We offer a friendly, approachable service that provides free initial advice, consultancy studies or software supported by optional training.
If you decided to engage us to complete your study, we will work with you to find the most economical and
effective way to solve your problems.
These tend to be very accurate digital twins of your process. Every detail is modelled from the system geometry and control system. They are useful for process understanding, sizing equipment where there are transient conditions such as batch reactors or undertaking safety studies where safeguard response times are important. A typical plant will take 200-300 hours to model to get to a point where highly useful answers are provided, but the investment tends to be worth it, as it provides other unexpected benefits.
The level of information required is high, but we can help with surveying on site and sorting through all your plant information.
We typically use AVEVA software (PRO/II, Dynsim and APS) for process simulation and HTRI for heat exchanger sizing.
These studies are carried out using the AFT suite of software to help with sizing and checking piping networks. Typical examples are cooling water systems or oil and gas pipelines. We can complete transient surge analysis using AFT Impulse. This can then be linked to stress analysis software such as Caesar II to assess pipe mechanical designs.
If you have batch reactors that have exothermic reactions, then you may be familiar with the requirements of two-phase relief and sizing containment vessels. We are using our in house developed software, SureVent (which uses ProSim Thermodynamics) to size two phase relief systems that experience tempered, hybrid or gassy relief modes. We can also assist with scenario development and provide assistance with directing reaction calorimetry work. Each reactor relief system is given a document pack containing scenarios, calculations and datasheets for relief devices. We can also complete mechanical surveying of relief systems using our close associates to generate 2D and 3D models of the pipe layout.
We are the sole approved UK distributor for AFT software and an approved UK sales agent for ProSim software.
All software is supported by comprehensive support and training.
Whether you’re modeling gas or liquid piping systems, perfecting your system design, studying your system’s transient behavior or need fluid property data, AFT has the engineering software tools for you. Our industry-leading fluid dynamic simulation software is used by a variety of industries around the world to develop design solutions and troubleshoot existing systems.
ProSim offers process simulation software and services that allow industries to improve their operations, increase their profitability or reduce their environmental impact. For more than 30 years ProSim has been designing and developing process simulation and optimization software in the oil, gas, chemical, pharmaceutical, energy and other process industries.
Whether you’re modeling gas or liquid piping systems, perfecting your system design, studying your system’s transient behavior or need fluid property data, AFT has the engineering software tools for you. Our industry-leading fluid dynamic simulation software is used by a variety of industries around the world to develop design solutions and troubleshoot existing systems.
ProSim offers process simulation software and services that allow industries to improve their operations, increase their profitability or reduce their environmental impact. For more than 30 years ProSim has been designing and developing process simulation and optimization software in the oil, gas, chemical, pharmaceutical, energy and other process industries.
Software that makes your life so much easier by putting everything in one place.
Provide accurate dynamic calculations with changing concentrations and pressure.
See everything graphically instead of visualising through excel spreadsheets, making checking so much easier.
Green credentials are becoming increasingly important. Size your system to minimise energy costs and reduce the carbon footprint.
When you lease our recommended software you should expect an excellent user experience. Tools written by engineers for engineers
Don’t oversize your pipes, optimise the whole network to save your project serious amounts of capital.
Expect to save serious time, and get your checking done with one of our free viewers so you can carry on working.
Try every possible design scenario to show that the design works first time.
Save multiple copies of your design and test different process conditions all in one tool.
Demonstrate to your key clients that you are using the best methods to optimise your designs.
Get in touch and we can get you up and running very quickly.
I am a Chemical Engineer, starting my career back in 1991 and working my way into being a consultant over the last 15 years. I operate from my home base in Bristol but travel all over to meet clients and discuss their problems. My wide and varied experience for over 30 years has been working on and simulating process plants, from pharmaceuticals to Nuclear to Upstream oil and gas. So, there is a fair chance I may have some knowledge in your area of interest.
These tend to be very accurate digital twins of your process. Every detail is modelled from the system geometry and control system. They are useful for process understanding, sizing equipment where there are transient conditions such as batch reactors or undertaking safety studies where safeguard response times are important. A typical plant will take 200-300 hours to model to get to a point where highly useful answers are provided, but the investment tends to be worth it, as it provides other unexpected benefits.
The level of information required is high, but we can help with surveying on site and sorting through all your plant information.
We typically use AVEVA software (PRO/II, Dynsim and APS) for process simulation and HTRI for heat exchanger sizing.
Dynamic Simulation Models
Problem: The scale up of multiple fuel cells in combination with balance of plant needed to be designed. The low pressure operation and limitations of design pressure, made the operability of the system uncertain.
