Mechanical Engineering
Instrumentation Engineering

Process Engineering

Process Engineering

CARBON has excellent process engineering abilities, which are embodied in the people we employ and the problem solving culture of the organization. We love a challenge, simply we do.

 

CARBON will work with you at any or all stages of the life cycle of your process, plant, site or organization providing support services from cradle to grave, concept to demolition as part of a managed solution or as an individual bespoke package.

  • Concept Engineering
  • Front End Design [sometimes known as FEED Front End Engineering Design]
  • Detailed Design
  • Commissioning
  • Operation
  • Process Improvement
  • Taking out of Service [suspension with the intention of restarting]
  • Decommissioning
  • Demolition
  • Remediation and Re-Use

Process Control

Where does Process Control sit in the engineering firmament: with the Electrical Instrumentation and Control [EI & C] department, with the software writers or with the process engineers?

 

The answer is you need the skills of all three groups, but at different stages in the lifecycle of the
project. It is a very big but because getting the sequence wrong almost guarantees the outcome will
be at best poor and at worst, a disaster.

 

CARBON can provide you with complete lifecycle management of a Process Control System. One of our skills is found in our ability to translate the needs of one group into the actions of another.

Definition Phase led by Process Engineering and supported by EI&C

  • Define what you want to control [Equipment Boundary]
  • Define how you want to control [Control Philosophy]
  • Define what you want it to do [User Requirement Statement, URS]
  • Define what you need to measure to achieve the desired functionality [Instrumentation]
  • Define what you need to influence to deliver the desired functionality [Control]
  • Define the required functionality [Functional Design Specification]
  • Define how you want the system to react to events [trips and alarms]
  • Define what information you require the system to retain
  • Define how you want the system to interact with operators and management
  • Define what other systems you may need to communicate with

Testing Phase 1 at a supplier’s works [Factory Acceptance Test] are led by Process Engineering and supported software writers and EI&C. Involved are the client team after the first round of verification to check process mapping delivery and their expected results and allowing unexpected challenges to the system to check robustness.

  • Check sequences
  • Check alarms and trips
  • Check I/O mapping
  • Verify FDS requirements
  • Document the test, modify and retest where appropriate.

Testing Phase 2 when installed at the user site [Site Acceptance Test] are again led by Process Engineering and supported software writers and EI&C. We then use the FAT to ensure the software meets the required functionality on site. The first round testing is to be carried without process fluids, repeated with inert fluids and finally moved onto process fluids.

  • Check sequences
  • Check alarms and trips
  • Check I/O mapping
  • Verify FDS requirements
  • Document test
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