Mechanical Design Framework

NeqSim provides a comprehensive mechanical design framework for sizing and specifying process equipment according to industry standards. This document describes the architecture, usage patterns, and JSON export capabilities.

📘 Related Documentation

Topic Documentation

Pipelines Pipeline Mechanical Design - Wall thickness, stress analysis, cost estimation

Mathematical Methods Pipeline Design Math - Complete formula reference

Design Standards Mechanical Design Standards - Industry standards reference

Database Mechanical Design Database - Material properties, design factors

Cost Estimation COST_ESTIMATION_FRAMEWORK.md - CAPEX, OPEX, currency, location factors

Design Parameters EQUIPMENT_DESIGN_PARAMETERS.md - autoSize vs manual sizing guide

Topic	Documentation
Pipelines	Pipeline Mechanical Design - Wall thickness, stress analysis, cost estimation
Mathematical Methods	Pipeline Design Math - Complete formula reference
Design Standards	Mechanical Design Standards - Industry standards reference
Database	Mechanical Design Database - Material properties, design factors
Cost Estimation	COST_ESTIMATION_FRAMEWORK.md - CAPEX, OPEX, currency, location factors
Design Parameters	EQUIPMENT_DESIGN_PARAMETERS.md - autoSize vs manual sizing guide

Overview

The mechanical design system calculates:

Equipment sizing - Vessel dimensions, wall thickness, nozzle sizes
Weight estimation - Empty, operating, and test weights with breakdowns
Design conditions - Pressure and temperature with appropriate margins
Module dimensions - Plot space requirements for installation planning
Utility requirements - Power consumption, heating/cooling duties
Cost estimation - Material, fabrication, installation, and project costs
Bill of Materials - Complete BOM with quantities and costs

Architecture

Class Hierarchy

MechanicalDesign (base class)
├── SeparatorMechanicalDesign      → ASME VIII / API 12J
├── GasScrubberMechanicalDesign    → ASME VIII / API 12J
├── CompressorMechanicalDesign     → API 617
├── PumpMechanicalDesign           → API 610
├── ValveMechanicalDesign          → IEC 60534 / ANSI/ISA-75
├── ExpanderMechanicalDesign       → API 617
├── TankMechanicalDesign           → API 650/620
├── HeatExchangerMechanicalDesign  → TEMA
├── PipelineMechanicalDesign       → ASME B31.3/B31.4/B31.8, DNV-OS-F101, API 5L
│   └── PipeMechanicalDesignCalculator (wall thickness, stress, cost)
├── AdsorberMechanicalDesign       → ASME VIII
├── AbsorberMechanicalDesign       → ASME VIII
├── EjectorMechanicalDesign        → HEI
└── SafetyValveMechanicalDesign    → API 520/521

Pipeline Mechanical Design Features

The PipelineMechanicalDesign class provides comprehensive pipeline design including:

Feature	Description
Wall Thickness	ASME B31.3/B31.4/B31.8, DNV-OS-F101 calculations
Stress Analysis	Hoop, longitudinal, von Mises stress
External Pressure	Collapse and propagation buckling
Weight/Buoyancy	Steel, coating, concrete, contents
Thermal Design	Expansion loops, insulation sizing
Structural Design	Support spacing, spans, bend radius
Fatigue Analysis	S-N curves per DNV-RP-C203
Cost Estimation	Complete project cost with BOM

See Pipeline Mechanical Design for details.

Response Classes for JSON Export

MechanicalDesignResponse (base class)
├── CompressorMechanicalDesignResponse
├── PumpMechanicalDesignResponse
├── ValveMechanicalDesignResponse
├── SeparatorMechanicalDesignResponse
└── HeatExchangerMechanicalDesignResponse

System-Level Aggregation

SystemMechanicalDesign
└── Aggregates all equipment in a ProcessSystem
    ├── Total weights and volumes
    ├── Weight breakdown by equipment type
    ├── Weight breakdown by discipline
    ├── Utility requirements summary
    └── Equipment list with design parameters

Usage Patterns

Individual Equipment Design

// Create and run process equipment
SystemInterface fluid = new SystemSrkEos(298.0, 50.0);
fluid.addComponent("methane", 0.9);
fluid.addComponent("ethane", 0.1);
fluid.setMixingRule("classic");

Stream inlet = new Stream("feed", fluid);
inlet.setFlowRate(10000.0, "kg/hr");
inlet.run();

