Process engineering - process design
Process engineering, from individual calculations and conceptual solutions to high-quality P&IDs and basic engineering. We turn recommendations into concrete measures and support inherently safe process designs.
Drawing office
At Prohead Engineering, we have a specialised drawing office with experts in P&IDs (Process & Instrumentation Diagrams), PFDs (Process Flow Diagrams), HVAC (Heating, Ventilation and Air Conditioning) and piping design. Our experienced draughtsmen and engineers enable us to draw up and manage complete process documentation for large industrial sites, based on the relevant standards and client-specific requirements.
Our drawing office then takes care of visualising our engineering solutions. We can draw in both 2D and 3D, which enables us to deliver detailed and accurate documentation.
Concept engineering
At Prohead Engineering, we carry out technical concept studies to evaluate the feasibility of projects and solve process problems. We analyse multiple solutions for technical and economic feasibility and support, among other things, pilot-scale projects and process changes.
Our approach includes measurement campaigns, conceptual analyses, preliminary P&IDs, mass balances, risk analyses (PHA), determination of independent protection layers (IPLs), and much more. We take into account legislation, permits and market context, and provide an estimate of the CAPEX and design costs.
This provides a well-founded starting point for further engineering, based on realistic options and clear decision-making information.
Basic engineering
In the basic engineering phase, we lay down the technical specifications for tendering, execution and detailed engineering. We develop complete P&IDs, determine utility requirements and integrate new and existing equipment. We also draw up plot plans and design principles.
We carry out energy and mass balances, determine material and piping properties and develop control philosophies. We also take care of safety engineering, including functional safety and, for example, PED assessments.
Our structured approach provides a robust basis for the next project phases and guarantees an efficient and compliant execution of an inherently safe installation.
Safety engineering calculations
At Prohead Engineering, we carry out in-depth technical calculations that form the backbone of a safe and compliant process installation.
Our experts calculate, among other things:
- The sizing of PSVs according to API 520/521, including analysis of blowdown lines and backpressure.
- Explosion panels and vent areas for dust explosions (Pmax, Pred, burst pressure).
- CFD analyses for consequence modelling, including:
- Gas and vapour dispersion (in the open air or inside structures),
- Explosion pressure build-up and flame propagation (e.g. for hydrogen or dust),
- Pressure waves and radiation loads from jet fires or pool fires.
- BLEVE calculations for flammable liquids stored under pressure (e.g. LPG, NH₃).
- Thermal runaway analysis of chemical reactions based on calorimetry and kinetic data.
- Auto-ignition time and temperature of substances such as H₂, solvents or dust clouds, crucial for ventilation or inerting designs.
Verification of detailed engineering
Prohead Engineering supports clients in assessing detailed engineering by, for example, EPC contractors. We review design documents for quality, completeness, technical requirements and compliance with legislation, permits and safety requirements.
We also analyse the impact on construction, commissioning and operations. Our feedback contains targeted comments on errors, gaps and optimisations. If desired, we consult directly with the EPC contractor and follow up on updates.
This is how we help you achieve a safe, reliable and compliant design.
Execution
During the execution phase, Prohead Engineering provides support with procurement, detailed engineering and construction. We prepare tender documents, evaluate quotations and guide contract award with suppliers.
In the detailed engineering phase, we refine the design into construction drawings and specifications, including lists and safety reviews. During construction, we coordinate contractors, monitor progress and ensure compliance with standards and specifications. This is how we guarantee a smooth and compliant realisation of your project.
Validation
In the validation phase, installed systems and equipment are tested, adjusted and commissioned. This phase ensures that everything functions correctly before full operational scale is reached. Our validation services include, for example, drawing up and executing test plans for functional safety, performing mechanical ATEX verifications and validating the measures recommended in the risk analysis.
Our comprehensive approach in the validation phase ensures that your systems and equipment function reliably and safely, in full compliance with all requirements and standards.
Operation
During operation, we provide ongoing support and optimisation of your processes and installations. Our services include troubleshooting and maintenance to safeguard operational efficiency and safety.
Our operation and maintenance services include, for example, drawing up procedures within the Safety Life Cycle (SLC), updating the Explosion Protection Document (EPD), and drawing up technical files for CE marking.
We also provide support for any modifications to your installations. This includes drawing up management of change (MoC) procedures and carrying out HAZOP studies.
Our comprehensive approach during operation ensures that your systems and installations continue to function reliably and safely, in full compliance with all requirements and standards.
