Process Mechanical Engineering for Energy and Industrial Projects
Process mechanical engineering is one of the key disciplines within Chess Energy’s comprehensive engineering design services.
We provide complete mechanical design for pipelines, well sites, industrial steel structures and process equipment, from concept development through construction support.
Building on our oil and gas experience, we also support mechanical engineering tasks in geothermal and process industry projects, where the safe and efficient design of pressure systems, pipeline networks and process units is particularly important.
Well-prepared mechanical design helps reduce technical risks, maintain cost control and support more predictable project delivery.
When Is Process Mechanical Engineering Required?
Process mechanical engineering tasks arise when developing new facilities, expanding or reconstructing existing systems, or optimising process technologies.
Properly prepared mechanical design supports safe operation, efficient construction preparation and reduced project risk.
Mechanical design is typically required in the following situations:
- 1
Development of New Industrial Facilities
When designing new process systems, pipeline networks and equipment, the mechanical configuration fundamentally influences the safe and efficient operation of the facility.
- 2
Expansion of Existing Systems
When increasing capacity or integrating new process units, designing mechanical solutions that interface correctly with the existing system is a key task.
- 3
Reconstruction and Modernisation
The refurbishment or modernisation of older systems often requires the review and redesign of pipelines, equipment and related structures.
- 4
Process Optimisation
Improving process performance, increasing energy efficiency or eliminating operational problems often also requires mechanical modifications.
- 5
Redesign of Underperforming Systems
Where operational problems, reduced performance or recurring failures occur, system review and mechanical redesign can help eliminate the underlying causes.
What Does Process Mechanical Design Include?
Process mechanical engineering covers the design of pipeline systems, process equipment and associated structures for energy and industrial facilities.
The objective is to develop technical solutions that support safe operation, efficient performance and predictable construction delivery.
Pipeline and Well-Site Design
Mechanical design of pipeline systems and well sites tailored to the requirements of oil and gas, geothermal and industrial projects.
Appropriate pipeline configuration is fundamental to system safety and reliable long-term operation.
Equipment Integration
Mechanical design for integrating equipment associated with process operations, including pumps, compressors, heat exchangers and separators.
Effective integration supports the safe and efficient operation of the equipment
Design and Modification of Industrial Steel Structures
Design or modification of pipe supports, operating platforms, access structures and other industrial steelwork in line with the requirements of the process system.
Safe operation and maintainability are both important considerations in structural design.
Development of Complete Process Units
Mechanical design of complex process systems, including gas treatment and heat-utilisation technologies.
The objective is to develop a technically sound and efficient system aligned with the process requirements.
In Which Industries Do We Provide Process Mechanical Design?
Process mechanical engineering plays a key role across all three of our industries, although each sector presents different technical challenges and design considerations.
We apply our oil and gas experience to geothermal and process industry projects while adapting our approach to the requirements of each specific process environment.
Oil and Gas Industry
We provide mechanical design and integration for the pipelines and associated equipment of surface production systems, well sites and gathering stations, including separators, compressors and gas treatment units.
These systems operate with pressurised hydrocarbon media, making safe, standards-compliant design particularly important.
Geothermal Energy
We support the mechanical design of surface pipelines in thermal-water circuits, heat-utilisation and reinjection systems, and associated pumps and heat exchangers.
High-temperature media, thermal expansion and reliable operation are particularly important design considerations in geothermal systems.
Process Industry
We participate in the design of pressurised pipeline networks, tanks, pumps and process equipment in chemical, food-processing, paint and coatings industry environments.
These systems often involve flammable or specialist media together with enhanced safety requirements.
Although these markets involve different process environments, the core principles of process mechanical engineering – standards-compliant piping design, accurate sizing and safe equipment integration – remain the same.
This enables us to apply experience and proven engineering solutions gained across different industries throughout our projects.
Engineering Capabilities Supporting Accurate and Reliable Design
In process mechanical engineering, accurate input data, standards-compliant design solutions and modern engineering tools have a significant influence on design quality.
Chess Energy applies capabilities throughout the design process that support more accurate modelling, reduce potential errors and enable more reliable technical solutions.
3D Laser Scanning and Reverse Modelling
For existing facilities, high-accuracy 3D laser scanning can provide the basis for design.
The method enables well sites, pipe racks, heating centres, production halls, steel structures and complete industrial areas to be surveyed in their as-built condition.
Processing the resulting 3D point cloud is the first step in the design process. This includes:
Based on the processed data, we create a detailed 3D reverse model using Plant 3D (AutoCAD Plant 3D plant and piping design software).
This provides a reliable basis for reconstruction and design tasks, enabling the design process to use accurate, real-world data from the earliest phase.
Accurate surveying and reverse modelling contribute to safe operation, support construction preparation and reduce the risk of unexpected technical issues during the project.
Standards, Piping Classes and Standard Designs
Our mechanical design processes are based on internationally recognised EN standards and the PED (Pressure Equipment Directive).
This supports standards-compliant and safe pipeline design, which is particularly important for pressurised energy and process industry systems.
Our work is supported by a comprehensive, industry-specific library of standard designs that we continuously apply and develop across our projects.
In addition to standard designs, predefined piping classes are available, allowing components with the appropriate pressure rating and design temperature – including flanges, ball valves and fittings – to be selected for each project.
The use of standardised design solutions, standard designs and piping classes supports design efficiency, reduces the potential for errors and contributes to technically sound, consistent documentation.
Stress Analysis Using ROHR2
Stress analysis is an important complement to process mechanical design and can also be commissioned as a standalone service.
The analysis supports assessment of the mechanical behaviour of pipeline systems, identification of critical loads and development of safer, more durable technical solutions.
