Process Design
Main Activities
Definition of process plants and facilities fundamental parameters. Unit operations, equipment sizing, instrumentation control, etc.
Technical support to engineering activities for optimum expedition of basic design.
In-depth examination of engineering specifications and drawings, acceptance of deviations from the basic engineering design, etc.
Technical support to business development with reference to exploring, identifying and consolidating the needs and the requirements of prospective clients.
Activities detail description
Feasibility Studies
Ensure the technical as well as the economic feasibility of an expenditure, or of an altered mode of operation of a unit within a plant.
Optimization of Operating Schemes
Optimization of the arrangement of a number of operating units in order to achieve the most efficient scheme from a production point of view, the less costly from an operating point of view, and simultaneously achieve the best rate of return for the expenditure envisioned.
License Technology Selection Studies
Preparation and forward of Invitations to Bid to licensors. Evaluation of the bids received from a technical and economic point of view. Bids are classified with reference to their compliance with the qualitative requirements, the economic level of the total capital investment including the operating and maintenance costs, the lower license fee associated with the project, and the cost of the basic process package.
Expedition of Basic Design
Process Flow Diagram finalization, execution of material and energy balances calculations, preparation of process data sheets for equipment and instrumentation, preparation of P&IDs, estimation of utilities consumption, and preparation of guidelines for the start-up, operation and shut-down of an operating unit.
Detail Engineering Follow-Up
Utilities line sizing, sizing of utility and flare headers, review of the pressure drop in critical lines, review of the equipment and instrument material requisitions prepared by the engineering division disciplines, review of the P&IDs, the plot plan, the piping arrangement and piping lay-out drawings, the isometrics drawings, and the 3-D model.
Operating Manual
Involved in the detailed write-up of the procedures and guidelines during the unit start-up (initial start-up, regular start-up), its operation, the regular shut-down, and the emergency shut-down.
Initial Start-Up Phase
Clarifications concerning the basic design and the operating manual and resolution of problems arising during the start-up phase.
Test Run
Preparation of log sheets for collection of operating data during the test run, overview of the smooth test run operation and preparation of the test run successful report following evaluation of the data collected.
Proposal Write-Up
Engaged in the overall description of the project and in the identification of the specific studies and design activities the Process Division is to perform.
ITBs Write-Up
Description of the project scope and of the extent of the basic design involved.
Technical Evaluation Of Proposals Or Bids Submitted
Evaluation of the compliance of sub-contractors to the specific scope of work and to the process design performed.
Environmental Impact Studies
Definition of the gaseous, liquid and solid effluents from a process unit and proposal of schemes for reduction of their lever or elimination.
Safety Studies
Identification of the possible dangerous scenarios linked with the operation of a process unit and suggestion of ways to either limit down such events or means to deal with them effectively.
Business Development
Develop an insight of the needs and requirements of prospective Asprofos clients and identification of the services that might be successfully rendered by Asprofos.
Know How & Experience
In the sector of refineries, the Process Division has acquired extensive experience in the area of Basic Design of non-proprietary refinery units, such as :
- Crude Distillation
- Vacuum Distillation
- Naphtha and Gasoil Hydrodesulfurization
- Acid Gas removal with amines in gaseous and liquid streams
- Sour Water stripping
Additionally, it possesses Basic Design know-how on all offsites facilities, storage facilities, refinery product transfer, blending, and loading/unloading.
Further, The Process Division possesses know-how in the basic design of co-generation plants (steam/electricity). In parallel, The Process Division has developed extensive knowledge in the area of Load Shedding and re-acceleration, areas of utmost importance in refineries units whose operation is not strictly based on steam, but rather on electricity.
Asprofos’ involvement in the Natural Gas project proved to be fundamental in the acquisition of know-how in this specific area. The Process Division now boasts of having successfully performed the basic design of the main natural gas pipeline as well as of its branches. The design activities were based on the extensive use of the TGNET software package for static and dynamic simulations performed.
The Process Division expanded even further its experience and capabilities through direct involvement in the basic design of metering and pressure control stations along the natural gas pipeline transfer system, and enhanced its strong position by acquiring experience in the area of cryogenic installations which constitute an integral part of the Liquified Natural Gas storage terminal.
Tools
The Process Division employs the following tools to perform the studies it undertakes:
Foster Wheeler’s Design Practices and methods for estimation of refinery products properties.
Design procedures owned by clients and used in older projects.
Technical volumes such as API Data Book, GPSA Data Book.
Calculation files and documents such as material requisitions, equipment and instrument data sheets, process flow diagrams and design basis memoranda, technical reports, process design packages and operating manuals from projects already successfully completed.
All of the above may be utilized effectively to expedite the Process Division’s activities in future projects.
Development Target
Flexible organizational matrix and development of proper methods, work instructions and techniques so that all engineers within the division may be able to expand and learn independently and under minor supervision and guidance, in an effort to perform the high level specialized activities of the Process Division in a correct, fast and competitive manner. Towards this end, continuous learning through on-the-job training is and will not cease to constitute the main means of engineers’ professional development. Seminar attendance and participation in short courses will also continue to provide the engineers with additional knowledge in areas of interest, provided the work load is not so excessive as to hinder dedication into other than work activities.