Fayaz M.

I am a Lead Mechanical Engineer with over 15 years of specialized experience in pressure vessel design, finite element analysis, and engineering software development, serving the oil & gas, petrochemical, and process industries. Throughout my career I have worked on technically demanding projects that require not only deep code knowledge but sound engineering judgment — the ability to identify what matters, resolve what is ambiguous, and deliver results that hold up under client review, third-party inspection, and regulatory scrutiny.

Pressure Vessel Design:
Pressure vessel engineering is my primary discipline. I design vessels to ASME BPVC Section VIII Division 1 and Division 2, covering wall thickness calculations, nozzle reinforcement, saddle support design, lifting lug analysis, wind and seismic load evaluation, and MAWP determination. My work extends into technically complex cases: high-temperature reactors requiring creep analysis and time-dependent allowables, sour service material selection per NACE MR0175/ISO 15156, post-forming heat treatment requirement calculations, and fiber elongation calculations for formed heads and shells.
I have deep experience with bolted flange joint analysis — one of the most frequently misunderstood areas in pressure vessel engineering. I perform calculations to ASME Appendix 2, ASME PCC-1, and WRC 438, covering gasket seating, bolt load requirements, pre-tension calculations, and leak tightness assessment. I also perform nozzle load evaluations using WRC 107/537 and WRC 297, and I am fully conversant with the limitations of each method and when FEA is the appropriate path forward.
I work regularly with major oil company engineering standards, reviewing vendor documents, preparing technical compliance matrices, and issuing engineering comments on fabrication drawings and design submissions. I understand what clients in the oil & gas sector require — calculations that pass and documentation that is traceable, clearly presented, and defensible at every stage of a project.

Finite Element Analysis:
I perform structural FEA using ANSYS Mechanical for pressure vessels and process equipment, covering linear elastic stress analysis, elastic-plastic analysis, limit load analysis, and fatigue evaluation — interpreted and reported in accordance with ASME VIII Division 2 Part 5 design-by-analysis requirements. I apply FEA where code analytical methods are insufficient: complex geometries, non-standard nozzle configurations, local structural discontinuities, and fitness-for-service assessments.
My FEA work is always anchored in engineering judgment. Simulation output alone is not an engineering result — it must be correctly interpreted against applicable code criteria, with proper consideration of mesh quality, boundary conditions, load combinations, and material behavior. Every FEA report I produce is structured to withstand third-party audit.
Engineering Software Development
I develop custom engineering tools that automate complex code calculations across multiple platforms: HTML/JavaScript for browser-based calculators, Excel VBA for calculation sheets integrated into existing workflows, ▒▒▒▒▒▒ for desktop applications with structured report generation, and AutoCAD .NET plugins for drawing automation. Tools I have built include ASME flange joint calculators, bolt torque and pre-tension tools, WRC 107 nozzle load calculators, fiber elongation and heat treatment tools, and creep damage calculators. These are engineering-grade tools — not generic utilities — built with proper input validation, code references, and clearly structured outputs.

What Clients Can Expect:
I work as a technical consultant, not simply a task executor. Before starting any project, I invest time in understanding the full engineering context — applicable codes, client requirements, constraints, and what the deliverable needs to achieve. My deliverables are accurate, well-organized, and properly documented. Calculations include clear assumptions, code references, and conclusions. FEA reports are structured for third-party review. Software tools are reliable and maintainable.
I am available for pressure vessel design calculations, FEA analysis and reporting, ASME code consulting, engineering document review, vendor submission evaluation, and custom engineering software development.