Inprocess’ Success Stories

Inprocess has been carrying out process simulation projects and training programs for the major operating companies in the Oil & Gas and Refining market segments (BP, ENI, CEPSA, ConocoPhillips, Wintershall, Tupras, PDO, Yinson, Repsol, Yasref, Saudi Aramco, Bayernoil, Tullow Oil, Total, NPCC, ADNOC, YPFB, CNRL, etc.), major EPC and Process Licensor companies (Saipem, Amec Foster-Wheeler, Tecnimont, Technip, Aker Solutions, Técnicas Reunidas, Linde, Espindesa, Hyundai, Mustang, Modec, SBM, Sener, Idom, Haldor Topsoe, etc.), several Petrochemical / Chemical companies (LyondelBasell, BASF, UBE Chemical, Sadara, Sabic, Borealis, Simplot, etc.), some Instrumentation Providers (Honeywell, Siemens, CCC, etc.) and different Compressor Manufacturers including Nuovo Pignone (GE Oil&Gas), MAN Turbo, Siemens and Atlas Copco.

Inprocess has solved the problems of such clients by applying its process simulation expertise. It is often beneficial to look outside one’s own industry to draw on the experience of others. This is why in this section you will find our most recent success stories, classified by the type of industry where we implemented our solutions. Don’t hesitate to request more information if needed.

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An FPSO is a Floating Production Storage and Offloading unit designed to produce oil and gas by processing the fluids arriving from offshore wells, usually in deep-water environments. Therefore, FPSOs have the capability to store the produced oil until a separate cargo offloads it from the FPSO tanks.

Inprocess has extensive experience in the development and implementation of online hydrogen network management tools that have helped the petrochemical industry and refineries achieve operational savings without capital investment.

As in any other industry, safety, reliability and profitability rely to a great extent on a sufficient level of knowledge, skills and aptitudes of the plant’s workforce. In such an energy-intensive industry, such as fertilizers, having the personnel properly trained is key to achieving corporate targets and KPIs.

Inprocess simulation analysis of the cooling water network helps companies to improve the performance of the plant. When this study is carried out, the result is that bottlenecks are identified and this way, the most critical points can be addressed with optimal solutions to improve the performance of the cooling water network ...

Plan and follow-up operators’ professional development by digitizing and centralizing in a single training environment all new and old learning material.

The steam network is responsible to provide heat and power to the different units of the complex. Usually, all the efforts are focused on maintaining steam production and improving it to the maximum, leaving aside the important role that the network plays in keeping the overall plant production.

Inprocess has helped this oil company to identify potential savings between $1 and $3 million per NGL train and year in one of its recovery plants, by applying optimization techniques, on top of an existing Advanced Process Control algorithm, in a three-phases project: Feasibility study, open loop adisory tool, closed-loop online optimizer. Discover how by downloading the attached document.

A considerable amount of equipment and piping in Oil & Gas processing plants is exposed to very low or even cryogenic temperatures during some transient events such as emergency blowdowns, depressurization after prolonged shutdowns or start-ups. Material must be selected within proper temperature ranges according to the Minimum Design Metal Temperature (MDMT).

Plant operators need deep training before the greenfield plant is started-up. Moreover, companies need to diminish potential operational problems related to the equipment sizing, control logic and safety systems by performing early analysis during the engineering design phases.

Gas turbine power plants have to achieve high reliability and maximum availability in order to be able to meet the dispatch requirements of electric grids at short notice. The power generation systems are high-availability assets, generally above 90%.

Dynamic Blow Down Study to investigate the adequacy of an existing flare system and to analyse different blow-down options. The scope of the integrated dynamic process simulation model includes a number of process unit sections as well as the flare header.

CEPSA contracted Inprocess to develop a Digital Twin based on a rigorous dynamic process simulation model of their revamped Linear Alkylbenzene (LAB) plant (which was moved to Detal technology), which is also connected to a detailed 3D Virtual Reality model of the plant.

A Major FPSO constructing and operating company has awarded Inprocess the construction of an Operator Training Simulator for their two new Floating Production Storage and Offloading (FPSO) platforms, which are soon to be installed off the coast of Brazil (in the Libra field).