Separator separator = new Separator("V-100", inlet);
separator.run();

// Access mechanical design
MechanicalDesign mecDesign = separator.getMechanicalDesign();

// Set design standards (optional - uses defaults if not specified)
mecDesign.setCompanySpecificDesignStandards("Equinor");

// Calculate design
mecDesign.calcDesign();

// Access results
double weight = mecDesign.getWeightTotal();           // kg
double wallThickness = mecDesign.getWallThickness();  // mm
double innerDiameter = mecDesign.getInnerDiameter();  // m
double length = mecDesign.getTantanLength();          // m
double designPressure = mecDesign.getMaxDesignPressure(); // bara

// Display results in GUI
mecDesign.displayResults();

System-Wide Mechanical Design

// Build a process system
ProcessSystem process = new ProcessSystem();
process.add(inlet);
process.add(separator);
process.add(gasStream);
process.add(compressor);
process.add(cooler);
process.add(outlet);
process.run();

// Create system mechanical design
SystemMechanicalDesign sysMecDesign = new SystemMechanicalDesign(process);

// Set company standards for all equipment
sysMecDesign.setCompanySpecificDesignStandards("Equinor");

// Run design calculations for all equipment
sysMecDesign.runDesignCalculation();

// Access aggregated results
double totalWeight = sysMecDesign.getTotalWeight();           // kg
double totalVolume = sysMecDesign.getTotalVolume();           // m³
double plotSpace = sysMecDesign.getTotalPlotSpace();          // m²
double powerRequired = sysMecDesign.getTotalPowerRequired();  // kW
double heatingDuty = sysMecDesign.getTotalHeatingDuty();      // kW
double coolingDuty = sysMecDesign.getTotalCoolingDuty();      // kW

// Get breakdowns
Map<String, Double> weightByType = sysMecDesign.getWeightByEquipmentType();
Map<String, Double> weightByDiscipline = sysMecDesign.getWeightByDiscipline();
Map<String, Integer> countByType = sysMecDesign.getEquipmentCountByType();

// Print summary report
System.out.println(sysMecDesign.generateSummaryReport());

JSON Export

Exporting Individual Equipment

// Calculate design
separator.getMechanicalDesign().calcDesign();

// Export to JSON
String json = separator.getMechanicalDesign().toJson();

// Example output:
/*
{
  "name": "V-100",
  "equipmentType": "Separator",
  "equipmentClass": "Separator",
  "designStandard": "ASME VIII / API 12J",
  "isSystemLevel": false,
  "totalWeight": 15420.5,
  "vesselWeight": 8500.0,
  "internalsWeight": 1200.0,
  "pipingWeight": 2100.0,
  "eiWeight": 1500.0,
  "structuralWeight": 2120.5,
  "maxDesignPressure": 55.0,
  "maxDesignTemperature": 80.0,
  "innerDiameter": 2.4,
  "tangentLength": 7.2,
  "wallThickness": 28.5,
  "moduleLength": 10.0,
  "moduleWidth": 5.0,
  "moduleHeight": 4.5,
  ...
}
*/

Exporting System-Wide Design

SystemMechanicalDesign sysMecDesign = new SystemMechanicalDesign(process);
sysMecDesign.runDesignCalculation();

String json = sysMecDesign.toJson();

// Example output:
/*
{
  "isSystemLevel": true,
  "processName": "Gas Processing Unit",
  "equipmentCount": 12,
  "totalWeight": 185000.0,
  "totalVolume": 450.5,
  "totalPlotSpace": 1200.0,
  "totalPowerRequired": 2500.0,
  "totalPowerRecovered": 150.0,
  "netPower": 2350.0,
  "totalHeatingDuty": 500.0,
  "totalCoolingDuty": 1800.0,
  "footprintLength": 40.0,
  "footprintWidth": 30.0,
  "maxHeight": 15.0,
  "weightByType": {
    "Separator": 45000.0,
    "Compressor": 85000.0,
    "HeatExchanger": 25000.0,
    "Valve": 5000.0,
    "Pump": 12000.0,
    "Other": 13000.0
  },
  "weightByDiscipline": {
    "Mechanical": 120000.0,
    "Piping": 35000.0,
    "E&I": 18000.0,
    "Structural": 12000.0
  },
  "equipmentList": [
    {
      "name": "V-100",
      "type": "Separator",
      "weight": 15420.5,
      "designPressure": 55.0,
      "designTemperature": 80.0,
      "power": 0.0,
      "duty": 0.0,
      "dimensions": "ID 2.4m x TT 7.2m"
    },
    ...
  ]
}
*/

