Process Engineering Design for Energy and Industrial Projects
Process engineering design is the leading discipline within Chess Energy’s engineering design services.
Its purpose is to transform project concepts into technically sound, documented and buildable process solutions.
The design scope covers the complete process system – from process definition and sizing through equipment specification to the definition of process-safety systems.
Our work is centred on ensuring that the proposed system is aligned with actual operating requirements.
Effective process engineering design supports safe operation, stable performance and well-founded investment decisions.
Which Engineering Tasks Are Included in Process Engineering Design?
The design process includes a series of interconnected engineering activities that address the complete process. The scope extends from defining and sizing the process to specifying equipment and developing process-safety solutions across the entire system.
Process engineering design typically includes the following interconnected engineering tasks:
Process Description and Process Documentation
The process description and associated process documentation form the foundation of process engineering design.
Their purpose is to ensure that the operation of the process system, the relationships between individual process steps and the principal design considerations are clearly documented and traceable.
- description and documentation of the process
- preparation of the PFD (Process Flow Diagram)
- preparation of the P&ID (Piping and Instrumentation Diagram)
- assessment of process cause-and-effect relationships
Hydraulic Sizing and Pipeline-System Design
The purpose of hydraulic sizing is to ensure that the individual elements of the process system operate correctly under the specified operating conditions.
The calculations and sizing activities provide the basis for selecting pipelines, pumps and other process equipment.
- hydraulic calculations
- sizing of pipeline diameters
- determination of pump suction conditions, including NPSH (Net Positive Suction Head), and required head
- preparation of mass and energy balances supported by process simulation
Thermal Design Calculations and Simulations
Thermal design calculations and assessments define the heat-transfer and energy-utilisation processes within the process system.
These calculations support the appropriate design of heat exchangers, heating systems and other thermal equipment, together with the evaluation of different operating conditions.
- sizing of shell-and-tube heat exchangers and preparation of TEMA data sheets for equipment specification
- preliminary sizing of plate heat exchangers, with final sizing typically completed by the supplier based on the data sheet
- preliminary determination of the heat demand of building and process heating systems, with final sizing coordinated with the building-services engineer
- assessment of phase changes, including flashing and condensation
Specification of Equipment and Rotating Machinery
An important part of process engineering design is defining the technical requirements of the principal equipment and rotating machinery.
Appropriate specifications provide the basis for equipment selection, supplier enquiries and compliance with subsequent operating requirements.
- sizing of separators for two- and three-phase separation
- specification of rotating equipment, including pumps, compressors and air coolers
- preliminary determination of the heat demand of building and process heating systems, with final sizing coordinated with the building-services engineer
preparation of boiler and heating-system specifications
Pressure Protection and Process Safety
Appropriate pressure protection and process-safety design are fundamental to the safe operation of process systems.
During design, we define the required protective solutions and assess the operating conditions that may affect safe system performance.
- definition of the pressure-protection concept
- sizing of safety valves, rupture discs and explosion-relief panels
- assessment of quick-closing devices and pressure limits
- specification of detonation and deflagration flame arresters
Feasibility, Optimisation and Risk Assessment
Process engineering design includes both development of the system and evaluation from technical, operational and safety perspectives.
The objective is to demonstrate feasibility, identify potential risks and compare process alternatives in support of well-founded engineering decisions.
- preparation of feasibility studies
- assessment of process alternatives
- identification of bottlenecks
- active participation in HAZOP (Hazard and Operability) studies
How Does the Process Engineering Design Process Work?
Process engineering design consists of several consecutive steps. The precise scope depends on the characteristics of the project, but the typical process is structured as follows:
Data Collection
Collection of input data, including design, operating and permitting pressures and temperatures, the physical and chemical properties of process media, and interface data for connection to the existing system.
Preparation and Approval of the PFD
Development and coordination of the process block diagram and Process Flow Diagram
Preliminary Site Layout
Preliminary development and approval of the plant layout.
Mass and Energy Balance
Definition of the physical and chemical properties of the process streams with support from process simulation.
Definition of Pressure Protection
Development and refinement of the pressure-protection concept.
Preparation of the P&ID
Development of the Piping and Instrumentation Diagram, supported by a HAZOP study where required.
Equipment Specifications
Preparation of data sheets and specifications for the principal equipment.
Preparation of the Process Design Manual
Preparation of the summary technical documentation for the process.
The consecutive design steps ensure that project concepts are transformed into technically sound, documented and buildable process solutions.
The calculations, technical documents and specifications produced during the process provide a basis for subsequent design, procurement and construction activities.
Process Engineering Design and Simulation with Aspen HYSYS
Process modelling is one of the key tools used in process engineering design.
It involves the mathematical modelling of chemical and energy systems under different operating conditions before implementation.
Simulation supports the identification of technical risks, assessment of system behaviour and preparation of better-founded investment decisions.
We use Aspen HYSYS, one of the industry’s leading process-simulation platforms. Our engineers have several years of experience in the simulation and analysis of process systems.
Which Questions Can Process Simulation Help Answer?
We use process simulation where complex processes need to be understood, designed or optimised virtually and without operational risk.
How can system performance be optimised where flow rate, pressure or temperature conditions differ from the design basis?
