marking Format

The framework generates the full Ex marking string:

Ex d IIA T3 Gb

Components: Protection type + Gas group + Temperature class + Equipment protection level.

7. Power Triangle and Load Analysis

Power Triangle

For AC systems the relationship between active, reactive, and apparent power:

\[S = P + jQ\] \[|S| = \frac{P}{\cos\varphi}\] \[Q = S \times \sin(\arccos(\cos\varphi))\]

where:

Full-Load Current (3-Phase)

\[I_{\text{FL}} = \frac{P_{\text{kW}} \times 1000}{\sqrt{3} \times V \times \cos\varphi}\]

Starting Current

Starting Method Starting Current
VFD $1.0 \times I_{\text{FL}}$
DOL $6.0\text{–}7.0 \times I_{\text{FL}}$
Star-Delta $2.0\text{–}2.3 \times I_{\text{FL}}$

Load List Aggregation (IEC 61936)

The electrical load list sums all equipment loads with demand and diversity factors:

\[P_{\text{max,demand}} = \sum_{i} P_{\text{absorbed},i} \times f_{\text{demand},i} \times f_{\text{diversity},i}\] \[S_{\text{max,demand}} = \sum_{i} \frac{P_{\text{max,demand},i}}{\cos\varphi_i}\]

Overall power factor:

\[\cos\varphi_{\text{overall}} = \frac{P_{\text{max,demand}}}{S_{\text{max,demand}}}\]

Transformer sizing with design margin:

\[S_{\text{transformer}} = S_{\text{max,demand}} \times 1.15\]

Generator sizing (extra margin):

\[S_{\text{generator}} = S_{\text{max,demand}} \times 1.15 \times 1.10\]

8. Efficiency Chain

The total efficiency from electrical supply to shaft output:

\[\eta_{\text{total}} = \eta_{\text{xfmr}} \times \eta_{\text{VFD}} \times \eta_{\text{motor}}\]

Total losses:

\[P_{\text{loss}} = P_{\text{electrical}} - P_{\text{shaft}}\]

For a typical system (IE3 motor, VFD, transformer):

9. ProcessSystem Integration

Workflow

// Step 1: Build and run process
ProcessSystem process = new ProcessSystem();
Stream feed = new Stream("Feed", gas);
Compressor comp1 = new Compressor("1st Stage", feed);
comp1.setOutletPressure(30.0);
Cooler cooler1 = new Cooler("Intercooler", comp1.getOutletStream());
cooler1.setOutTemperature(308.15);
Compressor comp2 = new Compressor("2nd Stage", cooler1.getOutletStream());
comp2.setOutletPressure(80.0);
Pump pump = new Pump("Export Pump", liquidStream);
pump.setOutletPressure(90.0);

process.add(feed);
process.add(comp1);
process.add(cooler1);
process.add(comp2);
process.add(pump);
process.run();

// Step 2: Run electrical designs
process.runAllElectricalDesigns();

// Step 3: Get load list
ElectricalLoadList loadList = process.getElectricalLoadList();
loadList.calculateSummary();
System.out.println("Total connected: " + loadList.getTotalConnectedLoadKW() + " kW");
System.out.println("Max demand: " + loadList.getMaximumDemandKW() + " kW");
System.out.println("Required transformer: " + loadList.getRequiredTransformerKVA() + " kVA");
System.out.println("Overall PF: " + loadList.getOverallPowerFactor());

// Step 4: JSON reports
System.out.println(loadList.toJson());

Individual Equipment Design

ElectricalDesign design = process.getEquipmentElectricalDesign("1st Stage");
System.out.println(design.toJson());

Compressor with VFD

Compressor comp = new Compressor("VFD Compressor", feed);
comp.setUseVFD(true);
// The CompressorElectricalDesign auto-detects VFD from driver type
// and includes auxiliary loads in the total
CompressorElectricalDesign ced =
    (CompressorElectricalDesign) comp.getElectricalDesign();
ced.calcDesign();
System.out.println("Total with auxiliaries: " + ced.getTotalConnectedLoadKW() + " kW");