Comprehensive Mechanical Design Report (JSON)

The MechanicalDesignReport class provides a combined JSON output that includes all mechanical design data for a process system, similar to how Report.generateJsonReport() works for process simulation:

// Create comprehensive mechanical design report
MechanicalDesignReport mechReport = new MechanicalDesignReport(process);
mechReport.runDesignCalculations();

// Generate combined JSON with all mechanical design data
String json = mechReport.toJson();

// Write to file
mechReport.writeJsonReport("mechanical_design_report.json");

// Example output structure:
/*
{
  "processName": "Gas Processing Unit",
  "reportType": "MechanicalDesignReport",
  "generatedAt": "2026-01-11T10:30:00Z",
  "systemSummary": {
    "totalEquipmentWeight_kg": 185000.0,
    "totalPipingWeight_kg": 35000.0,
    "totalWeight_kg": 220000.0,
    "totalVolume_m3": 450.5,
    "totalPlotSpace_m2": 1200.0,
    "equipmentCount": 12
  },
  "utilityRequirements": {
    "totalPowerRequired_kW": 2500.0,
    "totalPowerRecovered_kW": 150.0,
    "netPowerRequirement_kW": 2350.0,
    "totalHeatingDuty_kW": 500.0,
    "totalCoolingDuty_kW": 1800.0
  },
  "weightByEquipmentType": {
    "Separator": 45000.0,
    "Compressor": 85000.0,
    "HeatExchanger": 25000.0,
    "Valve": 5000.0,
    "Pump": 12000.0
  },
  "weightByDiscipline": {
    "Mechanical": 120000.0,
    "Piping": 35000.0,
    "E&I": 18000.0,
    "Structural": 12000.0
  },
  "equipment": [
    {
      "name": "V-100",
      "type": "Separator",
      "mechanicalDesign": {
        "designPressure": 55.0,
        "designTemperature": 80.0,
        "wallThickness": 28.5,
        "weight": 15420.5,
        ...
      }
    },
    ...
  ],
  "pipingDesign": {
    "totalLength_m": 450.0,
    "totalWeight_kg": 35000.0,
    "valveWeight_kg": 8500.0,
    "flangeWeight_kg": 4200.0,
    "fittingWeight_kg": 3100.0,
    "weightBySize": {
      "4 inch": 5200.0,
      "6 inch": 8400.0,
      "8 inch": 12300.0,
      ...
    },
    "pipeSegments": [
      {
        "fromEquipment": "V-100",
        "toEquipment": "K-100",
        "nominalSizeInch": 8.0,
        "outsideDiameter_mm": 219.1,
        "wallThickness_mm": 8.18,
        "schedule": "40",
        "length_m": 25.0,
        "weight_kg": 1050.0,
        "designPressure_bara": 55.0,
        "material": "A106-B",
        "isGasService": true
      },
      ...
    ]
  }
}
*/

Comparison: Process Simulation vs Mechanical Design JSON

Use Case	Class	Method
Process simulation results	`Report`	`generateJsonReport()`
System mechanical design only	`SystemMechanicalDesign`	`toJson()`
Complete mechanical design with piping	`MechanicalDesignReport`	`toJson()`

The MechanicalDesignReport.toJson() method provides the most comprehensive output, combining:

System-level aggregation from SystemMechanicalDesign
Individual equipment mechanical design data
Piping interconnection design from ProcessInterconnectionDesign

Using Specialized Response Classes

For equipment-specific data, use the typed response:

// Compressor-specific response
CompressorMechanicalDesignResponse response = 
    (CompressorMechanicalDesignResponse) compressor.getMechanicalDesign().getResponse();

int stages = response.getNumberOfStages();
double impellerDiameter = response.getImpellerDiameter();  // mm
double tipSpeed = response.getTipSpeed();                   // m/s
double driverPower = response.getDriverPower();             // kW
double tripSpeed = response.getTripSpeed();                 // rpm

// Valve-specific response
ValveMechanicalDesignResponse valveResponse = 
    (ValveMechanicalDesignResponse) valve.getMechanicalDesign().getResponse();

int ansiClass = valveResponse.getAnsiPressureClass();
double cvMax = valveResponse.getCvMax();
double faceToFace = valveResponse.getFaceToFace();  // mm
String valveType = valveResponse.getValveType();

