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Design & Engineering Services
- Feasibility Studies
- Project Scope Development
- Materials Selection
- Engineering Analysis
(Pipe System Stress,
Design Adequacy) - Finite Element Analysis (FEA)
- Project Specifications
- Construction Details and Drawings
- Vendor Qualification
- Technical Bid Evaluation
- Design Submittal Review
Overview
Design procedures for FRP differ from those for metallic equipment, in that FRP design standards and codes are relatively new and may not cover all aspects of the equipment design. Judgment is often required in the areas of seismic, snow and wind loadings, flange design, anchoring systems, ring support of vessels and concentrated loads where the standards invoke non-mandatory procedures. Available FRP standards can prevent gross structural failures when properly applied, but failures continue to occur at critical details where design latitude is permitted. Although current industry standards for FRP materials and equipment have provided a starting point for mechanical design, structural failures associated with improper equipment design and fabrication are still significant when not controlled by qualified, experienced FRP engineering.
When To Use FSE Engineering Services
A detailed design and specification prior to request for quotations should be considered for:
- New equipment applications when limited previous FRP performance information is available. These applications would include those that demand a high degree of design expertise using composite technology, and those that would exceed conventional design practices.
- Previous applications in which the service life of FRP equipment has been limited.
- Applications that involve unacceptable consequences of failure or unscheduled shutdowns.
- Applications with severe environmental and operating conditions.
FSE Engineering Deliverables
Equipment:
- Engineering design elements and calculations, including selection of resins , reinforcing materials and specification of laminate sequences for all FRP components that will optimize the design for the intended service.
- Descriptive or modified performanced based specifications which control critical aspects of design and fabrication that impact the quality and service life of the equipment.
- Complete fabrication drawings covering all critical construction details.
- Vendor qualification when required.
Above ground piping:
Appropriate services described above plus:
- Finite element analysis of the piping system to determine the type
and location of supports, guides and anchors to maintain system stress
levels within allowable limits.
- Reaction loads at each support, guide and anchor to assist others in the design of associated structural steel components.
- Specifications for all supports, guides and anchors.
- Pipe assembly and spool drawings, including detailed fabrication drawings and specifications for fittings, flanges and other system components.
- Descriptive specifications for the fabrication, shop and field assembly of the piping system and components.
Below ground piping:
Appropriate services described for above ground piping plus:
- Analysis of the buried piping system, accounting for all installation, design and operating conditions and loads.
- Determination and specification of thrust block requirements.
- Burial specification covering trenching, types of backfill, compaction requirements, allowable circumferential and longitudinal deflections and other parameters critical to long term service life.
Benefits of the Complete Design Service
- The Owner retains important control over the design and fabrication process, assuring that all equipment requirements and the desires of the Owner are fully integrated into the design. This assures that the cost/benefit tradeoffs are managed in accordance with the Owner's interests.
- The FSE engineering staff is very experienced in the design of FRP equipment and piping systems. Proven design procedures are used to develop the critical details in non-mandatory areas of the design specifications where considerable judgment is required. The FSE design package will be optimized for the design conditions to provide the longest cost effective service life possible for the FRP equipment. Descriptive specifications, construction details and fabrication drawings supplied with the FSE design package cover all fabrication issues significant to the design analysis and provide for verification of the important criteria through inspection and testing. Compliance to these quality-related details assures long-term performance of the equipment.
- The detailed fabrication drawings and descriptive specifications furnished by FSE will provide the basis for competitive bidding, assuring "apples-to-apples" pricing for one design. The same drawings and specifications will be used by the successful vendor for fabrication. No vendor fabrication or design submittals will be required.
Fabricator (Vendor) Design Submittal Review
Overview
The objective of FSE's submittal review service is to provide confidence in the structural adequacy and quality of FRP purchased directly from the fabricator, based on a general "performance" specification, wherein the fabricator takes responsibility for detailed design, fabrication and suitability for service. Rather than rely on a "performance" specification to ensure equipment adequacy, Owners may review several designs submitted during the bidding stage prior to award of the contract. In addition, a design review may be performed on the final calculations and fabrication drawings of the successful bidder prior to the start of fabrication.
Where To Use These Services
Review of fabricator design and fabrication proposals should be considered for:
- Applications involving unacceptable consequences of failure or unscheduled downtime for repairs or modifications.
- Newer applications where no ready comparisons can be drawn to existing equipment or there is a lack of long-term performance history in similar applications.
- Applications involving relatively severe service conditions.
FSE Submittal Review Deliverables
FSE submittal review services can be tailored to the needs of the project, and may include the following:
- List of design and fabrication submittal data required for evaluation of the adequacy of proposed designs. These requirements will include detailed construction information, specific engineering calculations and physical property data.
- Review of calculations and fabrication drawings. Errors, omissions, low safety factors, non-conservative physical properties, assumptions or other design issues presented in the calculations are identified. The evaluation also includes a review of all major FRP components and construction details, such as the bottom cone and knuckle, shell laminates, stiffening rings, joining laminates, nozzles, cross-over piping and insulation details (if applicable). Transmittal of design details to shop drawings is also confirmed.
- A report will be provided to summarize and discuss the design adequacy, errors, omissions and compliance with contract documents and current industry practice. Recommendations are provided which the client can use as a basis for discussion with the fabricator(s) to obtain needed changes or corrections. Additional recommendations are included as appropriate regarding fabrication details, compliance with current industry practices and other features of the proposed design.
- Detailed calculations and modifications to augment fabricator designs, if requested.
Benefits of Fabricator (Vendor) Design Submittal Services
Obtaining a design review of proposals submitted by fabricators can provide the following benefits to the Owner:
- Greater control over equipment adequacy than is obtained by reliance on a performance specification only.
- The ability to place the proposals on an equivalent basis for evaluation.
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