10. Applicable Standards

Standard Scope Used By
IEC 60034-30-1 Motor efficiency classes IE1–IE4 ElectricalMotor
IEC 60072 Motor frame sizes ElectricalMotor
IEC 60228 Cable conductor sizes ElectricalCable
IEC 60364-5-52 Cable installation / derating ElectricalCable
IEC 60502 Power cables up to 36 kV ElectricalCable
IEC 60949 Short-circuit thermal withstand ElectricalCable
IEC 60076 Power transformers Transformer
IEC 61439 LV switchgear assemblies Switchgear
IEC 61936 Power installations > 1 kV ElectricalLoadList
IEC 60079-10 Hazardous area classification HazardousAreaClassification
IECEx / ATEX Equipment for explosive atmospheres HazardousAreaClassification
IEEE 519 Harmonic limits VariableFrequencyDrive
NEMA MG1 Motor standards (US) ElectricalMotor (NEMA mode)

Class Reference

Class Package Description
ElectricalDesign process.electricaldesign Base class — sizes motor, VFD, cables, switchgear
ElectricalDesignResponse process.electricaldesign JSON serialization helper
ElectricalMotor process.electricaldesign.components AC induction motor model
VariableFrequencyDrive process.electricaldesign.components VFD with harmonics / topology
ElectricalCable process.electricaldesign.components Cable sizing with derating
Transformer process.electricaldesign.components Power transformer model
Switchgear process.electricaldesign.components MCC / switchgear bucket
HazardousAreaClassification process.electricaldesign.components Zone / Ex marking
CompressorElectricalDesign process.electricaldesign.compressor Compressor-specific design
PumpElectricalDesign process.electricaldesign.pump Pump-specific design
SeparatorElectricalDesign process.electricaldesign.separator Separator auxiliary loads (valves, instruments, lighting, heat tracing)
HeatExchangerElectricalDesign process.electricaldesign.heatexchanger Heat exchanger design (electric heater / air cooler / shell-and-tube)
PipelineElectricalDesign process.electricaldesign.pipeline Pipeline heat tracing, cathodic protection, instrumentation
SystemElectricalDesign process.electricaldesign.system Plant-wide aggregation, transformer and generator sizing
LoadItem process.electricaldesign.loadanalysis Single load entry
ElectricalLoadList process.electricaldesign.loadanalysis Plant-wide load aggregation

Equipment-Specific Electrical Design Details

Separator Electrical Design

Separators have no rotating equipment. All electrical loads are auxiliary:

Load Default Typical Range
Control valve actuators 3 × 1.0 kW = 3.0 kW 0.5–2 kW each
Instrumentation 2.0 kW 1–3 kW
Lighting (hazardous area rated) 0.5 kW 0.5–1 kW
Heat tracing (optional) 0 kW 5–20 kW 
Separator sep = new Separator("HP Sep", feed);
sep.run();

SeparatorElectricalDesign elecDesign =
    (SeparatorElectricalDesign) sep.getElectricalDesign();
elecDesign.setNumberOfControlValves(4);
elecDesign.setHasHeatTracing(true);
elecDesign.setHeatTracingKW(10.0);
elecDesign.calcDesign();

System.out.println("Total auxiliary: " + elecDesign.getTotalAuxiliaryKW() + " kW");

Heat Exchanger Electrical Design

The design auto-detects the type from the equipment class:

Equipment Class Detected Type Electrical Scope
Heater ELECTRIC_HEATER Full thermal duty as electrical — motor/cable sizing via base class
Cooler AIR_COOLER Fan motors sized at ~1% of duty (min 2 kW per fan)
Manual override SHELL_AND_TUBE Instrumentation + CW pump only (no motor) 
Heater heater = new Heater("Electric Heater", feed);
heater.setOutTemperature(273.15 + 80.0);
heater.run();

HeatExchangerElectricalDesign hxDesign =
    (HeatExchangerElectricalDesign) heater.getElectricalDesign();
hxDesign.calcDesign();

System.out.println("Type: " + hxDesign.getHeatExchangerType());
System.out.println("Input: " + hxDesign.getElectricalInputKW() + " kW");

Pipeline Electrical Design

Pipelines have no shaft power but may have significant distributed loads:

Load Default Formula
Heat tracing Off $P_{\text{EHT}} = W_{\text{per_m}} \times L / 1000$ (kW)
Cathodic protection Off Fixed kW (default 2.0 kW per TR unit)
Instrumentation 1.0 kW Fixed 
AdiabaticPipe pipe = new AdiabaticPipe("Export Line", feed);
pipe.setLength(50000.0);
pipe.setDiameter(0.508);
pipe.run();

