Process Engineering Associates, LLC services

PROCESS provides a full range of services relative to the sizing, verification, and modeling of Flare Systems and Pressure Safety Relief Valves (PSVs or PSRVs) including the following: Generate all calculations and associated documentation for the sizing and selection of PSVs per API and/or ASME Code requirements. This also includes: Identification of and calculations for all credible scenarios, not just the controlling scenario. Physical properties generated by CHEMCAD process simulation models for each stream.

We offer the most efficiently run PHA meetings that most of our clients have ever experienced, often cutting meeting time down by as much as 50%. We do this by performing tasks outside of the PHA meeting that don`t need input from the PHA team. This allows PROCESS, with our unique knowledge base, to quickly, efficiently, and thoroughly move through the PHA in less time than most trained facilitators are capable of doing. This translates to less time that you and your personnel have to sit through PHA meetings....and let`s face it, time is money. Our experience as plant operations chemical engineers and process designers also gives us exceptional insight on most aspects of a processing facility. Give PROCESS a try and you too can benefit from the most efficiently run PHA meeting you have ever experienced.

Title V permitting support: Emissions estimating. Emissions inventory preparation. Regulatory assessment support. Compliance assessment support. Reasonably Available Control Technology (RACT) evaluations. Best Available Control Technology (BACT) evaluations. Maximum Achievable Control Technology (MACT) evaluations. Lowest Achievable Emission Rate (LAER) evaluations. Monitoring, reporting, record keeping requirements. Plan Approval application preparation.

Assessment of process inputs/feeds. Assessment/inventory of recycle/reuse and substitution opportunities. Evaluate process modifications to enhance performance. Regulatory assessment to summarize current and future requirements. Process Water or Wastewater treatment system design. Groundwater treatment system design. Wastewater permit preparation support. Preparation of laboratory/bench test protocols. Stormwater permit preparation support. Wastewater generation planning for future facilities.

Assessment of process waste (residues), treatment and disposition alternatives. Evaluation of opportunities to recycle/reuse or minimize waste generation. Preparation of laboratory/bench test protocols. Solid waste residue treatment system design to meet disposal requirements. Solid waste permit preparation support. Waste waste residue generation planning, for future facilities.

When clients are contemplating a new plant or major process expansion, they typically have more questions than answers. Will the idea even work? PROCESS is able to assist by providing experienced and knowledgeable chemical engineers that can identify, and systematically narrow down, the possible technical options for a given process goal. By necessity this occurs at the major unit operations level. Once the viable technical options are identified, an economic evaluation is performed. Based on technical merits, system reliability, and economics (capital and operating), and other factors, a preferred choice is usually clear as to which direction the future process design should take. At this point a conceptual design can be done that includes preliminary process flow diagrams, mass & energy balances, and a list of major equipment. A very rough order of magnitude cost estimate can be provided as well.

The very front end of every large design project is critical to the long-term success or failure of the plant.  While the business plan identifies the economic opportunity, the Front End Engineering Design Study (FEED) will establish the set of process operating conditions and equipment to achieve the level of reliability, efficiency, and safety required. This design phase sets the direction for the rest of the project. Because it is so critical to the future success or failure of the overall objectives, we feel our clients make the wise choice by purchasing proven licensed processes or selecting a firm like ours which specializes in process design engineering.

The Schedule A or Basic Engineering Design 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 detail engineering of the plant (details such a structural steel supports, buildings, wiring, piping details, insulation, equipment vendor/model selection, etc.). PROCESS provides this package and is there to answer any questions the client or engineering firm might have to ensure a smooth transition into the detail engineering phase. We provide these packages for both Inside Battery Limits (IBL) and Outside Batter Limits (OBL) design requirements.

More and more, PROCESS is requested to remain on during the detail engineering and construction phases of projects for which we have performed the process design. In this oversight role, any process change requests are routed through our engineers for approval or comment. This helps ensure that the client understands what the impact may be on the process as changes and alternatives are suggested. Many times there is great pressure to hold down costs as the civil, mechanical, electrical, and instrumentation details of the plant are developed. The temptation to remove seemingly inconsequential process components can lead to off-spec product, inadequate throughput, high operating costs, etc. We are able to help prevent such problems simply by serving as the process integrity watchdog. Project Examples - Detail Engineering Phase Project Support, Project Examples - Construction Phase Project Support

We are often called upon by clients to evaluate process options aimed at achieving one or more specific goals. These goals run the gamut from improved throughput, quality, or consistency, to emissions reduction, energy recovery, or waste minimization. In such cases we begin by determining the current state of the process. This is done through a series of interviews and discussions with the client`s technical, engineering, and plant operating personnel. Additionally plant process data is collected in various forms, some of which include P&IDs, batch sheets, DCS data logs, heat and material balance information (if it exists), operation logs, etc.