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Process Equipment |
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| Pressure Vessels: Extensive experience in ASME Boiler and Pressure Vessel Code, including Section VIII Division 1, 2, and 3 as well as Pressure Vessels for Human Occupancy. In addition to standard design for coded fabrication shops we have done analyses involving thermal-induced fatigue, cyclic loadings from associated equipment, excessive stress due to high local temperature gradients, design reviews for wind and water loads for offshore applications, and remaining life estimates due to corrosion or changes in code. | |
| Tanks: Extensive experience with API 620, 650, and 653. In addition to standard design projects for fabricators we have designed reinforcements for agitator loads, analyzed, and when necessary, redesigned tanks to accommodate additional equipment or piping loads, and remaining life estimates due to corrosion. | |
Heat Exchangers: Past work includes detailed experience with TEMA and ASME heat exchanger codes. In addition to standard design projects for fabricators we have designed custom heat exchangers, analyzed structural elements for mechanical and thermal response, and modeled fluids (water, steam, air, hydrocarbons) to determine velocities, heat transfer, film coefficients, and structural interactions. Tools such as FEA and CFD complement code calculation software and traditional methods. The figure below shows a design interaction for a burner-fired heat exchanger using a can around the burner flame, a primary stack on the burner side of the cabin, and a smaller stack on the other end for sampling the flow. While this design was eventually not selected, the various design iterations allowed the overall flow be evaluated before sizing and locating the process coils.
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| Piping: ASME B31.1 and B31.3, AWWA pipelines, API piping, and pipe stress analysis. In addition to standard design projects for petrochemical facilities, past projects include high pressure hydrogen lines, steam traced lines, and process lines running at negative pressures. Past work includes process design, pipe stress (thermal, wind, water, and seismic loads), loss calculations, FEA of overall structure (beam elements) and local effects (shell and brick elements), CFD to evaluate flow balances within headers, dynamic analysis, and acoustic analysis. | |
| Process coils: Past work includes designing coils as ASME coded pressure vessels, evaluating coils for thermally induced fatigue, analyzing structural response due to external (agitator) loads, calculating heat transfer and sizing coils to provide a specified heat transfer. | |
Pumps and Compressors: Past work includes rating refurbished compressors, modeling pump flow to troubleshoot performance issues, seal design and analysis, sizing pumps for specific processes, flow balances, evaluating repaired equipment, and general troubleshooting. |
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Manufacturing and Product Design |
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| Plastic Part Design Review: A client had proposed a new plastic part to replace several metal parts. KES conducted an iterative nonlinear FEA to determine its maximum load capacity in order to compare its performance to the parts to be replaced. | |
| Counter Rotating Vertical Lift Gate: A client had a long history of manufacturing vertical lift gates with the counterbalance on the end of the gate arm. An opportunity arose to put in a gate in an application in which there was no room for the arm to extend past the operator housing. KES worked with their staff to develop a counter-rotating counterweight, geared to the primary pivot shaft, and modeled the design through its full range of operation (with mechanical losses, wind loads, and ice loads) to determine the torque requirements, bearing loads, and transmission component loads through the full operational cycle. | |
Tire Rim Design: An industrial design client had sketches of custom tire rims but his new buyer wanted detailed drawings. KES used solid modeling to provide full 3-D computer models of the rims, then generated rendered views as well as multi-perspective dimensioned drawings for less than cost quoted to the client for a single perspective drawing using traditional CAD. |
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| 6-foot Diameter Commercial Retort: A manufacturer had a successful existing horizontal pass through retort design but needed to change the door mechanism and seals. Instead of the heads swinging horizontally, the heads had to swing vertically. KES provided the ASME Section VIII, Div. 1 analysis as well as reviewed the design for fatigue for its useful life and overall reliability of the vessel and the door mechanism. | |
Prototype and Patent Development: KES has assisted clients with one-off designs or modifications of existing designs. Computer modeling has allowed detailed examination of the mechanical response (stress, deflection, heat transfer) as well as predict performance and examine fit-up, clearances, and fabrication issues. KES has assisted others in developing their patents as well as developing prototypes from their patents. KES is also involved in their own proprietary developments and currently has a patent pending in the Republic of Ireland regarding a mechanical process for recycling. |
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