Chess Energy uses ROHR2 piping flexibility and stress-analysis software, supported by several years of calculation experience within our engineering team.
What Is Stress Analysis Used For?
Stress analysis evaluates the mechanical behaviour of pipeline systems under different loads.
It enables assessment of structural capacity, safety, expected loading and compliance with the applicable standards.
Performed during the design phase, the analysis supports early identification of potential problems and contributes to safer, optimised pipeline systems.
When Is Stress Analysis Required?
Stress analysis is typically required when designing new pipeline systems and when redesigning or modernising existing systems.
It may be particularly important where high temperatures, significant thermal expansion or increased mechanical loads are present, such as geothermal thermal-water circuits and hot process lines in the process industry.
What Does Pipeline Stress Analysis Assess?
The analysis evaluates the following areas, among others:
stresses in pipe sections and fittings,
displacements at characteristic points of the pipeline system,
elastic deformation of the system,
loads transferred to equipment nozzles,
reaction forces at restraints and pipe supports.
The analysis helps identify critical loads and hazardous stress concentrations and reduce the risk of unexpected failures.
Which Loads Are Included in the Assessment?
The assessment evaluates the structural behaviour of the piping system under different operating conditions and load cases.
The analysis typically covers:
sustained and operating loads,
loads arising from the system’s own weight,
the effects of thermal expansion,
loads resulting from operating conditions,
loads occurring during pressure testing,
wind and seismic loads.
The results enable the critical load cases, pipeline stresses and reaction forces transferred to supporting structures and pipe supports to be determined.
This allows system compliance to be assessed against the applicable standards and operating requirements.
What Does the Client Receive from the Stress Analysis?
At the end of projects that include stress analysis, the client receives a concise technical report containing the main stress and deformation distributions, assessment of critical points, analysis of loads and identified risks.
The report may also include technical recommendations supporting safer and more durable operation and better-founded design and operational decisions.
The results support material optimisation, reduction of technical risks and reliable long-term system performance.
What Documentation Is Produced During Process Mechanical Design?
The design process results in detailed documentation that supports construction preparation, procurement and project delivery.
The objective is to ensure that every participant in construction can work from clear, transparent and technically sound information.
The documentation prepared during design includes:
Together, these documents provide detailed and traceable design information supporting construction, material procurement and technical coordination across the different project phases.
Why Do Clients Choose Chess Energy for Process Mechanical Engineering Projects?
Technical accuracy, compliance with standards and practical experience are all decisive in mechanical design.
Chess Energy applies engineering capabilities and tools that support well-founded technical decisions and more predictable project delivery.
Practical Oil and Gas Experience
Our design approach is built on experience gained in real operating environments.
We also apply the knowledge acquired in oil and gas projects to the mechanical engineering of geothermal and process industry systems.
Accurate Surveying and Reverse Modelling
3D laser scanning and Plant 3D-based modelling provide accurate input data for design. This is particularly important when expanding, modernising or reconstructing existing facilities.
Standards-Compliant Design
Our work is based on EN standards and the PED, while stress analyses are prepared with reference to the applicable MSZ EN, Eurocode and Hungarian requirements. This supports technical compliance and safe operation.
Use of Standard Designs and Piping Classes
Pre-developed standard designs and piping classes enable faster and more consistent design while helping reduce errors and supporting cost-effective technical solutions.
In-House Stress Analysis
ROHR2-based calculations are performed using our own engineering capability. This allows design and verification to be coordinated, enabling faster feedback and more efficient engineering work.
Integrated Engineering Capability
Process mechanical engineering is one of the key disciplines within Chess Energy’s engineering design capability.
Alongside process engineering design, we also provide project management and independent technical supervision, enabling clients to rely on our expertise across several project phases.
Let’s Discuss Your Project
Are you planning a new facility, expansion or reconstruction project and looking for reliable mechanical design support?
Whether the project involves oil and gas, geothermal or process industry systems, let’s discuss how accurate surveying, standards-compliant design and stress analysis can support safer, more cost-effective and predictable delivery.
Further questions about process mechanical design are addressed in the FAQ section below.
Frequently Asked Questions – Process Mechanical Engineering
When is process mechanical design required?
The service may be required when developing a new facility, expanding an existing system, carrying out reconstruction or modernisation, or undertaking process optimisation.
In which industries can process mechanical design be applied?
We perform mechanical design tasks across all three of our industries: oil and gas, geothermal energy and the process industry.
Our experience is primarily rooted in the hydrocarbon industry, but piping, pressure-system and equipment-integration tasks require a similar engineering approach in the other two sectors.
How does process mechanical engineering differ between geothermal and process industry projects?
In geothermal systems, greater emphasis is typically placed on managing high-temperature thermal water and significant thermal expansion, while process industry projects often involve flammable or specialist media and enhanced safety requirements.
The underlying principles of process mechanical engineering in both sectors are nevertheless built on our oil and gas practice.
How can 3D laser scanning be used in process mechanical design?
3D laser scanning enables an accurate survey of an existing facility, while the processed point cloud can be used to create a detailed 3D model.
This provides a reliable basis for design and reduces the risk of unforeseen technical issues during construction.
What is stress analysis, and when should it be performed?
Stress analysis assesses the mechanical behaviour of a pipeline system under loads such as self-weight, thermal expansion, pressure testing, wind and earthquakes.
It is typically justified when designing new systems or redesigning existing systems and supports early identification of critical points.
Can process mechanical design and stress analysis be commissioned separately?
Yes. Mechanical design and stress analysis are both available as standalone services or can be applied together, depending on the requirements of the project.
The form of support is always tailored to the project’s specific technical needs.