Round-Trip Parsing

// Export to JSON
String json = sysMecDesign.toJson();

// Parse back to object
MechanicalDesignResponse parsed = MechanicalDesignResponse.fromJson(json);

// Access parsed data
double weight = parsed.getTotalWeight();
boolean isSystem = parsed.isSystemLevel();

Merging with Process Data

// Get mechanical design response
MechanicalDesignResponse mecResponse = sysMecDesign.getResponse();

// Get process simulation JSON
String processJson = process.toJson();

// Merge into combined document
String combined = mecResponse.mergeWithEquipmentJson(processJson);

// Result has both "processData" and "mechanicalDesign" sections

Process Design Parameters

Process design parameters define the sizing basis and validation limits for equipment per industry standards. These parameters can be loaded from the database or set manually.

Loading from Database

// Load company-specific process design standards
separator.getMechanicalDesign().setCompanySpecificDesignStandards("MyCompany");
separator.getMechanicalDesign().loadProcessDesignParameters();  // Loads from TechnicalRequirements_Process table

Equipment Process Design Parameters

Separator Process Design Parameters

Parameter	Method	Unit	Typical Range	Description
Foam allowance factor	`getFoamAllowanceFactor()`	-	1.0-1.5	Liquid level increase due to foaming
Gas-liquid droplet diameter	`getDropletDiameterGasLiquid()`	μm	100-150	Design droplet size for gas-liquid separation
Liquid-liquid droplet diameter	`getDropletDiameterLiquidLiquid()`	μm	300-500	Design droplet size for liquid-liquid separation
Maximum gas velocity	`getMaxGasVelocityLimit()`	m/s	2.0-4.0	Upper limit for gas velocity
Maximum liquid velocity	`getMaxLiquidVelocity()`	m/s	0.5-1.5	Upper limit for liquid outlet velocity
Minimum oil retention time	`getMinOilRetentionTime()`	min	2.0-5.0	Minimum oil residence time
Minimum water retention time	`getMinWaterRetentionTime()`	min	3.0-10.0	Minimum water residence time
Demister pressure drop	`getDemisterPressureDrop()`	mbar	1.0-3.0	Design pressure drop across mist eliminator
Demister void fraction	`getDemisterVoidFraction()`	-	0.97-0.99	Wire mesh demister void fraction
Design pressure margin	`getDesignPressureMargin()`	-	1.05-1.15	Factor above max operating pressure

Compressor Process Design Parameters

Parameter	Method	Unit	Typical Range	Description
Surge margin	`getSurgeMarginPercent()`	%	10-20	Minimum margin from surge line
Stonewall margin	`getStonewallMarginPercent()`	%	10-15	Minimum margin from stonewall
Minimum turndown	`getTurndownPercent()`	%	60-80	Minimum operating flow as % of design
Target polytropic efficiency	`getTargetPolytropicEfficiency()`	%	75-85	Design efficiency target
Maximum discharge temperature	`getMaxDischargeTemperatureC()`	°C	150-180	Material/process limit
Maximum pressure ratio per stage	`getMaxPressureRatioPerStage()`	-	2.5-3.5	Single stage limit
Maximum vibration	`getMaxVibrationMmPerSec()`	mm/s	2.0-4.0	Unfiltered vibration limit
Seal type	`getSealType()`	-	-	Dry gas, oil film, labyrinth
Bearing type	`getBearingType()`	-	-	Tilting pad, plain, magnetic

Pump Process Design Parameters (API-610)

Parameter	Method	Unit	Typical Range	Description
NPSH margin factor	`getNpshMarginFactor()`	-	1.1-1.3	NPSHa / NPSHr requirement
Hydraulic power margin	`getHydraulicPowerMargin()`	-	1.05-1.15	Driver sizing margin
POR low fraction	`getPorLowFraction()`	-	0.70-0.80	Preferred Operating Region low limit (of BEP)
POR high fraction	`getPorHighFraction()`	-	1.10-1.15	Preferred Operating Region high limit (of BEP)
AOR low fraction	`getAorLowFraction()`	-	0.60-0.70	Allowable Operating Region low limit
AOR high fraction	`getAorHighFraction()`	-	1.20-1.30	Allowable Operating Region high limit
Maximum suction specific speed	`getMaxSuctionSpecificSpeed()`	-	8000-13000	Nss limit for stable operation
Head margin factor	`getHeadMarginFactor()`	-	1.05-1.10	Head design margin

