Process Engineering (Topside & Plant Process Design)
Introduction
Our experienced team delivers process simulation engineering for topside production platforms, onshore gas processing plants, petroleum refining, NGL/LPG, LNG, and utilities/offsites. Using Aspen HYSYS / UniSim Design (steady‑state & dynamics) and thermodynamic packages aligned to PVT data, we optimise capacity, operability, safety, and lifecycle efficiency from FEED to detailed design, commissioning, and operations support.
Process Engineering: Scopes & Activities
- Steady‑state facility models: separation trains, gas treating (amine), dehydration (glycol/molecular sieve), compression, condensate stabilisation, fractionation, flare/fuel/utility networks.
- Dynamic simulation: start‑up, shut‑down, ramp‑up/turndown, trip/ESD response, compressor anti‑surge modelling and tuning, control loop testing and time constants, blowdown/depressurisation with minimum metal temperature checks (brittle fracture risk).
- Relief & flare system design: contingency mapping, PSV/PRV and rupture disc sizing, flare header hydraulics, built‑up/backpressure assessment, radiation and noise studies, KO drum sizing.
- Facility hydraulics: line sizing and pressure‑drop, control valve authority/rangeability, pump NPSH/cavitation margin, compressor maps and performance across turndown, erosion/corrosion velocity checks.
- Equipment sizing & specification: separators, columns (tray/packing hydraulics, flooding checks, pressure‑drop), heat exchangers (thermal design, fouling factors, approach temps, TEMA compliance), drums/filters/coalescers/surge vessels.
- Process control philosophy & safeguarding: PFDs, P&IDs, Cause & Effect matrices, shutdown keys, alarm rationalisation, permissives/interlocks, HIPPS integration, start‑up/shut‑down procedures and operating manuals.
- Debottlenecking & operability: case matrices across normal/upset/emergency scenarios; capacity verification, energy optimisation, and brownfield revamps.
Process Engineering Deliverables
- Basis of Design & Simulation Basis, model files (steady‑state & dynamic), case matrix, convergence & validation reports.
- Relief summary tables; PSV/PRV datasheets; flare radiation/noise reports; depressurisation curves & minimum metal temperature checks.
- Equipment datasheets/specifications; PFDs/P&IDs; C&E matrices; control narratives; start‑up/shut‑down procedures; operating manuals.
Why Choose Our Process Simulation Engineering
Experienced team with topside & plant track record:
Our process simulation engineers are highly experienced and competent, having delivered multiple topside and onshore plant projects for major operators and Tier‑1 EPC contractors. Their portfolio spans concept selection, FEED, detailed design, commissioning, and operations support, including brownfield debottlenecking, dynamic start‑up/shut‑down modelling, and code‑compliant relief/flare designs. This depth ensures buildable designs, robust operating philosophies, and models that reflect real‑world behaviour.
Our methodology & Approach
We integrate steady‑state and dynamic modelling, safety compliance, and practical operating strategies to deliver reliable capacity, safer operations, and reduced lifecycle costs. From concept to operations, our process simulation engineering improves performance with evidence‑based design decisions.
Call to Action
Contact us to discuss your topside or plant simulation needs, or to request a tailored debottlenecking study.