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Process Optimization

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At NEO Process Engineering, Our prime focus is to execute Process Engineering & Technical Safety projects with superior quality and optimized cost to customer. However, the long-term objectives include rigorous involvement in the development of future energy technologies, collaborative R & D and energy efficiency.

We provide the following services .

  • Process & engineering studies in improving current performance, standardization or modularization
  • Safety studies (HAZOP, SIL, QRA, Explosion Modelling, SIMOPS, FMEA, RAM studies, Safety Case development)
  • Reliability Centered Maintenance Studies
  • Development / updating of Standard operating procedures
  • Commissioning & Operations Support
  • Process simulation studies for standardizing or developing technical features in hydrocarbon processing.

Engineering& Consulting for Air Separation Units

Process Safety & Asset Integrity Studies 

Safety Studies

Hazard & Operability Study (HAZOP)

Safety Integrity Level Study (SIL)

Root Cause Analysis (RCA) & Incident Investigation Studies

PSM Implementation to OSHA guidelines

PSM audits

Asset Integrity studies

Failure Mode Effects & Criticality Analysis (FMECA)

Reliability Centered Maintenance (RCM) strategy development

Reliability, Availability & Maintainability (RAM) studies

Risk Based Inspection

NEO Differentiators (Consultant references)

Design & Operational safety competencies across all ASU process & utility blocks

Part of Design safety rules development teams

Numerous references for safety studies & reliability studies

Project Experiences

HAZOP studies for more than 20 Air Separation Units

More than 10 training programs on design and operational safety

Part of development of more than 10 design safety rules at international level

Expertise in DNV Maros – Reliability software

Energy Efficiency

Air Separation units

Highly energy intensive

Gaseous & liquid product mix influences energy

Savings potential of upto 7 – 10% in all type of plants when design and energy competencies are utilized

Quick start-up times reduces energy losses

Advanced Process Control saves 3 – 4% energy from base level

Energy distribution

Air compression & purification

Boosters + turbine combination

Plate fin exchange blocks

Cryogenic storage

Savings potential (process-wise)

Air compression + purification : 2 - 3%

Liquefaction : 3 - 4%

Utility systems : 2 - 3%

Targeted systems

Main air compressor

Adsorbers

BAC + Turbine

Heat Exchange

Overall plant controls

 

Process & Energy Services

Overview

Process optimization studies to hydrocarbon process industries

Exploration & Production, Refining & Petrochemicals

Energy management services for energy intensive installations

Power plants, Cryogenic air separation units, LNG plants, Iron & steel plants and Hydrocarbon processing industries

Wide network of Process & energy experts

Process simulation software (Hysys, Pro II, Unisim)

In-house thermodynamic tools for energy optimization

Success Indicators – References (team) 

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KEY STRENGTHS

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INDUSTRIAL SECTORS

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KEY REFERENCES

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RIL – Dahej : ASUs for Petrochemicals

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at LP GOX compressor outlet

at LP GOX compressor outlet

GOX production capacity increased by 25 t/d (from both phase-1&2)

Process Safety

Major Accident Hazards (MAH) in LNG plants

Loss of containment (of Hydrocarbons) leading to Fire and explosion events

Cryogenic hazards (frost bite, Rapid Phase Transition (RPT))

Dropped objects during operation & maintenance

Safety Studies

Hazard Identification Study (HAZID)

Hazard & Operability Study (HAZOP)

SIL Assessment and SIL Verification

Bowtie Analysis

Quantitative Risk Assessment (QRA)

Building Risk Assessment (BRA)

Fire & Gas Mapping (3D)

ALARP Demonstration

Operational HSE Case Development

Asset Integrity Studies

Safety Critical Element (SCE) Identification

Performance Standards development

Reliability Centered Maintenance (RCM) methodology development

Failure Mode Effects & Analysis (FMEA)

Reliability, Availability and Maintainability (RAM) study

NEO Differentiators (Consultant references)

Knowledge of Petronas HSE guidelines /PTS

Development of 6 HSE cases for Malaysian O & G facilities

Numerous Formal Safety Assessments (FSA) for Malaysian clients

Asset Integrity projects for Petronas Assets

RCM methodology development (ECA & FMEA)

Project Experiences

HSE Case development for Onshore Gas Terminal (OGT) of PetronasCarigaliSdn Bhd., (PCSB)

HSE Case development for Baronia and Erb West Fields of PCSB

Formal Safety Assessment (FSA) studies for Exxon Mobil E & P Malaysia (EMEPMI)

RCM studies for MISC Berhad etc.,

Energy Efficiency

LNG Plants

Highly energy intensive

Proven technology (C3/MR) with inherent safety

LNG produces lower CO2 emissions that coal / oil

Base load availability ~ 90%

Energy distribution

NG pre-treatment (AGRU, Dehydration, Hg removal, NGL removal)

Liquefaction blocks

Utilities

Cryogenic storage

Savings potential (process-wise)

Gas pre-treatment : 5 – 10%

Liquefaction : 10 – 15%

Utility systems : 5 – 10%

Targeted systems

AGRU and Dehydration unit regeneration optimization

Heat exchange line (Pinch analysis and reduced DP)

C3 / MR compression

Boil-off Gas recondensation

Dynamic simulation and Feed forward control for process units

Utility systems

Engineering & Consulting Services for LNG Plants

img-6

Process Safety

Major Accident Hazards (MAH) in LNG plants

Loss of containment (of Hydrocarbons) leading to Fire and explosion events

Cryogenic hazards (frost bite, Rapid Phase Transition (RPT))

Dropped objects during operation & maintenance

Safety Studies

Hazard Identification Study (HAZID)

Hazard & Operability Study (HAZOP)

SIL Assessment and SIL Verification

Bowtie Analysis

Quantitative Risk Assessment (QRA)

Building Risk Assessment (BRA)

Fire & Gas Mapping (3D)

ALARP Demonstration

Operational HSE Case Development

Asset Integrity Studies

Safety Critical Element (SCE) Identification

Performance Standards development

Reliability Centered Maintenance (RCM) methodology development

Failure Mode Effects & Analysis (FMEA)

Reliability, Availability and Maintainability (RAM) study

NEO Differentiators (Consultant references)

Knowledge of Petronas HSE guidelines /PTS

Development of 6 HSE cases for Malaysian O & G facilities

Numerous Formal Safety Assessments (FSA) for Malaysian clients

Asset Integrity projects for Petronas Assets

RCM methodology development (ECA & FMEA)

Project Experiences

HSE Case development for Onshore Gas Terminal (OGT) of PetronasCarigaliSdn Bhd., (PCSB)

HSE Case development for Baronia and Erb West Fields of PCSB

Formal Safety Assessment (FSA) studies for Exxon Mobil E & P Malaysia (EMEPMI)

RCM studies for MISC Berhad etc.,

Energy Efficiency

LNG Plants

Highly energy intensive

Proven technology (C3/MR) with inherent safety

LNG produces lower CO2 emissions that coal / oil

Base load availability ~ 90%

Energy distribution

NG pre-treatment (AGRU, Dehydration, Hg removal, NGL removal)

Liquefaction blocks

Utilities

Cryogenic storage

Savings potential (process-wise)

Gas pre-treatment : 5 – 10%

Liquefaction : 10 – 15%

Utility systems : 5 – 10%

Targeted systems

AGRU and Dehydration unit regeneration optimization

Heat exchange line (Pinch analysis and reduced DP)

C3 / MR compression

Boil-off Gas recondensation

Dynamic simulation and Feed forward control for process units

Utility systems