Heat Exchanger Process Design Parameters (TEMA)

Parameter	Method	Unit	Typical Range	Description
Shell fouling resistance (HC)	`getFoulingResistanceShellHC()`	m²K/W	0.00018-0.00053	Hydrocarbon service
Tube fouling resistance (HC)	`getFoulingResistanceTubeHC()`	m²K/W	0.00018-0.00053	Hydrocarbon service
Shell fouling resistance (water)	`getFoulingResistanceShellWater()`	m²K/W	0.00009-0.00035	Water service
Tube fouling resistance (water)	`getFoulingResistanceTubeWater()`	m²K/W	0.00009-0.00035	Water service
Maximum tube velocity	`getMaxTubeVelocity()`	m/s	2.0-4.0	Erosion limit
Minimum tube velocity	`getMinTubeVelocity()`	m/s	0.5-1.0	Fouling prevention
Maximum shell velocity	`getMaxShellVelocity()`	m/s	1.5-3.0	Vibration/erosion limit
Minimum approach temperature	`getMinApproachTemperatureC()`	°C	5-15	Heat exchanger pinch
Maximum tube length	`getMaxTubeLengthM()`	m	3.0-9.0	Physical/mechanical limit
TEMA class	`getTemaClass()`	-	R, C, B	Equipment class designation

Design Validation

The mechanical design framework includes validation methods to verify designs against process requirements and industry standards. Each equipment class provides both individual parameter validation and comprehensive design validation.

Validation Result Classes

Each equipment type has a validation result class that collects issues:

// Separator validation
SeparatorMechanicalDesign.SeparatorValidationResult result = sepDesign.validateDesignComprehensive();
if (!result.isValid()) {
    for (String issue : result.getIssues()) {
        System.out.println("Issue: " + issue);
    }
}

// Compressor validation
CompressorMechanicalDesign.CompressorValidationResult result = compDesign.validateDesign();

// Pump validation  
PumpMechanicalDesign.PumpValidationResult result = pumpDesign.validateDesign();

// Heat exchanger validation
HeatExchangerMechanicalDesign.HeatExchangerValidationResult result = hxDesign.validateDesign();

Individual Parameter Validation

Separator Validation Methods

SeparatorMechanicalDesign sepDesign = (SeparatorMechanicalDesign) separator.getMechanicalDesign();

// Validate gas velocity
boolean gasVelOk = sepDesign.validateGasVelocity(actualVelocity);  // m/s

// Validate liquid velocity  
boolean liqVelOk = sepDesign.validateLiquidVelocity(actualVelocity);  // m/s

// Validate retention time (isOil = true for oil, false for water)
boolean retTimeOk = sepDesign.validateRetentionTime(actualMinutes, isOil);

// Validate droplet diameter (isGasLiquid = true for gas-liquid separation)
boolean dropletOk = sepDesign.validateDropletDiameter(actualDiameterUm, isGasLiquid);

Compressor Validation Methods

CompressorMechanicalDesign compDesign = compressor.getMechanicalDesign();

// Validate polytropic efficiency (value as percentage, e.g., 78.0 for 78%)
boolean effOk = compDesign.validateEfficiency(actualEfficiencyPercent);

// Validate discharge temperature
boolean tempOk = compDesign.validateDischargeTemperature(actualTempC);

// Validate pressure ratio per stage
boolean prOk = compDesign.validatePressureRatioPerStage(actualPressureRatio);

// Validate vibration
boolean vibOk = compDesign.validateVibration(actualVibrationMmPerSec);

Pump Validation Methods

PumpMechanicalDesign pumpDesign = pump.getMechanicalDesign();

// Validate NPSH margin
boolean npshOk = pumpDesign.validateNpshMargin(npshAvailable, npshRequired);

// Validate operating in Preferred Operating Region
boolean porOk = pumpDesign.validateOperatingInPOR(operatingFlow, bepFlow);

// Validate operating in Allowable Operating Region  
boolean aorOk = pumpDesign.validateOperatingInAOR(operatingFlow, bepFlow);

// Validate suction specific speed
boolean nssOk = pumpDesign.validateSuctionSpecificSpeed(actualNss);

Heat Exchanger Validation Methods

HeatExchangerMechanicalDesign hxDesign = heatExchanger.getMechanicalDesign();

