Process engineering

We have proven capability in developing the design of processes from laboratory, pilot scale or existing plant into new production facilities in close cooperation with our clients. Our team of process engineers have wide experience in both manufacturing and contracting environments and will always bring a pragmatic approach to a project. It is our ability to appreciate the relevant safety, health and environmental issues and requirements for a particular industry which ensures the plants we design conform to best current practice.

Our capability covers the full range of expertise expected of a top-level process engineering operation, including:

process design and development
process modelling and optimisation
mass and energy balances
User Requirement Specifications, to define key system/process requirements (URS)
PFDs and P&IDs
establishing the Basis of Safety
equipment specifications
detailed process calculations
control and operating philosophy
hazard identification and risk assessment.

Some of the specialist areas of expertise we would integrate into a project are:

process chemistry scale-up and assessment of reaction hazards, leading to practical choices of prevention and protection measures
clear control and safety strategy for a plant to ensure conformance with IEC Standards 61508 and/or 61511 for functional safety. This includes determining safety integrity levels (SIL) of specific safety instrumented functions, generally by Layer of Protection Analysis (LOPA), although risk graph methodology can be used for initial screening. More quantified fault tree analysis may occasionally be used for complex systems
leading hazard studies of the appropriate level during the project lifecycle or as a specific exercise. Typically we utilise the recognised 6-stage hazard study process which includes HAZOP at Stage 3. We also customise the format of a study to meet the particular needs of a project or client, e.g. control systems and operability
hazardous area classification in line with the methodologies embodied in IEC 79-10 and IP 15, and generating documentation which satisfies the ATEX 137 Directive and DSEAR 2002 Regulations. In addition, carrying out risk assessment and risk reduction/elimination measures for ATEX and DSEAR compliance purposes
design of pressure relief systems and associated disengagement and environmental control systems. Recognition of two-phase flow potential, the need for testing work, and subsequent design based on DIERS methodology
assessment of alternative strategies for minimising SHE related risks during the handling and processing of flammable, explosive and toxic vapours, liquids, solids and dusts, including cost benefit analysis.

All our services are provided as a total package or as separate elements.

The key to our success is our process engineers, who:

are personable and hard working. Many have worked in similar companies to our clients and understand their needs, expectations and problems
possess high technical and professional integrity and capability, including the ability to challenge accepted practice and think laterally when devising solutions in many different industries including pharmaceutical, biotechnology, food, chemicals and fibres
are a good mixture of youth, experience and technical training
have determination and application of skills to meet client objectives.

We always embody best current practice whether the project is large or small, consultancy or a full Engineering, Procurement, Construction, Management and Validation (EPCMV) project.