• Process flow sheets

    We will usually start with sketching one or more process flow diagrams of your process. This will break down the complexity to well-know unit operations which we can connect with mass streams, power and control signals.

    A first process flow sheet will typically just be sketched in hand or in a power point presentation, so it is easy and cheap to modify as we explore the possibilities to find the most feasible solution. It can also be on a blackboard in a first kick-off meeting.

    Even a simple model will often provide more insight leading to certain modifications of the flowsheet. This could for example be integration of a heat exchanger to reduce external heating and cooling demands.

  • Process simulations

    We can build a virtual model of your process which will give a complete overview of all the mass and energy streams connecting the unit operations in your process.

    OPEX: The operating costs are usually directly proportional to the energy streams

    CAPEX: The capital investment costs are determined by the dimensions of the equipment which can be estimated based on the mass streams, some design rules, contacting to vendors or gained from experience

    TCO: The Total Cost of Ownership is easy to calculate once the OPEX and CAPEX are known.

    The model can be a stationary or dynamic model. A dynamic model can also be used to train process operators before they get responsibility for operating the real plant. A dynamic model can also be used for a HAZOP study to avoid failures and serious accidents. This is often required by the classification company for approval.

    The Matlab Simulations can be linked to an excel user interface so all stakeholders can benefit from the simulation results without knowing the details behind the model. We can also make and host a web application, so the model is easy to access from any web browser. This will avoid any IT security problems as no software or macros need to be installed locally. The web application can be password protected.

  • Process and Instrumentation Diagram (P&ID)

    Once the flowsheet is more established, we can help to make a more professional P&ID in AutoCad or similar. This will also include the necessary valves and instrumentation for controlling the process.

    When the desired solution has been selected, we can transform the process flow diagram into a detailed process and instrumentation diagram (P&ID) including all valves and sensors for proper control and monitoring of your process.

    All process units, pipes, valves, and instruments will be equipped with a tag number so a part list can be generated. Based on this, we can start to approach different suppliers to access the likely dimensions and costs of all the equipment.

    The detailed P&ID can be generated in AutoCAD Plant 3D and shared to all stake holders.

  • Control software

    The detailed P&ID must be linked to an operation philosophy, which is a high-level description of how the process should be controlled. This is also a very important document for the class approval and for any programmers to make a more detailed PLC code. We can help you with all this.

  • Data analysis and visualization

    Once the process is up running, data from the most vital sensors will normally be logged.

    Based on these data, it is possible to tune the parameters in the model, so it becomes even more certain to predict the future and more applicable for further process optimization and trouble shooting. A smaller test unit might also be installed first to generate data. These data together with the model are then the key to scale-up to a larger process facility with greatest possible certainty.

    Visualisation of the data is important to create awareness about “what matters” among the operators and other stakeholders. More dynamic and interactive charts can provide a much faster and precise overview of certain key performance indicators (KPIs) compared to old fashion trend plots or excel sheets.