// Validate tube velocity (must be between min and max)
boolean tubeVelOk = hxDesign.validateTubeVelocity(actualVelocity);

// Validate shell velocity
boolean shellVelOk = hxDesign.validateShellVelocity(actualVelocity);

// Validate approach temperature
boolean approachOk = hxDesign.validateApproachTemperature(actualApproachC);

// Validate tube length
boolean lengthOk = hxDesign.validateTubeLength(actualLengthM);

Comprehensive Validation Example

// Run equipment
separator.run();
separator.getMechanicalDesign().calcDesign();

// Comprehensive validation
SeparatorMechanicalDesign sepDesign = (SeparatorMechanicalDesign) separator.getMechanicalDesign();
SeparatorMechanicalDesign.SeparatorValidationResult result = sepDesign.validateDesignComprehensive();

System.out.println("Design valid: " + result.isValid());
System.out.println("Issues found: " + result.getIssues().size());

for (String issue : result.getIssues()) {
    System.out.println("  - " + issue);
}

// Example output:
// Design valid: false
// Issues found: 2
//   - Gas velocity 3.50 m/s exceeds maximum 3.00 m/s
//   - L/D ratio 7.5 outside recommended range 2.0-6.0

Equipment-Specific Design Standards

Separators (API 12J / ASME VIII / NORSOK P-001)

SeparatorMechanicalDesign sepDesign = 
    (SeparatorMechanicalDesign) separator.getMechanicalDesign();

// Key parameters
double gasLoadFactor = sepDesign.getGasLoadFactor();      // K-factor
double retentionTime = sepDesign.getRetentionTime();      // seconds
double liquidLevelFraction = sepDesign.getFg();           // Fg factor

// Process design parameters
double foamFactor = sepDesign.getFoamAllowanceFactor();
double maxGasVel = sepDesign.getMaxGasVelocityLimit();
double minOilRetention = sepDesign.getMinOilRetentionTime();  // minutes

Design calculations include:

Gas capacity based on Souders-Brown equation
Liquid retention time requirements
Vessel L/D optimization
Demister sizing with pressure drop calculation
Nozzle sizing per API RP 14E
Foam allowance for foaming services

Compressors (API 617)

CompressorMechanicalDesign compDesign = 
    (CompressorMechanicalDesign) compressor.getMechanicalDesign();

// Key parameters
int stages = compDesign.getNumberOfStages();
double headPerStage = compDesign.getHeadPerStage();       // kJ/kg
double impellerDia = compDesign.getImpellerDiameter();    // mm
double tipSpeed = compDesign.getTipSpeed();                // m/s
double driverPower = compDesign.getDriverPower();          // kW

// Process design parameters
double surgeMargin = compDesign.getSurgeMarginPercent();
double stonewallMargin = compDesign.getStonewallMarginPercent();
double turndown = compDesign.getTurndownPercent();
double targetEff = compDesign.getTargetPolytropicEfficiency();
double maxDischargeTemp = compDesign.getMaxDischargeTemperatureC();
String sealType = compDesign.getSealType();
String bearingType = compDesign.getBearingType();

Design calculations include:

Number of stages based on max head per stage (30 kJ/kg typical)
Impeller sizing based on flow coefficient
Driver margin per API 617 (10-25% depending on power)
Casing type selection (barrel vs split)
Rotordynamic estimates (critical speeds)
Surge/stonewall margin verification
Discharge temperature limit checking

Pumps (API 610)

PumpMechanicalDesign pumpDesign = 
    (PumpMechanicalDesign) pump.getMechanicalDesign();

// Key parameters
double specificSpeed = pumpDesign.getSpecificSpeed();
double npshRequired = pumpDesign.getNpshRequired();        // m
double impellerDia = pumpDesign.getImpellerDiameter();     // mm
double driverPower = pumpDesign.getDriverPower();          // kW

// Process design parameters
double npshMarginFactor = pumpDesign.getNpshMarginFactor();
double porLow = pumpDesign.getPorLowFraction();   // Preferred Operating Region
double porHigh = pumpDesign.getPorHighFraction();
double aorLow = pumpDesign.getAorLowFraction();   // Allowable Operating Region
double aorHigh = pumpDesign.getAorHighFraction();
double maxNss = pumpDesign.getMaxSuctionSpecificSpeed();
double headMargin = pumpDesign.getHeadMarginFactor();

Design calculations include:

