The staff of Process Engineering International, LLC (PROCESS) has experience providing a wide range of Process Engineering Services, including process design, process modeling and simulation, process safety services, and operations support.
PROCESS offers exceptional Process Design Services including FEL-0, FEL-1, FEL-2, and FEL-3 services for the development of conceptual and detail process design packages for a broad range of process types and processing industries. PROCESS also provides process engineering oversight and support throughout all phases of detail engineering, construction, startup, and optimization.
The engineers at PROCESS are highly-skilled in the application of various process simulation software including Aspen, Hysys, ChemCAD, and others. Our Process Simulation Services can help your facility improve operations, debottleneck existing processes, and can assist providing a solution to complex process design and engineering challenges.
PROCESS has a division dedicated to Process Safety Services and teaching Process Safety Training Courses to help new and existing facilities operate safely by design. Services include traditional Process Safety Services such as HAZOPs, SIL Selection, LOPA studies and also includes other process engineering services related to process safety such as safety and relief device sizing and verification, Piping and Instrumentation Diagram (P&ID) field walk downs and updates, flare system modeling and sizing, operating procedure development or improvements, and similar. PROCESS also offers on site process safety training courses that include Process Hazards Analyses (PHA) Leadership Training and Management of Change Hazard Review Training.
The engineers at PROCESS have significant operations experience in operating facilities. Our employees understand the challenges of production; the daily issues faced by operators and management; and the need for uninterrupted, efficient, and economical generation of product. Because of our employees' backgrounds, we are able to offer Operations Support Services to existing facilities and processes.
Process Engineering International, LLC offers services that improve operations by using world class chemical process engineers to make chemical processes efficient, economical and reliable. For a complete list of services, click the link below.
To learn how PROCESS can assist your individual needs, please contact us at +1 865 220 8722 or email us at firstname.lastname@example.org
The map below shows some of the countries in which PROCESS has performed projects
Conceptual and Preliminary Process Designs and Process Evaluations (FEL-0 / FEL-1)
Detailed Process Design Development (FEL-2 / FEL-3)
Detail Engineering Phase Process Integrity Oversight
Process Design Components
Third Party Process Evaluations, etc.
After a process goal (new design, modification of design, etc.) has been determined, one of the first steps in developing a new project is to identify the alternatives that will need to be evaluated. Operating companies usually have identified a list of potential solutions that may ultimately satisfy the process goals. PROCESS can assist these companies in the identification of other potential solutions that the client may not be aware of, or may not have identified as options. PROCESS uses sound engineering principles, limited research and it's employee's diverse backgrounds and wealth of experience to help identify options to achieve the process goals. A list of alternatives is developed as a deliverable with a brief listing of positives and negatives that may be associated with the implementation of these options.
PROCESS is able to assist clients that are considering installing a new process or modifying an existing process by providing world class chemical engineers that can identify, and systematically narrow down, the possible technical alternatives that can achieve a given process goal. The resulting deliverables from this phase of the project can be customized for your organization's needs. Our services deliver a package that will give the client the needed data to choose the best process option to move forward with. PROCESS can also develop a presentation that allows the client to present the results of the preliminary process design to the operating company's management or to investors.
Once the viable technical options are identified by the client's staff or with assistance from PROCESS, baseline process engineering is accomplished and a preliminary economic evaluation is performed. Based on the process technical abilities, system reliability, economics (capital and operating), and other factors, the client can decide how the future process design should proceed. PROCESS will develop a conceptual design suitable for process screening. Basic process design deliverables for this phase of work typically include a preliminary process design basis, block flow diagrams, preliminary mass & energy balances, preliminary Process Flow Diagrams (PFDs) identification of major equipment requirements, and a very rough cost estimate with accuracy depending on the amount of engineering design work completed. As a part of services offered, PROCESS can identify potential risks associated with the design (such as difficult to obtain specialty equipment, required pilot testing, insufficient data, risky scale-ups, and similar) so that a plan can be developed to address these issues prior to or during the next phase of the project.
FEL 0 - Identification Phase (Conceptual Process Design or Screening Study)
Industrial project opportunities can target revenue growth; expense reductions; strategic growth; improved safety; improved reliability and/or efficiency; or other goals identified by management. Clients typically identify opportunities by evaluating the value of project implementation and by identifying key risks and uncertainties. It is important to evaluate opportunities on a consistent basis for comparison purposes. The basis for the first decision gate is a high level screening study or conceptual process design study. This level of work involves reviewing promising chemical conversion pathways or major licensed technologies, narrowing the project down to one or more options, identifying major equipment, developing block flow diagrams, and generating an Order of Magnitude capital cost estimate range.
Deliverables from a standard FEL-0 Package include:
- Overall Chemical Reactions/Product Pathways
- Expected Licensed Technologies Needed
- Block Flow Diagrams
- Major Equipment Identification
- Order of Magnitude Capital Cost Estimate
FEL 1 - Appraisal and Selection Phases (Process Appraisal and Preliminary Process Design)
During the appraisal phase of the project a series of processing alternatives and unit operations are analyzed and further assessment of the process value, risk, and uncertainty is conducted. Some examples may include alternatives such as batch versus continuous processing, use of different types of separation techniques (extraction versus distillation, pressure filtration versus a centrifuge), etc. The most promising development concepts progress forward to the Selection phase.
