Basic & Detail Engineering Services

A combination of a highly dedicated, industry skilled team with cutting edge technical tools and
expertise utilizing more than 90 different state-of-the-art software enables Ingenero to provide
design and engineering services to our clients, customized to meet their targets. Ingenero’s highly
experienced engineers have extensive process engineering expertise in oil and gas, refining,
gasification, petrochemical, pharmaceutical and specialty chemicals. Ingenero's engineering team
has successfully performed over 3 million man hours in projects of various sizes and scope over
the past few years. Ingenero's most popular engineering delivery modes are:
 Engineering excellence centre for EPC contractors.
 Engineering for Green and Brown fields projects.

Engineering excellence centre for EPC contractors Ingenero serves as a seamless part of
engineering divisions of EPC companies, either through remote engineering services or a
dedicated, on-site engineering service team. Our remote satellite office setup specifically for
catering to clients’ needs provides best cost country advantage to several engineering
conglomerates and manufacturing companies’ world wide. The typical work flow for the
Engineering excellence center:
Engineering for Green and Brown fields projects Ingenero provides end-to-end engineering
solutions that combine leading edge technology with a best practices approach where highly
qualified engineers routinely optimize designs. We provide assemblage of customized
engineering services to meet diversified needs of our Process Industry clients. Ingenero’s process
engineering offerings encompass:
 Conceptual Design
 Basic Engineering Design

 Front End Engineering Design

 Detail Engineering Design

Conceptual Design The conceptual design is a study phase in which ideas and possibilities are
evaluated. This phase results in a basic process concept, a preliminary schedule and a rough cost
estimate. At Ingenero, we evaluate the process to assess its technical feasibility and economic
viability for developing project scope as well as providing a well defined starting point for a
more detailed process design.
Ingenero’s Concept designing covers:
 Literature Survey
 Development of an Idea from scratch

 Concept development
  Conceptualization of Process Schemes
 Concept refinement
 Preliminary Process Flow Diagram (PFD)
 Overall Heat and Material Balance (HMB)
 Conceptual Layout
 Order of Magnitude Cost

Basic Engineering The basic engineering services offered by Ingenero consist of core
documentation of projects, including process flow diagrams, heat & mass balances, piping and
instrumentation diagrams (P&IDs), control & operational philosophy, basic equipment sizing,
equipment specifications, conceptual equipment layout, etc.
Ingenero’s basic engineering covers:
 Conceptual process studies (material balances, process flow-sheets,…)
 Preliminary plot plan.

 Freezing the Master Layout of the Plant.

 Definition and sizing of main equipment resulting in process specifications.
 Preliminary Piping and Instrument Diagrams.
 Utility consumption figures.
 Schematic drawing of equipments on each floor.
 Definition of control and safety devices.
 Analysis and sizing of Safety Valve.
 Control valve hydraulics & process specifications.

Front End Engineering Design (FEED): Ingenero’s extensive experience facilitates the client
to have a FEED that reflects all technical specific requirements and avoid any significant
changes during execution of the same.
Ingenero’s FFED packages cover:
 Basis of Design.
 Feasibility Study.

 Preparation of the specification.

 Mechanical data sheets of the main equipment, starting from the process specifications
issued during the BED and incorporating the specific requirements of codes and
standards to be applied to the project.
  Development of process and utility Piping and Instrument Diagrams released for detail
engineering.
 Preparation of tender packages for the main equipment.
 Development of detailed plot plans and hazardous areas.
 Elaboration of the main piping, instrument, electrical and civil works layouts.
 Carrying out all the studies to be performed before ordering the main equipment.

Detail Engineering Detail engineering includes the extraction of all the essential information
from all the basic engineering drawings and calculations to provide the exact drawings in detail
for all production, fabrication & erection items and in turn the details of entire project along with
the precise bill of quantities and specifications for each of the equipment.
Ingenero’s detail engineering covers:
 Equipment List.
 Process data sheet.