Pump type selection (OH, BB, VS) based on application
Impeller sizing from affinity laws
NPSH margin verification against requirements
Driver margin per API 610 (10-25%)
Seal type selection
Operating region validation (POR/AOR vs BEP)
Suction specific speed verification

Valves (IEC 60534)

ValveMechanicalDesign valveDesign = 
    (ValveMechanicalDesign) valve.getMechanicalDesign();

// Key parameters
double cvMax = valveDesign.getValveCvMax();
int ansiClass = valveDesign.getAnsiPressureClass();
double faceToFace = valveDesign.getFaceToFace();           // mm
double actuatorThrust = valveDesign.getRequiredActuatorThrust(); // N

Design calculations include:

Cv/Kv sizing per IEC 60534
ANSI pressure class selection
Body sizing and wall thickness
Actuator sizing
Face-to-face dimensions per ANSI/ISA

Heat Exchangers (TEMA)

HeatExchangerMechanicalDesign hxDesign = 
    (HeatExchangerMechanicalDesign) heatExchanger.getMechanicalDesign();

// Key parameters
double area = hxDesign.getHeatTransferArea();              // m²
double uValue = hxDesign.getOverallHeatTransferCoefficient(); // W/m²K
int tubeCount = hxDesign.getTubeCount();
double shellDiameter = hxDesign.getShellDiameter();        // mm

// Process design parameters  
double shellFouling = hxDesign.getFoulingResistanceShellHC();  // m²K/W
double tubeFouling = hxDesign.getFoulingResistanceTubeHC();    // m²K/W
double maxTubeVel = hxDesign.getMaxTubeVelocity();             // m/s
double minTubeVel = hxDesign.getMinTubeVelocity();             // m/s
double maxShellVel = hxDesign.getMaxShellVelocity();           // m/s
double minApproach = hxDesign.getMinApproachTemperatureC();    // °C
double maxTubeLength = hxDesign.getMaxTubeLengthM();           // m
String temaClass = hxDesign.getTemaClass();                    // "R", "C", or "B"

// Calculate clean and fouled U-values
double cleanU = hxDesign.calculateCleanU(shellHTC, tubeHTC, wallThickness, conductivity);
double fouledU = hxDesign.calculateFouledU(cleanU, shellIsWater, tubeIsWater);

Design calculations include:

Heat transfer area calculation with fouling allowance
Tube count and layout per TEMA standards
Shell diameter sizing
Baffle spacing optimization
Pressure drop verification
Velocity limits for erosion/fouling prevention
Approach temperature validation
TEMA class (R, C, B) specification

Tanks (API 650/620)

Design calculations include:

Shell course thickness
Bottom plate sizing
Roof type selection
Wind/seismic loads
Foundation requirements

Weight Breakdown Categories

By Equipment Type

Separator
Compressor
Pump
Valve
HeatExchanger
Tank
Expander
Pipeline
Other

By Discipline

Mechanical - Vessel shells, rotating equipment, internals
Piping - Process piping, valves, fittings
E&I - Electrical, instrumentation, control systems
Structural - Steel supports, platforms, ladders

Design Margins

The framework applies industry-standard margins:

Parameter	Margin	Standard
Design Pressure	+10% above max operating	ASME VIII
Design Temperature	+30°C above max operating	ASME VIII
Driver Power (small)	+25% for < 22 kW	API 610/617
Driver Power (medium)	+15% for 22-75 kW	API 610/617
Driver Power (large)	+10% for > 75 kW	API 610/617
Wall Thickness	+CA (corrosion allowance)	ASME VIII

Integration with Cost Estimation

Each mechanical design class has an associated cost estimation class in neqsim.process.costestimation:

// Access cost estimate from mechanical design
UnitCostEstimateBaseClass costEstimate = mecDesign.getCostEstimate();
double equipmentCost = costEstimate.getEquipmentCost();    // USD
double installedCost = costEstimate.getInstalledCost();    // USD

Comprehensive Cost Estimation Framework

For detailed cost estimation including OPEX, financial metrics, currency conversion, and location factors, see the dedicated cost estimation documentation:

Document	Description
COST_ESTIMATION_FRAMEWORK.md	Comprehensive guide to capital and operating cost estimation
COST_ESTIMATION_API_REFERENCE.md	Detailed API reference for all cost estimation classes

Key Features:

Equipment costs using Turton et al., Peters & Timmerhaus, GPSA correlations
14+ equipment types (separators, compressors, heat exchangers, tanks, expanders, ejectors, absorbers, etc.)
Multi-currency support (USD, EUR, NOK, GBP, CNY, JPY)
Location factors for 11 global regions
Operating cost (OPEX) calculation with utility costs
Financial metrics (payback period, ROI, NPV)
Process-level cost aggregation with ProcessCostEstimate

// Example: Process-level cost estimation
ProcessCostEstimate processCost = new ProcessCostEstimate(process);

// Set location and currency
processCost.setLocationByRegion("North Sea");
processCost.setCurrency("NOK");

// Calculate costs
processCost.calculateCosts();

// Get results in selected currency
double totalCAPEX = processCost.getTotalCapitalCost();  // NOK
double totalOPEX = processCost.calculateOperatingCost(8760);  // NOK/year

// Export comprehensive JSON report
String json = processCost.toJson();

Best Practices

Always run equipment before calculating design - The mechanical design uses process conditions from the simulation.
Set design standards early - Call setCompanySpecificDesignStandards() before calcDesign().
Use system-level design for complete estimates - SystemMechanicalDesign handles all equipment consistently.
Export JSON for documentation - The toJson() method provides comprehensive, structured output.
Verify critical parameters - Check that design pressure/temperature exceed operating conditions.

Example: Complete Workflow

// 1. Create fluid system
SystemInterface fluid = new SystemSrkEos(298.0, 50.0);
fluid.addComponent("methane", 0.85);
fluid.addComponent("ethane", 0.10);
fluid.addComponent("propane", 0.05);
fluid.setMixingRule("classic");

// 2. Build process
Stream feed = new Stream("feed", fluid);
feed.setFlowRate(50000.0, "kg/hr");

Separator separator = new Separator("V-100", feed);

Stream gas = new Stream("gas", separator.getGasOutStream());

Compressor compressor = new Compressor("K-100", gas);
compressor.setOutletPressure(80.0, "bara");

Cooler cooler = new Cooler("E-100", compressor.getOutletStream());
cooler.setOutTemperature(40.0, "C");

ProcessSystem process = new ProcessSystem();
process.add(feed);
process.add(separator);
process.add(gas);
process.add(compressor);
process.add(cooler);
process.run();

// 3. Calculate mechanical design
SystemMechanicalDesign sysMecDesign = new SystemMechanicalDesign(process);
sysMecDesign.setCompanySpecificDesignStandards("Equinor");
sysMecDesign.runDesignCalculation();

// 4. Generate reports
System.out.println(sysMecDesign.generateSummaryReport());

// 5. Export JSON for documentation/integration
String json = sysMecDesign.toJson();
Files.write(Paths.get("mechanical_design.json"), json.getBytes());

// 6. Access specific equipment details
CompressorMechanicalDesignResponse compResponse = 
    (CompressorMechanicalDesignResponse) compressor.getMechanicalDesign().getResponse();
System.out.println("Compressor stages: " + compResponse.getNumberOfStages());
System.out.println("Driver power: " + compResponse.getDriverPower() + " kW");

Mechanical Design Framework

Overview

Architecture

Class Hierarchy

Pipeline Mechanical Design Features

Response Classes for JSON Export

System-Level Aggregation

Usage Patterns

Individual Equipment Design

System-Wide Mechanical Design

JSON Export

Exporting Individual Equipment

Exporting System-Wide Design

Comprehensive Mechanical Design Report (JSON)

Comparison: Process Simulation vs Mechanical Design JSON

Using Specialized Response Classes

Round-Trip Parsing

Merging with Process Data

Process Design Parameters

Loading from Database

Equipment Process Design Parameters

Separator Process Design Parameters

Compressor Process Design Parameters

Pump Process Design Parameters (API-610)

Heat Exchanger Process Design Parameters (TEMA)

Design Validation

Validation Result Classes

Individual Parameter Validation

Separator Validation Methods

Compressor Validation Methods

Pump Validation Methods

Heat Exchanger Validation Methods

Comprehensive Validation Example

Equipment-Specific Design Standards

Separators (API 12J / ASME VIII / NORSOK P-001)

Compressors (API 617)

Pumps (API 610)

Valves (IEC 60534)

Heat Exchangers (TEMA)

Tanks (API 650/620)

Weight Breakdown Categories

By Equipment Type

By Discipline

Design Margins

Integration with Cost Estimation

Comprehensive Cost Estimation Framework

Best Practices

Example: Complete Workflow

See Also