Selection (Preliminary Process Design)
The objective of the Selection phase of the project is to identify a single process concept for progression to the Detailed Process Design phase of the project and to develop base line deliverables that can be further developed in future phases of the project. Preparation of work deliverables requires that a single process concept be selected and further developed during this phase. Once a concept has been selected, the team will complete the level of detail necessary to develop a cost estimate and preliminary project schedule with a typical target accuracy of –30% to +50%. Deliverables at this stage often include the following:
- Preliminary Process Design Basis
- Process Alternatives Evaluations Summary
- Preliminary Process Simulation and Heat and Material Balance Data
- Preliminary Process Flow Diagrams (PFDs)
- Preliminary Equipment List
- Preliminary Major Equipment List with Conditions of Service
- Preliminary Capital and Operating Cost Estimate (target accuracy of +50% /-30%)
- Preliminary Summary of Raw Materials and Utility Requirements
- Process Risk Summary.
FEL-2 / FEL-3, Front End Engineering Design (FEED), or Basic Engineering Packages
Once the process configuration has been clearly defined, a detailed process design package can be prepared. This package defines the process and identifies the chemical process engineering requirements that other engineering disciplines will build upon in the future.
FEL-2 Process Design Package
The FEL-2 Process Design Package or Front End Engineering Design Package (FEED) will establish the specific set of process operating conditions and equipment necessary to achieve the level of reliability, efficiency, and safety required. This design phase sets the direction for the entire project. At the completion of this phase of the project, a cost estimate with target accuracies of +40%/-20% can typically be developed.
Typical Process Engineering Deliverables for an FEL-2 package can include the following or a smaller subset of these items:
- Project Scope Summary
- Process design basis
- Raw material specifications
- Plant capacity requirements
- Product specifications
- Critical plant operating parameters
- Available utilities specifications
- Individual unit operations performance requirements
- Process regulatory requirements
- Other operating goals and constraints desired by the plant owners/operators/engineers.
- Material & Energy Balance (M&EB)
- Process Flow Diagrams (PFDs)
- Process descriptions
- Utility Balances and Utility Flow Diagrams (UFDs)
- Preliminary Piping & Instrumentation Diagrams (P&IDs)
- Process control description
- Preliminary line list
- Preliminary instrument list
- Process equipment list
- Preliminary Tie-in list
- Equipment process datasheets
- Instrument process datasheets
- Hydraulic design reports
- Cost estimate with target of +40%/-20% accuracy.
FEL-3 Detailed Process Design Package
The FEL-3 Package or detailed process design package (PDP), which is sometimes referred to as a Schedule A or Basic Engineering Design (BED) 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 final engineering of the plant. PROCESS provides this package and helps to answer any questions the client or engineering firm might have to ensure a smooth transition into the detail engineering phase. PROCESS provides process design packages for both Inside Battery Limits (ISBL) and Outside Battery Limits (OSBL) design requirements.
In addition to updating the items mentioned above in FEL-2, the following items are typically added during the FEL-3 phase.
- Preliminary general arrangement drawings
- Preliminary building requirements
- General description of the project site
- Budget pricing from vendors on major pieces of equipment
- Process design philosophies
- Relief system design basis
- Relief scenario datasheets and relief valve process datasheets
- Material Selection Diagrams (MSDs) and piping specifications
- Tie-in list
- Identification of power source and location
- Preliminary single line diagrams
- Process specialty items list
- Raw material and product storage and handling requirements
- Process effluent and emissions summary
- Process risk analysis (PHA, HAZOP, etc.)
- Preliminary operating procedures
- Preliminary product and in-process QC sampling/testing plan
- Preliminary project schedule
- Cost estimate with target +25%/-15% accuracy.
Listed below are the types of plant operations support that PROCESS typically provides to operating companies. Additionally, process engineering staff augmentation can be provided for operating facilities within reasonable commuting distance from one of our regional offices.
- Process evaluation, troubleshooting, optimization
- Control system startup, tuning, optimization
- Commissioning and startup assistance
- Existing operations design basis development
- Operating procedures, process documentation
- Operator and technical staff training
- Statistical process control.
- PSM programs
- Process Hazard Analyses (PHAs)
- Layer of Protection Analyses (LOPAs)
- Resolving/Engineering/Implementing PHA recommendations
- PHA Revalidations
- Safety Integrity Level (SIL) selection analyses for Safety Instrumented Systems (SISs)
- Layer of Protection Analysis (LOPA)
- PSM Compliance Audits
- Preliminary Hazard and Operability Studies (HAZOPs)
- New Plant HAZOPs and PHAs
- PHA facilitation training
- Incident investigation training
- Independent Program Assessments
- Performing Hazard Assessments
- Environmental Risk Management Plans
- Plan Development
- RMP Strategic Planning
- Compliance Audits
- Offsite Consequence Analysis
- Hazards Assessment
- Emergency Response Programs
- Worst Case Scenario and ARS Documentation
- Environmental Risk Management Plan Updates
- Mechanical Integrity Program Development
- Mechanical Integrity Audits
- Decommissioning Studies
- Detail Design/EPC process support
- Facility Siting Analysis and Evaluation
- Pre-Acquisition Due Diligence Surveys
- Operating Procedures Development
- Review or Revalidation of Operating Procedures
- Operator Task Analysis
- Incident Investigation
- Technical Writing
- Developing and Updating Process Safety Information, including
- Process flow diagrams (PFDs)
- Process chemistry
- Chemical compatibility matrix
- Maximum Intended Inventories
- Safe upper and lower operating limits and consequences of deviations
- Materials of construction
- Piping and instrumentation diagrams (P&IDs)
- Electrical Classification drawings and interpretation of codes and standards regarding area electrical classification
- Relief System design and design basis, including determining relief valve sizing bases and evaluating flare header capacity, liquid knockout requirements, and flare stack design for adequacy
- Ventilation System design information such as compressor building ventilation systems, including interpretation of applicable codes and standards for determining ventilation requirements
- Material and energy balances
- Safety systems documentation, including safety system plot plans and written descriptions of safety systems (e.g., interlocks, detection, suppression, utility, and containment systems).
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