PipelineElectricalDesign pipeDesign =
    (PipelineElectricalDesign) pipe.getElectricalDesign();
pipeDesign.setHasHeatTracing(true);
pipeDesign.setHeatTracingWPerM(25.0);  // 25 W/m
pipeDesign.setHasCathodicProtection(true);
pipeDesign.setCathodicProtectionKW(3.0);
pipeDesign.calcDesign();

// Heat tracing: 25 W/m × 50000 m = 1250 kW
System.out.println("Total: " + pipeDesign.getTotalAuxiliaryKW() + " kW");

System Electrical Design (Plant-Wide)

Aggregates all equipment loads and adds system-level requirements:

\[P_{\text{plant}} = P_{\text{process}} + P_{\text{utility}} + P_{\text{UPS}}\] \[S_{\text{transformer}} = \frac{P_{\text{plant}} \times (1 + f_{\text{expansion}})}{\cos\varphi}\]
Parameter Default Description
Utility load 7% of process HVAC, lighting, fire & gas
UPS load 2% of process Critical instrumentation
Future expansion 15% Design margin for growth
Emergency generator 35% of plant Essential loads
Main bus voltage 11 kV HV distribution
Distribution voltage 400 V LV distribution 
ProcessSystem process = new ProcessSystem();
// ... add equipment ...
process.run();

SystemElectricalDesign sysDesign = process.getSystemElectricalDesign();

System.out.println("Process load:    " + sysDesign.getTotalProcessLoadKW() + " kW");
System.out.println("Plant load:      " + sysDesign.getTotalPlantLoadKW() + " kW");
System.out.println("Main transformer: " + sysDesign.getMainTransformerKVA() + " kVA");
System.out.println("Emergency gen:   " + sysDesign.getEmergencyGeneratorKVA() + " kVA");

11. Motor Mechanical Design Integration

The electrical design package sizes motor and cable from an electrical perspective. MotorMechanicalDesign complements this by computing the physical and mechanical aspects of the selected motor:

Aspect Electrical Design Motor Mechanical Design
Motor sizing Rated power, voltage, efficiency class Weight, frame dimensions, cooling
Drive selection VFD topology, harmonics, cable sizing VFD derating notes, bearing currents
Environment Hazardous area zone, Ex marking IP rating, enclosure type, NORSOK noise
Structural — Foundation mass, bolt pattern, vibration zone
Reliability — Bearing L10 life, lubrication interval

Linking Electrical and Mechanical Motor Design

MotorMechanicalDesign can take its inputs directly from a completed ElectricalDesign, avoiding manual re-entry of motor parameters:

// After running electrical design
ElectricalDesign elecDesign = compressor.getElectricalDesign();
elecDesign.calcDesign();

// Create motor mechanical design from electrical results
MotorMechanicalDesign motorDesign = new MotorMechanicalDesign(compressor);
motorDesign.setFromElectricalDesign(elecDesign);
motorDesign.calcDesign();

// Motor physical properties
System.out.println("Weight: " + motorDesign.getMotorWeightKg() + " kg");
System.out.println("Foundation: " + motorDesign.getFoundationType());
System.out.println("Vibration zone: " + motorDesign.getVibrationZone());
System.out.println("Noise: " + motorDesign.getSoundPressureLevelAt1mDbA() + " dB(A)");
System.out.println("Bearing L10: " + motorDesign.getBearingL10LifeHours() + " hours");

See the Motor Mechanical Design Guide for full API reference and design calculation details.

12. Combined Equipment Design Report

EquipmentDesignReport aggregates mechanical design, electrical design, and motor mechanical design into a single report with an overall feasibility verdict:

EquipmentDesignReport report = new EquipmentDesignReport(compressor);
report.setHazardousZone(1);
report.setAmbientTemperatureC(45.0);
report.generateReport();

String verdict = report.getVerdict();      // FEASIBLE / FEASIBLE_WITH_WARNINGS / NOT_FEASIBLE
String json = report.toJson();             // Full combined JSON report
Map<String, Object> loadEntry = report.toLoadListEntry();  // For electrical load list

The report runs all three design layers in sequence and collects any issues:

  1. Mechanical design — wall thickness, weight, materials (from equipment-specific MechanicalDesign)
  2. Electrical design — motor, cable, VFD, switchgear, hazardous area (from ElectricalDesign)
  3. Motor mechanical design — foundation, vibration, cooling, bearings, noise (from MotorMechanicalDesign)

See the Motor Mechanical Design Guide — Combined Report for JSON output structure and full configuration options.