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Equipment Design and Evaluation
Some equipment design can be considered "standard engineering," such as ASME Section VIII, Div. 1 pressure vessels. The design involves known processes, tried and true calculations, and often are for equipment with identical or substantially similar equipment in operation. Traditional engineering methods and code software, coupled with engineering experience, can provide an appropriate design quickly and inexpensively; however, addressing new equipment needs can require new engineering solutions. Standard code software may not address all of the design criteria. KEG can provide a full spectrum of equipment design services, ranging from "standard engineering" to conceptual designs to prototypes to final production models as well as modifications and repairs of existing equipment.
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As Built" versus "As Designed"
The real world is unpredictable. Computer models alone are often not sufficient to develop a final solution. The real world can introduce forces, conditions, and variations not anticipated by the client during design or specification. Sometimes there are significant differences between the equipment drawings on file and the actual system in the field. However, with appropriate field data the computer models can be developed and "tuned" to the real-world response of the system, creating a highly accurate simulation that can then be put through a full range of conditions and loads such as pressures, temperatures, forces, moments, friction, and flow. This technique allows a client to explore conditions with a minimum of physical testing to determine existing equipment reliability and life expectancy, and even provide the basis for equipment component selection and purchase.
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Repairs and Modifications
Modifications and repairs often share a common challenge: make something "better than new." Changes in processes or equipment can mean you have to modify equipment to fit the new conditions. Repairs have the built-in problem of dealing with something that has already failed. Computer modeling such as FEA or kinematic modeling can allow a client to explore several approaches against a full range of operating conditions before the first weld is put down. This can be critical in preparing for turnarounds, when you have a very limited amount of time to make a repair or modification. There is no time to "just try something"--you need to know it will work when the turnaround is over. It is even possible to "try out" a repair addressing equipment access, systems integration, and other issues before the turnaround. Some codes such as API 653 and ASME Section VIII, Div. 2 require extensive physical testing such as hydrotesting or in-depth engineering analysis taking into account all factors required by the particular code. Quite often the analysis, including supporting tests such as ultrasound and metallurgical samples, is far more cost-effective, in actual costs as well as production time, than testing the entire system. Finally, you can evaluate the repairs for reliability. Will it last until the next turnaround or will it outlast the rest of the equipment? Comparing the costs of a repair can hinge on a repair's reliability and its impact on the system as a whole. KES can provide the right mix of services to address your repair and modification challenges.
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Failure Analysis and Reliability Studies
Designing or specifying equipment for infinite life is not usually cost effective. Most equipment will fail, either due to its natural life cycle or due to changes in the operating conditions. While it can often be more cost-effective to simply repair or replace equipment than repair it, repeated failures or failures in critical equipment can cause lost production costing far more than the equipment itself. In these cases, replacement is no longer cost-effective. A root cause failure analysis can determine the source of the failures and lead to a successful solution to reducing or eliminating the cause for lost production.
For manufacturers, product failures can be caused by customer misapplication or misuse. Failure analysis can allow manufacturers to properly assess their product and its application to ensure the design, documentation, and intended application are within specification. Reliability analysis can direct equipment redesign towards more robust product development. KES can provide address failure or reliability issues comprehensively and efficiently. |
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Product and Service Development
Many products and services reach the marketplace without significant engineering. While the ideas driving these products and services were sound, flaws can later surface as the product goes into public use. These flaws can result in shortened equipment life spans, customer dissatisfaction, and even lawsuits. While many of these flaws could have been avoided through careful engineering, many small firms do not have the needed in-house resources and most engineering firms focus their resources on capital projects and large corporate clients. KES was established to work with small and mid-sized manufacturers to provide technical resources they need to develop or improve their products and services. Starting with the conceptual design, evolving into the first prototype, and taking it all the way to the final production level, KES can provide the in-depth services to help develop and target your product or services for your market. Finally, our creative service can develop the material you need to market your product or services to anyone ranging from corporate managers to trade shows to the general consumer public. KES provides full "concept to consumer" support for technical and creative projects. |