Where do losses occur within the system, including energy, heat and material losses?
Is the equipment optimally sized, or must heat exchangers, compressors or separators be resized for changed conditions?
How does the system respond to changes in operating conditions, such as feed composition, temperature or load?
Can the system be operated safely, including under potential overpressure or phase-change conditions?
Could a proposed modification or project be commercially justified based on a technical and economic comparison of alternatives?
What Can Aspen HYSYS Be Used For?
The process-simulation platform provides extensive capabilities for modelling and analysing process systems.
The level of model detail can always be aligned with the objective of the assessment, ranging from simpler steady-state calculations to dynamic, time-dependent process analysis.
Modelling can be applied from the assessment of a single item of equipment, such as a heat exchanger, to the analysis of complete process systems or entire plants.
For complex, multiphase and large-scale systems, Aspen HYSYS provides extensive component libraries and integrated modelling capabilities.
In Which Industries Can Process Simulation Be Applied?
Process modelling can be applied across a wide range of energy and industrial sectors to analyse, optimise and develop process systems.
The software is particularly effective for modelling complex multiphase processes.
Oil and Gas Industry
Process modelling can be applied to gas-processing and gas-treatment plants, separation operations, gas dehydration processes such as TEG dehydration, acid-gas or inert-gas removal systems, LNG and LPG technologies, and pressure-boosting systems.
Assessments can cover the full value chain from well streams and treatment through transportation, processing and operation.
Energy Sector
Process modelling supports the simulation of power-generation cycles, including steam cycles and ORC (Organic Rankine Cycle) systems, together with the technical assessment of different heat-utilisation solutions.
Process Industry
The method can be applied to the assessment and optimisation of fire- and explosion-hazardous gas, vapour and liquid systems. Modelling enables analysis of process phenomena arising from changes in temperature, pressure and phase.
Aspen HYSYS supports the assessment of more than 2,000 substances and the pseudocomponents created from them.
Geothermal Energy
Process simulation can be used to model heat-extraction and reinjection systems in thermal-water circuits, heat-exchanger networks and solutions for integration into district-heating systems.
The quantitative and qualitative characteristics of dissolved gases, well inflow conditions and time-dependent changes in pressure and temperature can also be assessed.
What Does the Client Receive from Process Simulation?
Projects that include process simulation result in a technical report summarising the principal findings of the assessment.
The documentation may include the main mass and energy balances, key equipment parameters, identified problem areas and recommendations supporting safer and more efficient operation.
The simulation results support the preparation of design and operational decisions, identification of technical risks and evaluation of system performance.
Why Do Clients Choose Chess Energy for Process Engineering Design Projects?
The effectiveness of process engineering design depends on the methods and tools applied, engineering experience and a systems-level perspective.
Chess Energy’s design work is supported by operational experience, a process-engineering approach and an engineering background that connects multiple disciplines.
Practical Operating Experience
Our professional background is primarily rooted in oil and gas projects.
Practical experience with surface facilities, pressure systems and process engineering directly supports our design work.
Systems-Level Process Engineering Perspective
During sizing and design, we assess the complete process system, including the relationships between individual items of equipment and process steps.
This enables us to identify both process interdependencies and optimisation opportunities.
Established Simulation Expertise
We support process engineering design using Aspen HYSYS, a platform widely used across the industry, together with several years of simulation experience.
Integrated Engineering Capability
Process engineering design at Chess Energy draws on three complementary capabilities: engineering design, project management and independent technical supervision.
This enables us to develop solutions that take account of technical, construction and operational considerations.
Let’s Discuss Your Project
Would you like to establish a more predictable and safer technical basis for the design of your process system?
Let’s discuss how process engineering design and process simulation can support well-founded investment decisions, more accurate sizing and efficient, safe operation.
Further questions about process-industry system design, project management or technical supervision are addressed in the FAQ section below.
Frequently Asked Questions – Process Engineering Design
What is the difference between a PFD and a P&ID?
A PFD (Process Flow Diagram) presents the main process logic, principal equipment and process streams during the earlier design phases.
A P&ID (Piping and Instrumentation Diagram) is more detailed because it also includes piping, valves and instrumentation, and can serve as a key document for detailed engineering.
When is process simulation recommended?
Simulation can be useful where the performance of a complex system must be predicted or where the efficiency and sizing of an existing system require assessment.
Because the assessment is completed virtually and without operational risk, it supports better-founded design and investment decisions.
What is a mass and energy balance, and why is it important?
Az anyag- és energiamérleg a rendszerbe belépő és onnan kilépő anyag- és energiaáramok összevetése.
It provides the basis for equipment sizing and specifications, so its accuracy can have a significant effect on system performance.
Can process engineering design be commissioned as a standalone service?
Yes. It is available as a standalone service, from feasibility studies through preparation of detailed engineering documentation.
The form of support is always tailored to the project and can be supplemented with project management or independent technical supervision where required.
In which industries can your process engineering design services be applied?
Our experience is primarily associated with the oil and gas industry, but the process-engineering approach can also be applied to geothermal energy and the process industry.
The engineering methods used can be applied effectively across several industries because many technical, operational and safety challenges require similar approaches.
