Design of Process Equipment

Design of Process Equipment

Maximise efficiency and minimise costs with expert project management tailored to your industrial needs. Achieve superior project outcomes through strategic planning, risk management, and sustainability-focused practices.

Overview of Our Design of Process Equipment Service
2 1 Design of Process Equipment 2

Design of Process Equipment refers to the comprehensive engineering practice involved in creating equipment used in various industrial processes. This includes a wide array of devices such as storage tanks, pressure vessels, boilers, heat exchangers, and reactors. The design process aims to ensure that these pieces of equipment can handle specific operational conditions, such as high pressures and temperatures, safely and efficiently.

Key Elements:

  • 1. Code Compliance

  • Ensuring that the design meets the required industry standards and codes, such as ASME (American Society of Mechanical Engineers), API (American Petroleum Institute), as well as UK and EU regulatory bodies like BSI (British Standards Institution) and EN (European Norms) standards. These codes are essential for maintaining safety and reliability in the equipment.

  • 2. Structural Analysis

  • Evaluating the mechanical integrity of the equipment, including stress analysis, thermal stresses, and vibration analysis. This is crucial for designing equipment that can withstand operational demands and environmental conditions.

  • 3. Material Selection

  • Choosing appropriate materials that can endure the chemical and physical stresses imposed by the process. This includes considerations for corrosion resistance, temperature tolerance, and mechanical strength.

  • 4. Detailed Design Documentation

  • Creating comprehensive design documents such as General Arrangement Drawings (GA), Process Flow Diagrams (PFD), Piping and Instrumentation Diagrams (P&ID), and Functional Design Specifications (FDS). These documents provide detailed guidance on how the equipment should be constructed, installed, and operated.

  • 5. Safety and Risk Management

  • Identifying potential hazards and incorporating safety features into the design to mitigate risks. This involves safety checks, fail-safes, and compliance with safety regulations to protect both personnel and the environment.

  • 6. Performance Optimisation

  • Ensuring that the equipment operates at peak efficiency to meet process requirements. This includes optimising the design for energy efficiency, reducing waste, and ensuring reliable performance over the equipment’s lifecycle.

The design of process equipment is critical in industries such as chemical processing, oil and gas, pharmaceuticals, and food processing, where the reliability and safety of the equipment are paramount. The process involves collaboration between mechanical, structural, and chemical engineers to achieve a design that meets all operational, safety, and regulatory requirements.

Our Process for Design of Process Equipment

Our client-focused approach combines engineering expertise with industry standards to ensure our designs meet operational needs and expectations. To accomplish this, Enertherm Engineering follows a structured methodology in the execution of equipment design work.

  • 1. Initial Consultation

  • Project Objectives: We begin by meeting with the customer to understand the project objectives, operational challenges, and specific requirements for the equipment. This stage involves gathering detailed requirements, including operational conditions, constraints, and expectations, ensuring alignment between the client's needs and the engineering team's understanding.

  • 2. Conceptual Design

  • Initial Design Concepts: Based on the customer's input, feasibility studies, and technical requirements, we develop initial design concepts. This includes creating preliminary sketches and models, and conducting feasibility studies to evaluate different design options. Factors like cost, efficiency, and potential operational impacts are considered to select the most viable concept.

  • 3. Detailed Engineering Design

  • Comprehensive Engineering Drawings: We then create comprehensive engineering drawings and models, developing detailed 2D and 3D models that specify dimensions, materials, and manufacturing processes. This step ensures all design details meet the technical and operational requirements necessary for successful equipment performance.

  • 4. Simulation and Analysis

  • Advanced Simulation Tools: Using advanced simulation tools such as Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA), we analyse the design's performance under various operating conditions. This helps to evaluate efficiency, reliability, and safety, allowing us to adjust design parameters to optimise performance based on simulation results.

  • 5. Prototype Development

  • Prototype Validation: If required, we build prototypes to validate design concepts, functionality, and feasibility before proceeding to full-scale production. This involves testing prototypes to gather data and refine the design, ensuring it meets all operational expectations.

