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EvenSolEvenSol
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mechanical design updates (#1949)
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‎.github/skills/neqsim-capability-map/SKILL.md‎

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@@ -298,6 +298,27 @@ transport properties (viscosity, thermal conductivity, density).
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| `SURFCostEstimator` | Subsea CAPEX | `process.mechanicaldesign.subsea` |
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| `SubseaCostEstimator` | Regional cost factors | `process.mechanicaldesign.subsea` |
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| `FieldDevelopmentDesignOrchestrator` | Full field design | `process.mechanicaldesign` |
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| `MotorMechanicalDesign` | Motor foundation, vibration, cooling, bearings, noise, enclosure | `process.mechanicaldesign.motor` |
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| `EquipmentDesignReport` | Combined mech + elec + motor design report with verdict | `process.mechanicaldesign` |
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### Electrical Design
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| Class | Purpose | Package |
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|-------|---------|---------|
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| `ElectricalDesign` | Base class — sizes motor, VFD, cables, switchgear | `process.electricaldesign` |
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| `ElectricalMotor` | AC induction motor model (IEC 60034, IEEE 841) | `process.electricaldesign.components` |
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| `VariableFrequencyDrive` | VFD with topology, harmonics, efficiency | `process.electricaldesign.components` |
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| `ElectricalCable` | Cable sizing with derating (IEC 60502) | `process.electricaldesign.components` |
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| `Transformer` | Power transformer model (IEC 60076) | `process.electricaldesign.components` |
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| `Switchgear` | MCC / switchgear bucket (IEC 61439) | `process.electricaldesign.components` |
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| `HazardousAreaClassification` | Zone / Ex marking (IEC 60079) | `process.electricaldesign.components` |
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| `CompressorElectricalDesign` | Compressor-specific with auxiliary loads | `process.electricaldesign.compressor` |
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| `PumpElectricalDesign` | Pump-specific design | `process.electricaldesign.pump` |
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| `SeparatorElectricalDesign` | Separator auxiliary loads | `process.electricaldesign.separator` |
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| `HeatExchangerElectricalDesign` | Electric heater / air cooler / S&T detection | `process.electricaldesign.heatexchanger` |
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| `PipelineElectricalDesign` | Heat tracing, cathodic protection | `process.electricaldesign.pipeline` |
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| `SystemElectricalDesign` | Plant-wide load aggregation, transformer sizing | `process.electricaldesign.system` |
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| `ElectricalLoadList` | Load list with demand/diversity factors | `process.electricaldesign.loadanalysis` |
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---
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@@ -435,3 +456,11 @@ transport properties (viscosity, thermal conductivity, density).
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| Scale prediction? | ❌ | Not available |
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| Detailed HX design? | ❌ | Use duty + LMTD |
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| Full reservoir sim? | ❌ | `SimpleReservoir` only |
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| Motor sizing? | ✅ | `ElectricalMotor.sizeMotor()` |
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| Motor foundation design? | ✅ | `MotorMechanicalDesign` |
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| Motor vibration check? | ✅ | `MotorMechanicalDesign.getVibrationZone()` |
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| Electrical load list? | ✅ | `ElectricalLoadList` |
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| Combined design report? | ✅ | `EquipmentDesignReport` |
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| VFD selection? | ✅ | `VariableFrequencyDrive` |
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| Cable sizing? | ✅ | `ElectricalCable` |
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| Hazardous area classification? | ✅ | `HazardousAreaClassification` |

