RAY ALVARADO, P.E.

1. MECHANICAL ENGINEERING RAY ALVARADO, P.E. Member, Mapua Alumni Association Alberta Chapter

2. Presentation Breakdown • INTRODUCTION • MECHANICAL ENGINEERING

3. Acronyms • CAE – Computer Aided Engineering • CAD – Computer Aided Design • FEA – Finite Element Analysis • CFD – Computational Fluid Dynamics • RCFA – Root Cause Failure Analysis • LNG – Liquefied Natural Gas • FCC – Fluid Catalytic Cracking, an oil refinery process • DCU – Delayed Coker Unit, an oil refinery process • S&T – Shell-and-Tube, type of heat exchanger • P&F – Plate-and-Frame, type of heat exchanger • NDE – Non-Destructive Examination

4. MECHANICAL ENGINEERING • MECHANICAL ENGINEERING in the oil-and-gas industry is exclusively responsible for all large machinery and process equipment, within a project or industrial facility. • Other industries may have different scopes of responsibility. • Usually, plant piping and pipelines are looked after by the Piping Engineer or Pipeline Engineer – not the Mechanical Engineer. • Many of these equipment needs collaboration and shared responsibilities with the Process Engineer and Controls Engineer. • Two broad classifications of machinery in oil-and-gas: A) Rotating Equipment (Dynamic) B) Stationary Equipment (Static)

5. MECHANICAL ENGINEERING Usual entry-level positions: • Mechanical Design Engineer • Mechanical Equipment Engineer • Rotating Equipment Engineer • Stationary Equipment Engineer Minimum Skill Sets for a Junior Mechanical Engineer: • Undergraduate degree in Mechanical Engineering, Chemical Engineering, or related sub-discipline. • Basic knowledge of Fluid Dynamics, Thermodynamics, Heat-Mass Transfer, Structural Mechanics, Strength of Materials, and Machine Elements Design. • Supplemental knowledge in Materials Science, Turbo-Machinery Dynamics, Chemical Processes, and Welding Technology.

6. MECHANICAL ENGINEERING Important Deliverables: • Equipment Data Sheets…..all rotating and stationary equipment, including vendor drawings and diagrams. • Sizing Calculations……fluid flow, heat loss, heat transfer, pressure containment, combustion/stoichiometry, structural supports, nozzle reinforcement, dynamic loading, FEA/CFD analysis, emissions control, and materials selection. • Procurement & Delivery Support……initial requisitioning, technical evaluation, bids review, and purchase orders. Also includes written certifications (metallurgy, casting/forging, welding WPS/PQR, coating, transport/packaging) and shop tests (NDE, specimen failure, water/air leak-strength, performance).

7. MECHANICAL ENGINEERINGROTATING EQUIPMENT

8. MECHANICAL ENGINEERINGPumps Centrifugal pump, horizontal, single stage….most common rotating equipment Positive-displacement (reciprocating) pump Centrifugal pump, vertical, multi-stage

9. MECHANICAL ENGINEERINGPump Jacks, an industry icon Cross-section of sucker rod assembly Or “donkey heads”, are special positive-displacement pumps

10. MECHANICAL ENGINEERINGCompressors, Reciprocating Detail of double-acting piston head assembly Reciprocating compressor, multi-stage, on skid with auxiliaries

11. MECHANICAL ENGINEERINGCompressors, Centrifugal Cutaway of centrifugal compressor, multi-stage Cutaway of centrifugal compressor, single-stage

12. MECHANICAL ENGINEERINGCompressors, Axial and Screw Type Screw (lobe) type compressor Axial compressor with casing opened, showing rotating and stationary blades

13. MECHANICAL ENGINEERINGGas Turbines, Compressor-Turbine Unit Cross-section of an industrial gas turbine assembly Gas turbine and auxiliaries on self-contained module