 Reconfirmation of the process and mechanical design of all equipment Detailed

specifications for vendor supplied items such as pumps, compressors, etc.
 Management of vendor drawings.
 Thermal rating and vibration analysis of heat exchangers.
 Piping and Instrument Diagrams.
 Trip Logic and safeguards.
 Cause and Effect Diagrams.
 Review of P& ID - Jointly with Client.
 Hazard and Operability Study (HAZOP)
 Line List.
 Valve List.
 Control valve data sheet.
 Relief valve data sheet.
 Planning and piping design.
 Detailed piping drawings, including isometrics and stress calculations.
 Bill of Quantity (BOQ).
 Tender Bid evaluation and procurement assistance.
  Detailed drawings and documents related to instrumentation, electrical facilities and civil
works. Schedule and cost control.
 Start up procedures, Operating and Commissioning manuals.

Commissioning and Start-up assistance

 Field inspection of equipment, pipes, instruments, relief valves
 Water Flushing and hydro-testing

 Air Blowing and Pneumatic Pressure Testing.

 Testing of Motor drives
 Stroking of Control Valves
 Testing of Control Loops
 Test runs of Rotating Equipment
 Nitrogen Purging
 Pickling / Passivation
 Feed Cut in

http://www.ingenero.com/basic-detailed-engineering-services.php
Types of Process Engineering Services

Conceptual and Preliminary Process Designs (FEL-0 / FEL-1)

Detailed Process Designs (FEL-2 / FEL-3)

Detail Engineering Phase Process Integrity Oversight

Process Technical & Economic Evaluations

Pilot Plant Evaluation and Scale Up

Process Design Components

Process Modeling and Simulation

Operations Support

Third Party Process Evaluations, etc.

Conceptual and Preliminary Process Designs

Feasibility Studies and Conceptual/Preliminary Process Design (FEL-0 / FEL-1 / pre-FEED) -
Project Examples

When clients are contemplating a new pilot facility, new plant, or major process expansion, they
typically have more questions than answers. Is it technically feasible? What is the best process
configuration? Should it be batch or continuous? How much would it cost? 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. Once the
viable technical options are identified, an economic evaluation is performed. Based on technical
merits, system reliability, economics (capital and operating), and other factors, it usually
becomes clear as to how the future process design should progress. At this point a conceptual
design can be developed by PROCESS that includes preliminary process flow diagrams, mass &
energy balances, a list of major equipment, and a rough order of magnitude cost estimate.
PROCESS can also assist at this point in identifying potential risks associated with the design
(weak areas in the design basis, insufficient lab data etc.) so that a plan can be developed to
address these issues prior to or during the next phase of the project.

It is widely recognized that this key front end work will have a major impact on the overall project and
ultimate operation of the process. If this work is not done properly then the project is in trouble no
matter how good the subsequent detail engineering, construction, and project management work are
executed.

FEL 0 - Identification Phase (Conceptual Process Design or Screening Study)

Industrial project opportunities can target revenue growth; expense reductions; strategic growth;
or improved reliability and/or efficiency. Clients typically identify opportunities by evaluating
the value and identifying key risks and uncertainties. It is important to evaluate opportunities on
a consistent basis for comparison purposes. The basis for the first decision gate is a high level
screening study or conceptual process design study. This level of work involves identifying
promising chemical conversion pathways or major licensed technologies, narrowing the project
down to one or more options, identifying major equipment, developing block flow diagrams, and
generating an Order of Magnitude capital cost estimate range ($1MM, $10MM, $100MM, etc.).

FEL 1 - Appraisal and Selection Phases (Alternatives Evaluation and Preliminary Process
Design)

Appraisal (Alternatives Evaluation)

During the appraisal phase of the project a series of process alternatives is developed and further
assessment of the process value, risk, and uncertainty is conducted. Some examples may include
alternatives such as batch versus continuous processing, use of different types of separation
techniques (extraction versus distillation, pressure filtration versus a centrifuge), etc. The most
promising development concepts progress forward to the Selection phase.

