Process Consulting Solutions Brochure | Process Safety Management Brochure

Process Consulting Solutions

Ingenious Inc. is a leading provider of consulting services in the field of Process Simulation, Optimization and Process Engineering.

We have depth of expertise in various verticals, experience in systems and knowledge that allow us to deliver domain expertise in refining, power, chemical, and petrochemical industries. With our strong process knowledge and global execution capability we can provide engineering and simulation services that range from concept to commissioning. Ingenious provides a broad range of services including

  • Conceptual and feasibility studies

  • Front end, basic and systems engineering

  • Process Safety Management, PHA facilitation

  • Refinery configurations and planning models

  • Preparing SOPs, Operating Manuals

Case Study: Fortune 500 Refining Company

Task: Process Revamp study for a Hydrotreater plant.

Duration: 4 calendar months

Objective: Identify bottlenecks and explore the possibility to increase capacity by 40% while keeping environmental safety in mind.

Scope: Process simulation base case model, and revamp model. The study included design case validation, Test run case evaluation and a target case adequacy check of all the equipment of a plant, including piping. Re-rating of all equipment and a safety audit were conducted as well. Findings presented in a detailed professional report with simulation output.

Process Consulting Project Summary

A brief summary of some past projects
 
Consulting Projects Client, End user
Basic and detailed engineering for Hydrotreater units Major EPC firm, Lion Oil, Stone & Webster, Marathon
Process package for Delayed coking unit For end user United Refining Company
Process re-rating and revamp for DHDS/DHT units Valero Corporation
Refinery revamp project: Basic and detailed engineering Major EPC firm, Total Refining
Detailed design hydraulics, Relief valve sizes, Flare Design, Restriction Orifice and Control Valve Sizing, Utilities balance, Fire safety design, underground sewer design and technical bid evaluation. Project was supported using Unisim, Pro II and Flare net Shaw Stone & Webster
Plant optimization and alternate product study Bombay Dyeing Ltd.
Off-sites and Utilities project Stone & Webster, Marathon Oil
Safety relief sizing, P&ID detailing, process simulation Stone & Webster, SK Corporation
Basic engineering for CDU/VDU units Major EPC firm
Equipment hydraulics, sizing, PFD, P&ID for various refinery units Shaw Stone & Webster
Development of process simulation model for amine treating process for oil & gas company Indonesia Oil & Gas Academy
800 KTA Ethylene Grass Roots Project End user- PetroChina Fushun City, China
Calculation and Line-sizing for Pressure Relief Valve. Creating Line Designation Tables for Utilities area. Determining Design Pressure and Design Temperatures for plant equipments End user, Exxon Mobil
Crude expansion revamp project End user- Marathon Refinery
Develop isometrics & P&IDs for Alkylation & esterification processes Celerity3
Develop isometrics & P&IDs for skid facility for oil & gas platforms Zeppelin Systems USA
Feasibility study and process design of BTX facility GTC Technology Houston
Feasibility study and process design of Paraxylene facility GTC Technology Houston
Dynamic simulation of flare relief system KBR-Halliburton
Feasibility study and process design of PTA facility GTC Technology Houston
Refinery configuration study for grassroots refinery Indian Institute of Petroleum
Basic engineering study for product alternatives for DMT facility (Dimethyl terephthalate) Garware Chemicals Ltd
Optimization & simulation of Wash Water Requirement in an Ethylene Oxide Purification System Vinyl Chemicals Ltd
Design & simulation of Absorption Refrigeration Plant Vinyl Chemicals Ltd
Process Design for separation of Ethanol and Water from Ethyl Acetate Vinyl Chemicals Ltd
Minimizing waste stream in a Distillery Confidential
Process Design for Separation of Cinnamyl Alcohol and 3-Phenyl 1-Propanol Laxmi Organics Ltd.
Process design and simulation of by-product stream for ethylene recovery system. Removal of argon and separation of ethylene with hydrocarbons. At least 90 % recovery of ethylene. Vinyl Chemicals Ltd
Benzene reduction from gasoline per EPA requirement. Developing P&IDs, perform hydraulics calculations, PSV calculations, and other typical chemical engineering work. Developing P&IDs for fired heater. Shaw Stone and Webster
Heavy Oil Upgrading Feed #2: Hydraulics Calculation, P&ID development and prepare / check Datasheets for ARDS, FCC and PRP units. End User - Hyundai Oil bank Co. Ltd, Korea
Petrobras Steam Cracking unit project. This is a 1030 KTA ethylene plant. Shaw Stone and Webster
ExxonMobil Singapore Parallel Train (SPT) Ethylene Project: LDT, CVFE, steam hydraulics calculations, and P&ID development and mark-up for various equipments in the utility area. ExxonMobil
Control of Hazardous Air pollutants from mobile sources: Hydraulic Calculations, P&ID development and EIV analysis. MSAT (Robinson, Illinois) – Marathon Refinery
PSPC 800KTA Ethylene Complex Project: a process design package for an Ethylene Plant. Firewater design and cooling water distribution, PSV sizing, Hydraulics, Pump calculations and Line sizing. Petro China, Sichuan Petrochemical Company
Singapore Parallel Train Olefins Recovery Project: Detailed Engineering for an Ethylene Complex Plant. ExxonMobil
Crude Dewatering Project 150K BOPD. Meta Petroleum, Columbia
Process Scheduling for cost optimization of a condensate refinery using ProSched. Adding to build daily instructions for feed and product inventory management, tanker scheduling and product dispatch and production schedules. Laffan Refinery
Pressure relief analysis for Detroit Heavy Crude Upgrade Project Marathon Oil Company
Designed and created graphical user interface dashboard for real time process monitor system, set up data connection between plant data sources, calculation engine, database and user interface. ISS, Australia

