One team, every discipline
How each engineering discipline contributes to Process Engineering — coordinated through one lead engineer, one model and one document register.
- 6Disciplines
- 1Integrated model
- 4-levelChecking
Process
Leads the study with rigorous simulation and engineering calculations.
Key deliverables
- Steady-state simulation models
- Debottlenecking studies
- Energy and pinch analysis
- Equipment rating checks
Piping & Layout
Checks the hydraulic and routing impact of process changes.
Key deliverables
- Line sizing and hydraulics
- Flare header back-pressure checks
- Tie-in feasibility
- Pressure drop surveys
Mechanical (Static & Rotating)
Confirms existing equipment can handle new operating cases.
Key deliverables
- Pump and compressor re-rating
- Exchanger rating (HTRI)
- Vessel re-rating checks
- Vendor re-rate liaison
Instrumentation & Control
Reviews control valves and instruments for new process conditions.
Key deliverables
- Control valve sizing
- Instrument range checks
- Control scheme improvements
- Alarm and trip set-point review
HSE & Process Safety
Verifies relief and safety systems against the new cases.
Key deliverables
- Relief scenario analysis (API 520/521)
- Flare load summary
- Management of change input
- HAZOP support
Project Controls & Estimating
Quantifies the business case for recommended modifications.
Key deliverables
- Modification cost estimates
- Payback and benefit analysis
- Implementation plan
- Shutdown scope input
Steady-state simulation
Rigorous simulation provides the consistent process data on which equipment design, utilities and safety studies are based.
- Steady-state simulation in Aspen HYSYS, Aspen Plus or PRO/II
- Heat & material balances for design, normal, turndown and start-up cases
- Equipment sizing and rating: columns, exchangers, vessels, pumps, compressors
- Line sizing and pump hydraulics to project criteria
- Process data sheets and operating envelopes
Relief, flare & safeguarding
Overpressure protection and disposal systems are verified against the governing scenarios and applicable codes.
- Relief load calculations and PSV sizing to API 520 / 521
- Flare network hydraulics, radiation and dispersion checks
- Depressurisation (blowdown) studies and minimum metal temperature checks
- HAZOP / SIL study documentation and action close-out
- Cause & effect and safeguarding philosophy
Debottlenecking & optimisation
For existing units we build a calibrated model from plant data to identify capacity limits and practical improvements.
- Plant performance test data analysis and model calibration
- Capacity and bottleneck identification by equipment
- Energy efficiency and heat-integration (pinch) studies
- Revamp and modification process design
- Troubleshooting of operational and reliability issues
Frequently asked questions
Which simulation tools do you use?
Primarily Aspen HYSYS and Aspen Plus, with PRO/II and specialist vendor tools where required. We can also work in the client’s licensed software.
Do you perform relief and flare studies to API 520/521?
Yes — scenario identification, relief load calculation, PSV sizing, inlet and outlet line checks, flare header hydraulics and radiation studies.
Can you study an operating plant?
Yes. Using plant historian data, test runs and drawings, we calibrate a model of the current operation and identify capacity, energy and reliability improvements.
Do you support HAZOP studies?
We prepare the HAZOP documentation (nodes, P&IDs, design intent) and can provide a process engineer as scribe or technical participant, and close out the resulting actions.
What do we receive at the end of a study?
A study report with basis, methodology, results and recommendations, together with the simulation files, calculation sheets and updated documents where applicable.
Ready to start your next project?
Share your requirements and our engineering team will come back with a tailored proposal.
- ISO 9001:2015 Certified
- Offices in USA & India
- Codes & Standards Compliant