‎CHANGELOG_AGENT_NOTES.md‎

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---
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## 2026-03-22 — Motor Mechanical Design and Combined Equipment Design Report
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### New Classes
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- **`MotorMechanicalDesign`** (`process.mechanicaldesign.motor`) — Physical/mechanical design of electric motors:
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- Foundation loads (static + dynamic) and mass per IEEE 841 (3:1 ratio)
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- Cooling classification per IEC 60034-6 (IC411/IC611/IC81W)
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- Bearing selection and L10 life per ISO 281 (ball vs roller, lubrication)
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- Vibration limits per IEC 60034-14 Grade A and ISO 10816-3 zone classification
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- Noise assessment per IEC 60034-9 and NORSOK S-002 (83 dB(A) at 1m)
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- Enclosure/IP rating per IEC 60034-5, Ex marking per IEC 60079 (Zone 0/1/2)
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- Environmental derating per IEC 60034-1 (altitude: 1%/100m above 1000m; temperature: 2.5%/°C above 40°C)
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- Motor weight and dimensional estimation
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- Constructors: `MotorMechanicalDesign(double shaftPowerKW)`, `MotorMechanicalDesign(ElectricalDesign)`
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- **`EquipmentDesignReport`** (`process.mechanicaldesign`) — Combined design report for any process equipment:
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- Orchestrates mechanical design + electrical design + motor mechanical design
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- Produces FEASIBLE / FEASIBLE_WITH_WARNINGS / NOT_FEASIBLE verdict
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- Checks: motor undersizing, excessive derating, noise exceedance, low bearing life
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- `toJson()` — comprehensive JSON with all three design disciplines
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- `toLoadListEntry()` — summary for electrical load list integration
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- Works with any `ProcessEquipmentInterface` (compressor, pump, separator, etc.)
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### Key API Methods
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```java
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// Motor mechanical design — standalone
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MotorMechanicalDesign motorDesign = new MotorMechanicalDesign(250.0);
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motorDesign.setPoles(4);
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motorDesign.setAmbientTemperatureC(45.0);
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motorDesign.setAltitudeM(500.0);
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motorDesign.setHazardousZone(1);
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motorDesign.calcDesign();
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motorDesign.toJson();
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// Combined report — from any equipment
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EquipmentDesignReport report = new EquipmentDesignReport(compressor);
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report.setUseVFD(true);
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report.setRatedVoltageV(6600);
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report.setHazardousZone(1);
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report.generateReport();
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report.getVerdict(); // "FEASIBLE" / "FEASIBLE_WITH_WARNINGS" / "NOT_FEASIBLE"
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report.toJson();
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```
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### Bug Fix
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- Fixed IP rating override in Zone 0 hazardous areas — IEEE 841 IP55 minimum no longer overrides Zone 0 IP66 requirement
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### Test Coverage
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- 22 new tests in `MotorMechanicalDesignTest`: standalone design, small/large motors, altitude/temperature derating, hazardous area enclosure, vibration zones, NORSOK noise compliance, bearing L10 life, VFD notes, applied standards, compressor integration, JSON/Map output, combined reports
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### Documentation
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- New doc: `docs/process/motor-mechanical-design.md`
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- Updated: `REFERENCE_MANUAL_INDEX.md`, capability map, `mechanical_design.md`, `electrical-design.md`
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---
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## 2026-03-22 — Heat Exchanger Mechanical Design Standards Expansion
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### New Data Files

‎docs/REFERENCE_MANUAL_INDEX.md‎

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| Document | Path | Description |
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| --------------------------------- | ---------------------------------------------------------------------------------------------------------- | -------------------------------------------------------------------------------------------------------------------------------- |
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| **Electrical Design Guide** | [docs/process/electrical-design.md](process/electrical-design) | **Comprehensive guide to electrical design: motor sizing (IEC 60034), VFD topology, cable sizing, transformer, switchgear, hazardous area, load list, equipment-specific designs (separator, heater/cooler, pipeline), plant-wide SystemElectricalDesign** |
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| **Motor Mechanical Design** | [docs/process/motor-mechanical-design.md](process/motor-mechanical-design) | **Motor physical/mechanical design: foundation loads (IEEE 841), cooling (IEC 60034-6), bearings (ISO 281), vibration (ISO 10816-3), noise (IEC 60034-9, NORSOK S-002), enclosure (IEC 60034-5, IEC 60079), derating (IEC 60034-1)** |
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| **Combined Equipment Design Report** | [docs/process/motor-mechanical-design.md#equipmentdesignreport](process/motor-mechanical-design#equipmentdesignreport) | **EquipmentDesignReport: combined mechanical + electrical + motor design report with feasibility verdict for any equipment** |
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| **Compressor Electrical Design** | [examples/notebooks/electrical/compressor_electrical_design.ipynb](../examples/notebooks/electrical/compressor_electrical_design.ipynb) | **Jupyter notebook: 2-stage compression electrical design with motor curves, power triangle, efficiency chain** |
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| **Process Plant Load List** | [examples/notebooks/electrical/process_plant_load_list.ipynb](../examples/notebooks/electrical/process_plant_load_list.ipynb) | **Jupyter notebook: plant-wide electrical load list, demand/diversity factors, transformer sizing** |
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| **Motor & VFD Analysis** | [examples/notebooks/electrical/motor_vfd_analysis.ipynb](../examples/notebooks/electrical/motor_vfd_analysis.ipynb) | **Jupyter notebook: motor efficiency classes IE1-IE4, VFD topology selection, harmonics, efficiency maps, cable sizing, hazardous area** |