Selection (Preliminary Process Design)

The objective of the Selection phase of the project is to identify a single process concept for
progression to the Detailed Process Design phase of the project. Preparation of work deliverables
requires that a single process concept be selected and further developed during this phase. Once a
concept has been selected, the team will complete the level of detail necessary to develop a cost
estimate and preliminary project schedule with a typical accuracy of –30% to +50%.
Deliverables at this stage often include the following:

 Preliminary Process Design Basis

 Process Alternatives Evaluations Summary

 Preliminary Process Simulation and Heat and Material Balance Data

 Preliminary Process Flow Diagrams (PFDs)

 Preliminary Equipment List

 Preliminary Major Equipment Conditions of Service List

 Preliminary Capital and Operating Cost Estimate (+50% /-30%)

 Preliminary Summary of Raw Materials and Utility Requirements

  Process Risk Summary.

A more detailed breakdown of our experience can be found at Conceptual Process Design
Services ( Front End Loading FEL-0, FEL-1)

Detailed Process Designs

Detailed Process Design Schedule A, FEL-2 / FEL-3 / FEED, or Basic Engineering Packages -
Project Examples

Once the process configuration has been clearly defined a detailed process design package can be
prepared. This is very critical to the long term success of the project.

FEL-2 Process Design Package

The Process Design Package or Front End Engineering Design Study (FEED) will establish the
specific set of process operating conditions and equipment necessary to achieve the level of
reliability, efficiency, and safety required. This design phase sets the direction for the rest of the
project. At the completion of this phase, a cost estimate of +40%/-20% can typically be
developed for the project.

PROCESS puts great emphasis on the development of the Design Basis at the initiation of FEL-
2. When the design basis is complete, we typically have the following information defined:

 Raw material specifications

 Plant capacity requirements

 Product specifications

 Critical plant operating parameters

 Available utilities specifications

 Individual unit operations performance requirements

 Process regulatory requirements

 All other operating goals and constraints desired by the plant owners/operators/engineers.

Once the design basis is in place, and agreed upon with the client, PROCESS’s team of chemical
process engineers goes to work to create, analyze, and optimize the many aspects of the plant
design. The end result is process documentation that clearly defines the process.

Typical Process Engineering Deliverables for an FEL-2 package can include the following or a
smaller subset of these items:
  Process design basis
 Material & Energy Balance (M&EB)

 Process Flow Diagrams (PFDs)

 Process descriptions

 Utility balances and Utility Flow Diagrams (UFDs)

 Preliminary Piping & Instrumentation Diagrams (P&IDs)

 Process control description

 Preliminary line/pipe list

 Preliminary instrument list

 Process equipment list

 Preliminary Tie-in list

 Equipment process datasheets

 Instrument process datasheets

 Hydraulic design reports.

FEL-3 Detailed Process Design Package

The detailed process design package (PDP), which is sometimes referred to as a Schedule A or
Basic Engineering Design (BED) 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 final 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 helps to answer any questions the client or engineering
firm might have to ensure a smooth transition into the detail engineering phase. We provide
process design packages for both Inside Battery Limits (ISBL) and Outside Battery Limits
(OSBL) design requirements.

In addition to updating the items mentioned above in FEL-2, the following items are typically
added during the FEL-3 phase.

 Preliminary general arrangement drawings

 Preliminary building requirements

 General description of the project site

 Budget pricing from vendors on major pieces of equipment

 Process design philosophies

  Relief system design basis

 Relief scenario datasheets and relief valve process datasheets

 Material Selection Diagrams (MSDs) and piping specifications

 Tie-in list

 Identification of power source and location

 Preliminary single line diagrams

 Process specialty items list

 Raw material and product storage and handling requirements

 Process effluent and emissions summary

 Process risk analysis (PHA, HAZOP, etc.)

 Preliminary operating procedures

 Preliminary product and in-process QC sampling/testing plan

 Preliminary project schedule.

At the completion of this phase of the project, and cost estimate of +25%/-15% can typically be
generated for the project.