  • 6. Design Review

  • Thorough Reviews: Conducting thorough reviews with internal teams and stakeholders is crucial to refine and optimise the design. These reviews focus on enhancing functionality, manufacturability, and cost-effectiveness. Feedback from all stakeholders is incorporated to ensure a robust and reliable design.

  • 7. Compliance and Standards

  • Compliance with Standards: Ensuring the design complies with relevant standards and regulations is a key part of our process. We perform rigorous testing and validation to meet industry standards, safety regulations, and environmental guidelines, documenting all compliance measures and test results.

  • 8. Documentation

  • Comprehensive Documentation: We prepare comprehensive documentation to support manufacturing and assembly processes, creating detailed design specifications, technical drawings, and reports. This includes instructions for manufacturing, assembly, and quality control procedures to ensure consistent and accurate production.

  • 9. Design Validation

  • Validation Tests: We perform validation tests to verify the design's performance, durability, and reliability under real-world conditions. This helps to ensure the equipment will function as intended in its operational environment, and any necessary adjustments are made based on test results.

  • 10. Feedback and Iteration

  • Incorporating Feedback: Feedback from testing and validation phases is crucial to refining the design. We incorporate this feedback to address any identified issues and improvements, iterating on the design to achieve optimal performance and client satisfaction.

  • 11. Finalisation

  • Customer Approval: Finally, we finalise the design with customer approval, ensuring all requirements are met before moving into the manufacturing phase. This step involves preparing for the transition to manufacturing with all necessary documentation and approvals in place, ensuring a smooth handover to production.
By following this structured methodology, Enertherm Engineering ensures that the process equipment designed meets all operational needs, industry standards, and client expectations. This approach not only enhances the functionality and reliability of the equipment but also optimises the design process for efficiency and cost-effectiveness.
Benefits of Our Design of Process Equipment

Process equipment design is a critical aspect of industrial engineering that ensures the efficiency, safety, and profitability of operations in various sectors, such as chemical processing, manufacturing, and energy production.

Here are some key benefits of this service:

  • 1. Improved Efficiency and Performance

  • Well-designed process equipment is optimized for specific operational needs, leading to higher efficiency and better performance. This optimization includes minimizing energy consumption and maximizing throughput, which can significantly reduce operational costs.

  • 2. Enhanced Safety

  • Safety is a paramount concern in any industrial setting. Properly designed process equipment includes safety features and complies with relevant industry standards and regulations, reducing the risk of accidents and ensuring the well-being of employees and the surrounding community.

  • 3. Cost Savings

  • Investing in the design of process equipment can lead to long-term cost savings. Efficient designs reduce energy and raw material consumption, lower maintenance costs, and extend the lifespan of equipment, providing a better return on investment.

  • 4. Customisation and Flexibility

  • Custom-designed equipment can be tailored to meet the unique needs and challenges of a specific process. This customisation ensures that the equipment fits seamlessly into existing operations, enhancing overall productivity and flexibility to adapt to future changes or expansions.

  • 5. Quality Control

  • High-quality process equipment design ensures consistent product quality. By maintaining precise control over process parameters, the equipment can produce uniform products, reducing waste and the need for rework.

  • 6. Environmental Compliance

  • Modern process equipment design often incorporates features that reduce environmental impact. This includes reducing emissions, minimizing waste, and improving the efficiency of resource use, helping companies comply with environmental regulations and enhance their sustainability efforts.

  • 7. Innovation and Competitive Advantage

  • Advanced process equipment design can incorporate the latest technological innovations, such as automation, IoT integration, and advanced materials. These innovations can give companies a competitive edge by improving operational efficiency and opening up new capabilities.

  • 8. Ease of Maintenance and Operation

  • Advanced process equipment design can incorporate the latest technological innovations, such as automation, IoT integration, and advanced materials. These innovations can give companies a competitive edge by improving operational efficiency and opening up new capabilities.
By leveraging these benefits, companies can enhance their operational capabilities, achieve higher efficiency, ensure safety and compliance, and ultimately improve their bottom line.
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  • Enertherm Engineering,
    Allia Future Business Centre, London Rd,
    Peterborough PE2 8AN
  • +44 (0) 1733666701
  • info@enertherm-engineering.com

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