‎docs/development/ELECTRICAL_DESIGN_PROPOSAL.md‎

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| 4.5 | Integration with cost estimation framework | Planned |
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| 4.6 | Subsea power distribution (power umbilicals, step-out distance) | Planned |
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### Phase 5 — Motor Mechanical Design & Combined Reports ✅ IMPLEMENTED
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| Task | Description | Status |
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|------|-------------|--------|
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| 5.1 | `MotorMechanicalDesign` — physical motor design (weight, dimensions, cooling, foundation, vibration, bearings, noise, enclosure) per IEC 60034 / ISO 10816-3 / ISO 281 / NORSOK S-002 | ✅ Done |
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| 5.2 | `setFromElectricalDesign()` — link motor mechanical to electrical design results | ✅ Done |
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| 5.3 | Altitude and temperature derating per IEC 60034-1 | ✅ Done |
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| 5.4 | Foundation design (concrete block / steel skid) with bolt pattern | ✅ Done |
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| 5.5 | Vibration assessment per ISO 10816-3 (zones A/B/C/D) | ✅ Done |
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| 5.6 | NORSOK S-002 noise assessment (85 dB(A) at 1 m limit) | ✅ Done |
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| 5.7 | Bearing L10 life per ISO 281 | ✅ Done |
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| 5.8 | `EquipmentDesignReport` — combined mechanical + electrical + motor design report with FEASIBLE / FEASIBLE_WITH_WARNINGS / NOT_FEASIBLE verdict | ✅ Done |
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| 5.9 | `toLoadListEntry()` — electrical load list integration from combined report | ✅ Done |
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| 5.10 | Unit tests (22 tests covering all Phase 5 features) | ✅ Done |
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---
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## 12. Relationship to Existing Code
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│
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├── MechanicalDesign → wall thickness, materials, weights, vessel design
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│
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└── ElectricalDesign → motor, VFD, cables, switchgear, load list
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├── ElectricalDesign → motor, VFD, cables, switchgear, load list
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│
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├── MotorMechanicalDesign → motor weight, foundation, vibration, bearings,
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│ cooling, noise, enclosure (IEC 60034 / ISO 10816-3)
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│
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└── EquipmentDesignReport → combined report with FEASIBLE verdict
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├── runs MechanicalDesign.calcDesign()
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├── runs ElectricalDesign.calcDesign()
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└── runs MotorMechanicalDesign.calcDesign()
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```
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The `calcDesign()` methods can reference each other if needed:

‎docs/process/electrical-design.md‎

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System.out.println("Main transformer: " + sysDesign.getMainTransformerKVA() + " kVA");
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System.out.println("Emergency gen: " + sysDesign.getEmergencyGeneratorKVA() + " kVA");
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```
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---
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## 11. Motor Mechanical Design Integration
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The electrical design package sizes motor and cable from an electrical perspective.
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`MotorMechanicalDesign` complements this by computing the physical and mechanical
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aspects of the selected motor:
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| Aspect | Electrical Design | Motor Mechanical Design |
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|:---|:---|:---|
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| Motor sizing | Rated power, voltage, efficiency class | Weight, frame dimensions, cooling |
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| Drive selection | VFD topology, harmonics, cable sizing | VFD derating notes, bearing currents |
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| Environment | Hazardous area zone, Ex marking | IP rating, enclosure type, NORSOK noise |
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| Structural | — | Foundation mass, bolt pattern, vibration zone |
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| Reliability | — | Bearing L10 life, lubrication interval |
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### Linking Electrical and Mechanical Motor Design
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`MotorMechanicalDesign` can take its inputs directly from a completed
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`ElectricalDesign`, avoiding manual re-entry of motor parameters:
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```java
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// After running electrical design
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ElectricalDesign elecDesign = compressor.getElectricalDesign();
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elecDesign.calcDesign();
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// Create motor mechanical design from electrical results
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MotorMechanicalDesign motorDesign = new MotorMechanicalDesign(compressor);
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motorDesign.setFromElectricalDesign(elecDesign);
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motorDesign.calcDesign();
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// Motor physical properties
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System.out.println("Weight: " + motorDesign.getMotorWeightKg() + " kg");
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System.out.println("Foundation: " + motorDesign.getFoundationType());
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System.out.println("Vibration zone: " + motorDesign.getVibrationZone());
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System.out.println("Noise: " + motorDesign.getSoundPressureLevelAt1mDbA() + " dB(A)");
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System.out.println("Bearing L10: " + motorDesign.getBearingL10LifeHours() + " hours");
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```
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See the [Motor Mechanical Design Guide](motor-mechanical-design.md) for full
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API reference and design calculation details.
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---
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## 12. Combined Equipment Design Report
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`EquipmentDesignReport` aggregates mechanical design, electrical design, and
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motor mechanical design into a single report with an overall feasibility verdict:
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```java
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EquipmentDesignReport report = new EquipmentDesignReport(compressor);
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report.setHazardousZone(1);
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report.setAmbientTemperatureC(45.0);
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report.generateReport();
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String verdict = report.getVerdict(); // FEASIBLE / FEASIBLE_WITH_WARNINGS / NOT_FEASIBLE
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String json = report.toJson(); // Full combined JSON report
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Map<String, Object> loadEntry = report.toLoadListEntry(); // For electrical load list
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```
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The report runs all three design layers in sequence and collects any issues:
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1. **Mechanical design** — wall thickness, weight, materials (from equipment-specific `MechanicalDesign`)
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2. **Electrical design** — motor, cable, VFD, switchgear, hazardous area (from `ElectricalDesign`)
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3. **Motor mechanical design** — foundation, vibration, cooling, bearings, noise (from `MotorMechanicalDesign`)
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See the [Motor Mechanical Design Guide — Combined Report](motor-mechanical-design.md#combined-equipment-design-report)
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for JSON output structure and full configuration options.
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---
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## Related Documentation
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- [Motor Mechanical Design Guide](motor-mechanical-design.md) — foundation, vibration, cooling, bearings, noise, enclosure standards
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- [Mechanical Design Framework](mechanical_design.md) — base mechanical design architecture and class hierarchy
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- [Electrical Design Proposal](../development/ELECTRICAL_DESIGN_PROPOSAL.md) — original architecture blueprint

‎docs/process/mechanical_design.md‎

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└── WellMechanicalDesign → NORSOK D-010 / API 5CT / API Bull 5C3
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├── WellDesignCalculator (casing burst, collapse, tension)
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└── WellCostEstimator (drilling, completion, wellhead costs)
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MotorMechanicalDesign (standalone) → IEC 60034, IEEE 841, ISO 10816-3, ISO 281, NORSOK S-002
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└── Foundation, vibration, cooling, bearings, noise, enclosure, derating
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EquipmentDesignReport (aggregator)
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└── Combines MechanicalDesign + ElectricalDesign + MotorMechanicalDesign
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with feasibility verdict (FEASIBLE / FEASIBLE_WITH_WARNINGS / NOT_FEASIBLE)
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```
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### Pipeline Mechanical Design Features
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```java
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// Valve-specific response
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ValveMechanicalDesignResponse valveResponse =
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// Compressor validation
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CompressorMechanicalDesign.CompressorValidationResult result = compDesign.validateDesign();
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// Pump validation
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// Validate liquid velocity
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// Validate liquid velocity
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boolean liqVelOk = sepDesign.validateLiquidVelocity(actualVelocity); // m/s
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// Validate operating in Allowable Operating Region
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boolean aorOk = pumpDesign.validateOperatingInAOR(operatingFlow, bepFlow);
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// Validate suction specific speed
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### Separators (API 12J / ASME VIII / NORSOK P-001)
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```java
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### Compressors (API 617)
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```java
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### Pumps (API 610)
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### Valves (IEC 60534)
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```java
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### Heat Exchangers (TEMA)
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```java
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// Process design parameters
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// Process design parameters
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double shellFouling = hxDesign.getFoulingResistanceShellHC(); // m²K/W
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double tubeFouling = hxDesign.getFoulingResistanceTubeHC(); // m²K/W
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double maxTubeVel = hxDesign.getMaxTubeVelocity(); // m/s
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Files.write(Paths.get("mechanical_design.json"), json.getBytes());
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// 6. Access specific equipment details
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(CompressorMechanicalDesignResponse) compressor.getMechanicalDesign().getResponse();
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System.out.println("Compressor stages: " + compResponse.getNumberOfStages());
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System.out.println("Driver power: " + compResponse.getDriverPower() + " kW");

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