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Detailed Engineering Solutions

Process Simulation and Modelling

We deliver steady state and dynamic simulation for design, troubleshooting, and operator training

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Technical overview

Process Simulation
and Modelling

Process simulation reaches well beyond steady state design. Dynamic models validate ESD response times, prove control loop stability under upset conditions, and power the operator training simulators that build competency before first startup. Our team delivers validated steady state and dynamic models in HYSYS, Aspen Plus, gPROMS, and UniSim, from the FEED basis of design through to post startup troubleshooting, with full documentation of model assumptions and the evidence behind our validation.

Process Simulation and Modelling Overview
Engineering process

Process Simulation and Modelling workflow

Scope & Tool Selection

Define steady state vs dynamic simulation need, select HYSYS, Aspen Plus, gPROMS, UniSim, or ProMax.

Model Build & Validation

Construct simulation topology, validate against plant data, licensor performance curves, or experimental results.

Steady State Case Studies

Run design, turndown, and upset cases, document deviations from design intent and resolve reconciliation.

Dynamic Simulation

Build dynamic model for ESD validation, control loop tuning, startup/shutdown procedure support, or OTS.

Control & ESD Tuning

Tune PID parameters, safety function response times, and override logic against performance acceptance criteria.

Deliverable Package

Issue validated simulation files, steady state and dynamic case reports, and OTS scenario library.

Process Simulation and Modelling Scope
Scope of work

Every deliverable from basis to handover

Complete Process Simulation and Modelling scope covering every calculation, drawing, specification, and construction support activity.

Steady state design simulation across all operating cases and turndown
Property method selection validated against experimental and licensor data
Dynamic simulation for ESD response validation and control loop tuning
Operator training simulator build and scenario library development
Characterisation of distillation column and reactor performance
Integration and validation of compressor and pump performance curves
Heat integration and pinch analysis that targets energy recovery
HAZOP deviation analysis supported by simulation, with consequence bounds
Engineering outcomes

Outcomes of Process Simulation and Modelling

Operating Envelope and Transient Safety
  • Validates ESD response under transient conditions
  • Supports the design of startup and shutdown procedures
  • Strengthens HAZOP deviation analysis
  • Reduces commissioning risk
Process Data and Permit Defence
  • Stays aligned with recognised industry practice
  • Documents the design basis for the regulator
  • Supports permit and consent applications
  • Produces documentation that withstands client and licensor scrutiny
Control Strategy and Optimisation Quality
  • Improves DCS tuning and response
  • Supports operator training and competency
  • Identifies debottlenecking opportunities
  • Builds out your revamp planning
Energy and Yield Improvement Value
  • Reduces commissioning time and cost
  • Optimises energy and utility consumption
  • Avoids costly design rework
  • Builds operator competency through the training simulator
Standards & references

Codes & standards we work to

Aspen HYSYS Best PracticegPROMS PSEUniSim Design (Honeywell)ProMax (Bryan Research)AIChE Design Institute GuidelinesIEC 62381 (APC)ISO 10628IBR 1950 (Indian Boiler Regulations)IS 2825 / 803 / 4503 (BIS Pressure Vessel / Tank / HX)TEMA (Tubular Exchanger)CEA Regulations 2010 (India)NEC India (National Electrical Code)AspenTech / HYSYS / PRO II / UniSimNFPA 2 (Hydrogen)ASME B31.12 (Hydrogen Piping)
When to engage

Triggers that signal the need

FEED and detailed engineeringControl system tuningAn operator training simulator buildA debottlenecking studyA revamp designPost incident root cause work
Industries served

Where Process Simulation and Modelling applies

Oil & Gas, Upstream

Wellheads, separators, gas compression, FPSO topsides, produced water systems.

UpstreamOffshoreFPSO
Refineries & Petrochemicals

Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.

RefiningPetrochemical
LNG & Gas Processing

Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.

LNGCryogenic
Specialty Chemicals

Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.

ReactiveBatch
Power Generation

Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.

PowerHydrogen
Pharma & Food

Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.

PharmaFood & Bev
What we deliver

Tangible deliverables

  • Validated simulation model files
  • Steady state and dynamic case studies
  • An operator training simulator scenario library
  • A heat integration report
  • Column and exchanger performance analysis
  • Supporting data for the control philosophy
Get Started

Ready to start your project?

Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.

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