The main objective of the project is to deliver a dynamic simulation study for the Feed Gas Booster compression system and for the Boil-Off Gas compression system in order to confirm their proper operation under several defined procedural and upset conditions.

Development of two new Operator Training Simulators, as well as the upgrading and modernization of two existing simulators that have become obsolete.

Inprocess developed a dynamic simulation model, carrying out a series of dynamic simulation scenarios and delivering a training session (including model handover) for two compressor trains for the cracked gas process.

During this project, Inprocess developed a complete flare network revalidation study according to API520 and API521. The common relief scenarios were analysed for all the affected units and the sizing cases were determined in order to perform the revalidation study using dynamic simulation methods.

Inprocess delivered a complete dynamic simulation model of the turboexpander for an EPC company. This simulation was key in testing several operational scenarios for various normal and upset conditions ant to ensure the operability of a Turboexpander Dew Point Unit.

Inprocess developed a dynamic simulation study in order to ...

Inprocess carried out a detailed concept study of the Gas Grid pipeline system to identify and evaluate all possible options available to meet all gas delivery specifications and Gas Grid capacity for a minimum of 10 years.

An Inprocess client initiated an Expansion Project to commercialize the incremental resource into high margin gas markets based on a single LNG (liquefied natural gas) train expansion.

The Client had an OTS installed for the FCC unit and was interested in extending the OTS capability to two additional units: ICR and HPU units.

In a previous project, Inprocess developed a high-fidelity dynamic simulation model, including all topside equipment with detailed design data. Taking advantage of the existing model, Inprocess carried out a Lifecycle approach for the Operator Training System (OTS) of the FPSO, comprising three phases

The Phase I of the study was performed by Inprocess in order to determine the maximum possible operating capacity limits, by considering the safety limitation factors, when increasing well production.

Inprocess delivered a Dynamic Simulation Study for a Turbo Expander/Residue Gas Compressor, for a Gas Plant Train in Middle East in order to confirm high operational safety and reliability of the system.

The intention of Inproces's client was to integrate an in-house developed routine to specifically address non-linearity issues around quality control for binary columns with MVPC technology.

A mixture coming out from a biotechnology reactor needed separation and purification in order to reach purities above 99% for some of the alcohols that were in the fermentation broth. Inprocess was requested to prepare the process simulations that would support the conceptual design study in order to select the most promising separation and purification sequence of unit operations

An Operator Training System, directly connected with Siemens DCS, UniSim Design Dynamic Simulation; and the Inprocess Instructor Station, was developed and implemented in a new Ammonia plant (and its associated Hydrogen plant)

Many nitric acid plants had been designed and erected by the Client based on its own technology. In order to complement the Client's technological offer to its own clients, it was necessary to develop a dynamic model of the plant that would be used by the Client to show the plant operability to current customers as well as showing the plant and technology capabilities to future, potential customers.

A training tool for the operators of a chemical plant in Sweden was developed. An interesting technical challenge was solved by integrating the rigorous dynamic model in Aspen HYSYS with an emulation software of the Experion PKS from Proconex and an instructor station from Inprocess.

Operator Training System for two new chemical plants with a total of 3000 I/O points, based on dynamic simulation model, DeltaV control system & SIS emulation, and using Inprocess's proprietary Instructor Station (IIS)

Blow down studies of the CO2 compression system of a FPSO to determine the temperature profile and phase behaviour during depressurization of the “at risk” sections in order to determine if there was a real possibility of forming dry ice during compressor blow down

CDU/VDU Pre-heat Train Performance Monitoring and Cleaning Schedule Evaluation Tool
Inprocess developed a complete application to perform heat exchanger fouling monitoring for a 124000 BPD refinery CDU/VDU and, based on the predicted trends, it developed an automated tool to run different heat exchanger cleaning scenarios over one year of operation

Operator Training System based on a dynamic model of the processing facilities of an oil and gas field in Bolivia, linked to DeltaV DCS and SIS. Total I/O point was 1600.

Dynamic Blow Down Study to investigate the adequacy of an existing flare system and to analyse different blow-down options. The scope of the integrated dynamic process simulation model includes a number of process unit sections as well as the flare header.

Dynamic Simulation Study to determine the flare load of a crude unit and a Coker during a general power failure