Design Focus | Engineering Guidelines |
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Material Selection & Certification | Use corrosion-resistant alloys such as stainless steel (e.g., 316L), duplex steel, Inconel, or titanium for exposed components. Ensure that all materials are compliant with NACE MR0175 for sour gas environments and possess material certificates (e.g., ASTM A106, ASTM A182). |
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Pressure Resistance & Design Codes | Follow ASME B31.3 for piping design and ASME Section VIII for pressure vessels. Perform stress analysis using FEA to ensure that parts withstand internal and external pressures, accounting for burst pressure and fatigue resistance under cyclic loading conditions. |
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Weldability & Structural Integrity | Ensure weldability of selected materials with well-defined procedures per ASME IX. For critical joints, use full penetration welds, and ensure proper preheating and post-weld heat treatment (PWHT) to prevent cracking. Conduct non-destructive testing (NDT) per ASME V or API 1104. |
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Corrosion & Wear Resistance | For components exposed to aggressive environments (e.g., saltwater, acids), apply corrosion-resistant coatings such as chromium or zinc for enhanced protection. Specify cladding or overlay welding techniques to increase resistance to abrasive wear in high-flow or high-impact applications. |
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Heat & Thermal Management | Design heat exchangers and components exposed to high temperatures with materials that maintain integrity at elevated temperatures. Use thermal analysis to ensure that components perform within specified temperature ranges, and include thermal expansion allowances in joints and seals. |
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Fatigue & Stress Resistance | Evaluate the fatigue resistance of high-stress components using cyclic loading analysis per API 579 or ASME Section VIII. Ensure design margins account for fluctuating operational pressures, vibrations, and cyclic loads experienced in pumps, valves, and pipelines. |
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Sealing & Leak Prevention | Design for leak-tight sealing in flanges, valves, and pumps by selecting suitable sealing materials such as graphite, PTFE, or metal gaskets. Use double sealing systems where required, and conduct pressure testing as per API 598 or ASME B16.5 to validate seal integrity. |
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Dimensional Tolerances & Fit | Apply ISO 286 and ASME Y14.5 tolerancing to ensure parts fit within tight tolerances for critical components such as valve seats and pipe connections. Maintain concentricity, alignment, and surface finish quality (Ra ≤ 0.8 µm) for optimal fluid flow and leak resistance. |
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Inspection & Non-Destructive Testing (NDT) | Use NDT techniques such as ultrasonic testing (UT), radiographic testing (RT), and eddy current testing (ET) to inspect critical welds, pipe joints, and pressure vessels. Ensure compliance with ASME V or API 1104 standards, and document all inspections with appropriate reports and certifications. |
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Regulatory Compliance & Safety Standards | Ensure designs comply with international standards such as ASME B31.3, API 6A, and ISO 9001. Follow relevant safety codes such as NFPA 70E for electrical components and ensure fire and explosion protection compliance. Maintain all necessary documentation for regulatory approval and audits. |