A more detailed breakdown of our experience can be found at Process Design Services (Sch. A,
Basic Engineering Pkg. [BEP], Basic Process Design [BPD])

Process Integrity Oversight During Detail Engineering & Construction Phase

Support

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
In addition, many times PROCESS is asked to provide vendor technical and cost proposal
evaluations to assist the client in making the best technology selection possible. Since we are not
aligned with any equipment companies, we provide these services in a completely objective
manner and make what we feel is the best recommendation based solely upon the technical and
economic aspects of the options. We can also provide valuable assistance during the construction
phase of a process related project - Construction Phase Support Services

Process Technical and Economic Evaluations - Project Examples

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. Our
engineers then begin to analyze the situation via experience, calculations, simulation techniques,
and consultation with other engineers at PROCESS as needed. The outcome is a technical
engineering critique of the current process with a focus on the areas which need the most
improvement. The economic cost implications of the current process are modeled to establish the
baseline from which all potential improvements will be evaluated. Many times we are asked to
further identify viable technical options and provide an economic comparison between them.
Based on technical process option merits, economic cost implications (capital/operating,
fixed/variable), and our experienced based evaluation of the relative suitability of each process
option, a final solution is recommended. Although more detailed engineering effort is required to
make the best option a tangible operational solution, our clients can do so with confidence
knowing they have made an intelligent, thorough, systematic, and informed decision.

More information on our experience can be found at Technical and Economic Evaluations and
Process Alternatives Evaluations

Pilot Plants - Design & Testing Support Projects or Process Scale Up Design
Projects

Many clients come to us wanting chemical engineering process design assistance after they have
done some level of due diligence to confirm that their process technology should work in real
life. Sometimes the available information will include well executed pilot plant trial data, process
heat and materials balance information, and all the necessary physical and chemical properties
fully defined. Unfortunately, the more typical information consists of academic papers, some lab
test data, and maybe some pseudo pilot plant information with stream property information only
on the major products at best. The client usually has one or more technical staff members who
are excellent at coming up with the innovative process idea, but lack the industrial process or
design detail experience to bring the system to an efficiently functioning reality - that's were we
can help.

PROCESS will evaluate this information, review the pilot plant setup, interview the client's
technical staff, and often perform a literature search to determine at what stage the process
development is at and what information may be lacking. Frequently we perform preliminary
design verification calculations to ensure that the data and information, as presented, is not likely
breaking any of the irrefutable laws of physics or thermodynamics. Often the information is
insufficient to proceed and we then suggest a path forward to either collect additional
information to fill in the gaps or rethink the entire process if major flaws are uncovered. We
strongly encourage clients to utilize pilot plant trials to work through the large majority of the
process challenges. Our engineers at PROCESS have a great deal of experience with pilot plant
testing and scale up designs. Both our operations and design experience allow us to make many
critical improvement suggestions in areas such as materials of construction, equipment layout,
operational safety considerations, operability and maintenance, process controls, and more.
These inputs are folded into the scaled up design for the larger process. A rigorous process
simulation model is then created to provide compete heat and material balance information,
operating conditions, hydraulic pressure drop data, and more. At this stage the PROCESS will
frankly consult with the client to help evaluate the project's potential technical and economic
changes for success. Finally, assuming the project is deemed viable, P&IDs, equipment
specifications, and a cost estimate of the new commercial sized process is generated. This
package is then ready to be handed over for detail engineering, procurement, and construction
(EPC).

Process Design Components

Any of the design services listed above may include some or all of the following components.
The items included and level of detail will vary depending on clients desires or on which phase
the project is in. The more mature the process design, the more of these components will be
included.

 Process design basis development

 Regulatory basis development

 Conceptual process design

 Process computer simulation

 Mass and energy balances

 Technical and economic process alternatives evaluation

 Advanced spreadsheet-simulation-spreadsheet user interfacing

 Process control system design

 Detail process design

Complete process design packages normally include:

 Design basis
 Mass and energy balance computer simulations

 Process simulation models for client use

 Process flow diagrams (PFDs)

 Process control logic and process control diagrams (PCDs)

 Capital cost estimate

 Operating cost estimate

 Piping and instrumentation diagrams (P&IDs)