Advanced Solutions Project Summary

Training Solutions Client, End user
Refinery Training system development & management ExxonMobil
Developed lube oil reactor models, GTL models & Linear Programming models using ProPlan software US Government
Refinery Production scheduling system using ProSched Qatar Gas-Laffan Refining
Feasibility and production planning study for national oil Petro-Ex Canada
refinery  
Feasibility and refinery configuration study & training Suncor Energy USA Inc
Training simulator and system solutions Jubail Industrial System
Training & e-learning solutions Yanbu Industrial System
TEG Dehydration unit training simulator Kuwait University
LNG Dynamic training simulator KBR, Tangguh LNG
FCC unit training simulator Reliance Industries Ltd.
Hydrotreater and reformer training system PPE, Ventura Refining
Dynamic simulation project for Main air blower and compressor sections of FCC ABB Simcon
Dynamic simulation project for oil & gas platform PEMEX
Dynamic simulation project for Naphtha Hydrotreater Unit & GOHT model Confidential client
Dynamic simulation project for Delayed Coker Unit Pertamina, Indonesia
Dynamic simulation project for 2-stage Hydrocracker Unit Pertamina, Indonesia
Dynamic simulation project for Propylene Refrigeration Unit Dow Canada
Dynamic simulation and testing of hydrogen plant Honeywell for end-user, SOHAR refinery in Qatar
Integration of dynamic simulation model for process control with e-learning system NSF Grant-San Juan
Dynamic simulation of multiple train compressor system Honeywell
Dynamic simulation project for FCC Plant: Main Fractionator and related strippers PETROBRAS using RSI’s INDISS technology
Dynamic simulation project for Naphtha splitter tower, Gasoline Treater section Honeywell for confidential end-user
Dynamic simulation project for Ethylene Glycol system in a Gas plant Honeywell for confidential end-user
Dynamic simulation project for Reverse Osmosis Unit in a Gas Plant ABB Simcon for end-user, Saudi ARAMCO
Dynamic simulation project for Pulper in a Pulp/paper Mill DOMTAR, Montreal
Dynamic simulation project for Crude Units, Crude Storage and pumping facility ABB Simcon for end-user, Saudi ARAMCO
Dynamic simulation project for Deethanizer, Ethylene Stripper and Debutanizer ABB Simcon
Dynamic simulation project for HF Alkylation Unit, with Mitigation system Trident Computer resources for PEMEX as end user
Dynamic simulation project for MTBE Plant PDVSA, Venezuela
Dynamic simulation project for Sulfur Recovery Unit- Claus Process ABB Simcon for end-user, Saudi ARAMCO
Dynamic simulation project for Acetaldehyde removal unit of the Acetic acid plant Alkyl Amines Chemicals Ltd.

Process Safety Management (PSM) 

1. Plant Walk Down

2. Develop and Update the P&IDs

3. Process Safety Information (PSI) Collection

4. PSV sizing and re-rating

  • Analyze different scenarios, Simulation of relief conditions, pressure relief valve sizing

5. Flare Header design

  • Evaluate the flare header capacity and design flare stack for adequacy

  • Perform Dynamic Simulation of Flare Relief System

Process Hazard Analysis (PHA) Facilitation and Scribing

  • Systematic review of a process conducted for the purpose of identifying, evaluating and recommending controls of the hazards involved in the process

  • Analysis of safety of all process equipment, during startup, maintenance operations, and upset/emergency operations.

  • Prepare, facilitate and write reports for PHA which involves addressing hazards of the process, previous incidents and engineering and administrative controls by “What-if / checklist methodology” or “HAZOP methodology”.

SOFTWARE USED: - PPM-Berwanger, Customized Spreadsheets, HYSYS, Chemcad-SafetyNet, Petrosim Express, PHA-Pro 7, Fathom

PROCESS EXPERTISE: CDU/VDU, COGEN, Delayed Coker, DHDS/DHT, FCC, Flare header network, Hydrocracker, Hydrotreater, Hydrogen Plant, Alkylation, Reformer, SRU, Steam Cracking, Sour Water Stripper, Amine Treatment, Tank farm systems etc

REFERENCES: Shaw Stone & Webster, Siemens, KBR- Halliburton, Lion Copolymer.

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