Solution: A dynamic model of the whole plant was developed that incorporated equipment sizes, the proposed control system and compressible hold up volume to assess how the system could start up, operates and shut down safely. The model included the performance of the fuel cell and all chemical reactions that occurred in the cell and downstream in syn gas reactors. The model revealed response times for equipment failure and informed the design team of required changes. Modifications to the control philosophy were also made when a better understanding of how the whole system operated together.
Dynamic Simulation Models
Problem: The sizing of a batch reactor jacket heating and cooling systems was challenging because of the dynamic nature of the process.
The client was needing to expand operations by building more reactor capacity and realised that a more accurate way of sizing utility systems for reactor jackets was required. The process was complicated by the changing heat transfer rates because of increasing batch viscosity.
Solution: An accurate dynamic model of the reactor internals and external utility systems was constructed, and checked against laboratory, pilot and full-scale operations, before it was used on a new design to predict equipment sizes. A sequence was developed to show how the process runs from initial charges to discharge of final viscosity, and equipment sized in the model to achieve the required cycle time. Equipment datasheets were developed to support the capital project.
These studies are carried out using the AFT suite of software to help with sizing and checking piping networks. Typical examples are cooling water systems or oil and gas pipelines. We can complete transient surge analysis using AFT Impulse. This can then be linked to stress analysis software such as Caesar II to assess pipe mechanical designs.
Pipe Flow Network Models
Problem: Recent over pressure events had alerted site management that there could be an issue with the pipeline and further investigation was required. Existing records indicated that pipeline models were nearly 20 years old and changes in the system had not been included.
Solution: An updated pipe flow model was built from feed crude storage tank, through the transfer pumps and to the receiving tank. All detail was added from pipe survey drawings and site survey, and pump curve records. A steady state simulation of normal flow was developed to confirm the model accuracy and demonstrated that the system was generally operating correctly. A key resistance item was identified that was not shown on drawings, which would be important for transient events, surge. A surge study was then completed, which revealed some pressure transgressions which needed to be addressed by the site.
Pipe Flow Network Models
Problem: The cooling water system had developed over time and there were no records of the design basis. It had to be significantly expanded due to an increase in production.
Solution: A very detailed site survey was conducted of existing pipe runs and connected equipment design pressures. This revealed that much of the existing plant was not fit for purpose and had to be replaced. A survey of future connection points leads to a design of a new header based system, a new cooling tower and pumps and some new heat exchangers. A detailed simulation model was developed of the piping arrangements to demonstrate that pressure drops and velocities were acceptable, with no stagnant areas. Detailed datasheets for the cooling tower and cooling pumps were developed. Rigorous heat exchanger sizing was completed and new datasheets generated for purchase.
If you have batch reactors that have exothermic reactions, then you may be familiar with the requirements of two-phase relief and sizing containment vessels. We are using our in house developed software, SureVent to size two phase relief systems that experience tempered, hybrid or gassy relief modes. We can also assist with scenario development and direct calorimetry work. Each reactor is given a document pack containing scenarios, calculations and datasheets for relief devices. We also complete mechanical surveying of systems using our close associates to generate 3D models of the pipe layout.
Batch Reactor Pressure Relief
Problem: A new owner inherited neglected batch processing equipment which had not been correctly assessed for pressure relief cases on existing products. This had to be addressed quickly to keep the site operational.
Solution: A review of key production priorities together with a site survey was required. A systematic approach followed through documenting all relief scenarios and identifying missing reaction calorimetry data. Single- and two-phase relief calculations was completed on all reactors and proposed hardware changes were made based on practical site experience. All documentation was completed before and after changes to allow the site to have full documentation of their relief streams in a form that they could update themselves.
Batch Reactor Pressure Relief
Problem: PF Resin reactions are extremely exothermic and result in large relief systems. This is often impractical, so, a combination of safety trips and mechanical relief is the compromise. Safety trips maintain the process conditions to be manageable for the relief system capability. Keeping the process conditions within bounds can be restrictive to product quality, so, a compromise has to be reached.
Solution: A thorough literature survey followed by an extensive experimental program (reaction calorimetry) was directed while completing reactor relief calculations to fully understand the system. Many combination of process conditions (batch fill, vent sizes, reaction rates) can be run in SureVent to understand the relief system capability. Support was provided with developing a LOPA and Safety Requirement Specification for the associated trips which limit batch charges and operating temperatures to within the safe operating envelope. Technical support was given for HSE interventions.
Roger is based in Bristol but often travels nationally to carry out his consultancy work
Roger is ready to discuss your requirements. We can get to the heart of problems and provide you with the best possible solution.