14. MECHANICAL ENGINEERINGSteam Turbines Steam turbine operating principle, with rotating and stationary blades Cutaway of typical steam turbine prime mover, multi-stage

15. MECHANICAL ENGINEERINGMiscellaneous Rotating Machinery Turbo-Expander assembly Diesel engine prime mover set Axial fan assembly Centrifugal Fan assembly

16. MECHANICAL ENGINEERINGSTATIONARY EQUIPMENT

17. MECHANICAL ENGINEERINGPressure Vessels, for temporary storage of liquid or gas Horizontal pressure vessels Vertical pressure vessels Spherical pressure vessels

18. MECHANICAL ENGINEERINGProcess Reactors, FCC (Catalytic, Exothermic) Cyclone internals of reactor vessel Catalytic cracker and regenerator Vessels, part of FCC process unit

19. MECHANICAL ENGINEERINGDistillation Columns, Packed or Trayed (Internals Type) Spider Distributor Packed Section Trayed Section Bubble Trays

20. MECHANICAL ENGINEERINGHeat Exchangers Direct-Contact (Barometric) Condenser Shell-and-Tube Exchanger Plate-and-Frame Exchanger Fin-Fan Air Cooler

21. MECHANICAL ENGINEERINGFired Heaters (Fire Tube, Water Tube, Process Furnaces) Cutaway of heater (fire tube) Catalytic furnace for Reformer process unit Packaged boiler (water tube)

22. MECHANICAL ENGINEERINGStorage Tanks (crude oil, liquid products, liquefied vapor) Cutaway of a typical floating roof tank Fixed (cone) roof tanks

23. MECHANICAL ENGINEERINGStorage Tanks, LNG refrigerated tank LNG tanker with cryogenic sphere tanks Cross-section of LNG tank, showing special construction and low-temp insulation

24. MECHANICAL ENGINEERINGMiscellaneous Stationary Equipment Box-Type Cooling Tower Absorption RefrigerationUnit Ejector Assembly, mainly for creating vacuum

25. MECHANICAL ENGINEERINGMiscellaneous Stationary Equipment, Flare Stack Detail of alloy steel tip with auxiliary piping Emergency flaring at upset conditions

26. MECHANICAL ENGINEERING Mechanical Engineering and Beyond: • Advances in Equipment Reliability Prediction……PC-based computer assistance leads to greater accuracies in Root Cause Failure (RCF) results, statistical data gathering, parts metallurgy, and virtual machinery testing. • Emphasis on Equipment Efficiency and Environmental Friendliness…….use of low-impact feedstock/fuels, by-products reduction, emissions control, waste recovery, and high-speed balancing precision. • More Inter-Disciplinary Collaboration…….gone were the days of stand-alone engineering practice. To perform his/her task, it’s unavoidable for the next-generation Mechanical Engineer not to interface with the Process Engineer, Electrical Engineer, Chief Metallurgist, and/orCivil Engineer. • FEA/CFD Multi-Physics to the Mainstream……with stunning 3D graphics, highly interactive results, and more powerful simulation capabilities, engineering calculations can now be performed simultaneously e.g. structural, fluid flow, vibration, combustion, heat loss/heat transfer, and non-linear transients. • Highly Specialized Sub-Disciplines.......because Mechanical Engineering has broad coverage, one can choose to become a Pressure Vessel Engineer, Heat Transfer Engineer, Pump Engineer, Tank Engineer, or Compressor Engineer.

27. MECHANICAL ENGINEERINGFailure Prediction & Machine Component Analysis Predictive collapse of pressure vessel subjected to vacuum Failure analysis and deformation of large machinery skid Failure analysis of fan blade assembly

28. MECHANICAL ENGINEERINGCFD & Multi-Physics Analysis Multi-physics analysis (fluid flow + thermal) of shell-and-tube exchanger Predictive conditions (fluid flow + thermal) of gas ejector Forced air impingement (fluid flow + thermal) on tube of fin-fan cooler