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mechanical design updates#1845

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EvenSol merged 10 commits intomasterfrom
optimWorl
Jan 28, 2026
Merged

mechanical design updates#1845
EvenSol merged 10 commits intomasterfrom
optimWorl

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@EvenSol EvenSol commented Jan 28, 2026

Pull Request

Thank you for contributing to NeqSim! Please complete the following checklist before requesting review:

  • Confirm ./mvnw test runs successfully
  • Verify code formatting using Checkstyle
  • Update any relevant docs/README
  • Link to an associated issue or discussion

See CONTRIBUTING.md for the full contribution process.

- DatabaseTorgDataSource.loadFromLegacyTable: added @param/@return
- ProcessDerivativeCalculator: added docs for 5 methods (calculateJacobianSequential, calculateJacobianParallel, calculateForwardDifference, calculateCentralDifference, perturbAndEvaluate)
- ProcessVariableAccessor.matchesParams: added @param/@return
- IntegratedSafetySystemExample.runScenario4_PSVRelief: added all @param tags
- TechnicalRequirements_Process.csv: Add 93 new rows for design parameters
  - Separator: pressure margins, foam allowance, droplet diameters, demister specs
  - Heat exchanger: fouling resistance, TEMA classification, velocity limits
  - Compressor: surge margin, turndown, efficiency targets, vibration limits
  - Pump: NPSH margin, BEP region, max speed
  - Valve: Cv margin, velocity limits
  - Vessel: L/D ratio, joint efficiency, nozzle velocity
  - Cooler, flare system, PSV parameters

- ProcessDesignStandard.java: New class for process design calculations
  - Design pressure/temperature margin calculations
  - Design flow rate with turndown consideration
  - Design duty and area calculations
  - Database parameter loading by equipment type

- SeparatorMechanicalDesign.java: Process design enhancements
  - Foam allowance factor and droplet diameter fields
  - Demister/mist eliminator parameters
  - Stokes and Souders-Brown velocity calculations
  - Database loading for process design parameters

- HeatExchangerMechanicalDesign.java: TEMA and fouling enhancements
  - Fouling resistance for shell/tube water/HC services
  - TEMA classification (class, shell type, head types)
  - Tube bundle parameters (diameter, thickness, pitch, layout)
  - Velocity limits and baffle parameters

- CompressorMechanicalDesign.java: Operating range enhancements
  - Surge/stonewall margin tracking
  - Turndown and efficiency requirements
  - Seal and bearing type specifications
  - NACE compliance flag
…sign classes

- Add validation methods to Separator, HeatExchanger, Compressor, and Pump designs
- Add process design parameters to Response classes for JSON export
- Create comprehensive unit tests for validation methods (55 tests pass)
- Support industry standards: API-610, API-617, TEMA, API-12J/NORSOK-P-001

Parameters added:
- Separator: foam allowance, droplet diameters, demister specs, velocity limits
- HeatExchanger: fouling resistances, TEMA class, velocity limits, approach temp
- Compressor: surge/stonewall margins, turndown, efficiency targets
- Pump: NPSH margin, POR/AOR fractions, suction specific speed
…hods

- Add Process Design Parameters section to mechanical_design.md
  - Separator: foam allowance, droplet diameters, demister specs, velocity limits
  - Compressor: surge/stonewall margins, turndown, efficiency targets, seal/bearing types
  - Pump: NPSH margin, POR/AOR fractions, suction specific speed (API-610)
  - Heat Exchanger: fouling resistances, TEMA class, velocity limits (TEMA)

- Add Design Validation section with validation result classes
  - Individual parameter validation methods
  - Comprehensive validation with issue reporting
  - Examples for all equipment types

- Update EQUIPMENT_DESIGN_PARAMETERS.md with validation methods section
- Update REFERENCE_MANUAL_INDEX.md with new documentation references
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