Process Engineering Services

Process Design Types

Feasibility Studies and Conceptual Design

When clients are contemplating a new plant or major process expansion, they typically have more questions than answers. Will the idea even work? PROCESS is able to assist by providing experienced and knowledgeable chemical engineers that can identify, and systematically narrow down, the possible technical options for a given process goal. By necessity this occurs at the major unit operations level. Once the viable technical options are identified, an economic evaluation is performed. Based on technical merits, system reliability, and economics (capital and operating), and other factors, a preferred choice is usually clear as to which direction the future process design should take. At this point a conceptual design can be done that includes preliminary process flow diagrams, mass & energy balances, and a list of major equipment. A very rough order of magnitude cost estimate can be provided as well.

Front End Engineering Design (FEED)

The very front end of every large design project is critical to the long-term success or failure of the plant. While the business plan identifies the economic opportunity, the Front End Engineering Design (FEED) will establish the set of process operating conditions and equipment to achieve the level of reliability, efficiency, and safety required. This design phase sets the direction for the rest of the project. Because it is so critical to the future success or failure of the overall objectives, we feel our clients make the wise choice by purchasing proven licensed processes or selecting a firm like ours which specializes in process design engineering.

PROCESS has learned to put great emphasis on the development of the design basis at the initiation of the FEED. When the design basis is complete, we typically have the following information defined:

Raw material specifications
Plant capacity requirements
Product specifications
Critical plant operating parameters
Available utilities specifications
Individual unit operations performance requirements
Process regulatory requirements
All other operating goals and constraints desired by the plant owners/operators/engineers

Once the design basis is in place, and agreed upon by our client, our team of chemical process engineers goes to work to create, analyze, and refine the many aspects of the plant design. The end result is process documentation that describes the process from which future, more detailed, design work can be done.

Schedule A and Basic Engineering Design Packages

The Schedule A or Basic Engineering Design package refers to a completed process design package that includes all the necessary information required by an Engineering/Construction firm or Detail Engineering firm to perform the detail engineering of the plant (details such a structural steel supports, buildings, wiring, piping details, insulation, equipment vendor/model selection, etc.). PROCESS provides this package and is there to answer any questions the client or engineering firm might have to ensure a smooth transition into the detail engineering phase.

Process Integrity Oversight - Detail Engineering and Construction Phases

More and more, PROCESS is requested to remain on during the detail engineering and construction phases of projects for which we have performed the process design. In this oversight role, any process change requests are routed through our engineers for approval or comment. This helps ensure that the client understands what the impact may be on the process as changes and alternatives are suggested. Many times there is great pressure to hold down costs as the civil, mechanical, electrical, and instrumentation details of the plant are developed. The temptation to remove seemingly inconsequential process components can lead to off-spec product, inadequate throughput, high operating costs, etc. We are able to help prevent such problems simply by serving as the process integrity watchdog.

In addition, many times PROCESS is asked to provide vendor technical and cost proposal evaluations to assist the client in making the best technology selection possible. Since we are not aligned with any equipment companies, we provide these services in a completely objective manner and make what we feel is the best recommendation based solely upon the technical and economic aspects of the options.

Process Design Components

Any of the design services listed above may include some or all of the following components. The items included and level of detail will vary depending on clients desires or on which phase the project is in. The more mature the process design, the more of these components will be included.

Process design basis development
Regulatory basis development
Process computer simulation
Advanced spreadsheet-simulation-spreadsheet user interfacing
Mass and energy balances
Technical and economic process alternatives evaluation
Conceptual process design
Detail process design
Process control system design

Complete process design packages normally include:

Design basis
Mass and energy balance computer simulations
Process simulation models for client use
Process flow diagrams (PFDs)
Process control logic and process control diagrams (PCDs)
Capital cost estimate
Operating cost estimate
Piping and instrumentation diagrams (P&IDs)
Equipment plot plans
Utility flow diagrams
Equipment lists
Equipment sizing and specifications datasheets
Preliminary process hazards analysis documentation
Plant layouts
Preliminary process operating manuals

Process Modeling and Simulation

PROCESS uses long-term or short-term licensed commercial process simulation software (CHEMCAD, Aspen, Hysis, Pro/II, Simsci) and/or in-house simulation programs to perform:

Read About Running Plant Process Simulations, via Excel, without learning simulation software
Video time: 6.5 min.

Detailed mass and energy balances
Unit operation design/evaluation
Piping system hydraulics calculations
Relief and flare system design/evaluation
Heat exchanger design/evaluation

View more information on Why Use Process Simulation?, Process Simulation Projects, Advanced Simulation/Spreadsheet Interfacing

Operations Support

Process evaluation, troubleshooting, optimization
Debottlenecking
Control system startup, tuning, optimization
Commissioning and startup assistance
Operating procedures, process documentation
Operator and technical staff training
Statistical process control

Additional Capabilities

Process/equipment bid package preparation
Vendor bid evaluations and recommendations
Expert witness/legal team technical assistance