 Equipment plot plans

 Utility flow diagrams

 Equipment lists

 Equipment sizing and specifications datasheets

 Preliminary process hazards analysis documentation

 Plant layouts

 Preliminary process operating manuals

Process Modeling and Simulation

PROCESS uses long-term or short-term licensed commercial Read About Running Plant
process simulation software (CHEMCAD, Aspen, HYSYS, Process Simulations, via Excel,
Pro/II, Simsci) and/or in-house simulation programs to perform:
without learning simulation
 Detailed mass and energy balances software
 Unit operation design/evaluation

 Piping system hydraulics calculations

Video time: 6.5 min.
 Relief and flare system design/evaluation

 Heat exchanger design/evaluation

View more information on Why Use Process Simulation?, Process Simulation Projects,
Advanced Simulation/Spreadsheet Interfacing , Process Simulation Training Courses
A more detailed breakdown of our experience can be found at Process Simulation and Modeling
Services

Operations Support - Project Examples

Listed below are the types of plant operations support that PROCESS typically provides to
operating companies. Additionally, process engineering staff augmentation can be provided for
operating facilities within reasonable commuting distance from one of our regional offices.

 Process evaluation, troubleshooting, optimization

 Debottlenecking

 Control system startup, tuning, optimization

 Commissioning and startup assistance

 Existing operations design basis development

 Operating procedures, process documentation

 Operator and technical staff training

 Statistical process control

More information on our experience can be found at Operations Support Services

Third Party Process Evaluations, etc.

As a completely independent engineering company not affiliated with any other groups and not
selling licensed technologies, PROCESS is ideally qualified to provide a critical process
engineering evaluation before large project decisions are finalized. These services are sometime
provided to clients considering significant investment in industrial process projects. Learn more
about our Industrial Process Investor Services.

A list of past projects we have performed along these lines are provided by following the links
below:

 Independent 3rd Party Design Reviews

 Plant, Process, or Technology Pre-Purchase Due Diligence Support to Investors

More information on our experience can be found at 3rd Party Evaluation Services

http://www.processengr.com/process_engineering_services.html
Basic and detailed engineering

Prior to the construction of an industrial plant, engineering studies are needed

involving several engineering specialties such as :
 process
 pressure vessels
 rotating equipment
 instrumentation
 electrical facilities
 computing,
 piping, civil works
 cost control and scheduling

All these activities are covered and fully managed within TECHNIP

According to the nature of a project, engineering studies will include all or part of the following
steps:

1. Basic Engineering Design (BED) covering:

 Conceptual process studies (material balances, process flowsheets,…) and preliminary

plot plan.
 Preliminary Piping and Instrument Diagrams.
 Definition and sizing of main equipment resulting in process specifications.
 Specification of effluents.
 Definition of control and safety devices.
 And, generally speaking, all the basic studies required to support a Basic Engineering
Design Package (BEDP) containing all data needed by a competent contractor to perform
the Detail Engineering.

These basic engineering studies may consist of consolidating a Process Package initiated by an
external process licensor.

2. Front End Engineering Design (FEED) covering:

  Mechanical data sheets of the main equipment, starting from the process specifications
issued during the BED and incorporating the specific requirements of codes and
standards to be applied to the project in question.
 Thermal rating of heat exchangers.
 Preparation of tender packages for the main equipment.
 Development of process and utility Piping and Instrument Diagrams released for detail
engineering.
 Development of detailed plot plans and hazardous areas.
 Elaboration of the main piping, instrument, electrical and civil works layouts.
 And, generally speaking, all the studies to be performed before ordering the main
equipment.

3. Detail Engineering, covering:

 Purchasing of equipment, main and bulk.

 Thermal rating of heat exchangers.
 Development of Piping and Instrument Diagrams released for construction.
 Development of detailed piping drawings, including isometrics and stress calculations.
 Development of detailed drawings related to instrumentation, electrical facilities and civil
works.
 Management of vendor drawings.
 Cost and schedule control.
 Start-up procedures.

And, generally speaking, all the studies to be performed before construction of the plant.

http://www.technip.com/en/about-us/range-services/basic-and-detailed-engineering