Engineering Blog
Insights from
the Field
Technical articles on process engineering, simulation, process safety, and project management — written by engineers with over 100 years of combined upstream oil & gas experience.
Functional Safety Management to IEC 61511: The Full Lifecycle Explained
SIL classification is just one step in a much longer process. IEC 61511 defines a complete safety lifecycle — from hazard identification through design, installation, proof testing, and eventual decommissioning. Understanding the full lifecycle is essential for anyone managing safety instrumented systems in the process industry.
Dynamic Simulation in HYSYS: When Steady-State Isn't Enough
Steady-state simulation answers the design question: what does the process look like at normal operating conditions? Dynamic simulation answers the operational question: what happens when it doesn't. Here is when you need HYSYS Dynamics and what it can tell you that a steady-state model cannot.
Electrical Area Classification: Zone 0, Zone 1, and Zone 2 Explained
Electrical area classification determines what electrical and instrumentation equipment can be safely installed where. Getting it wrong puts facilities at risk of ignition. Getting it right — without being excessively conservative — keeps projects on budget and avoids equipment proliferation.
Cause and Effect Matrices: How to Structure a C&E for a Production Facility
The cause and effect matrix is the document that translates your P&ID interlocks into testable, auditable logic. A well-structured C&E prevents commissioning surprises, supports SIL verification, and gives operations a clear reference for every trip and alarm on the plant.
Reciprocating vs Centrifugal Compressors: How to Choose the Right Machine
Compressor selection is one of the most consequential decisions in a gas processing project. Choosing the wrong machine type leads to poor turndown, excessive maintenance, or a compressor that simply cannot meet the duty. Here is how to make the right call.
What Is a FEED Study and Why Does It Matter?
Front End Engineering Design is the engineering phase that turns a concept into a fundable project. Done well, it defines scope, cost, and schedule with enough accuracy to get investment approved. Done poorly, it creates expensive problems in detailed design.
How to Size a Three-Phase Production Separator
Three-phase separators are among the most common pieces of equipment in upstream oil and gas. Sizing them correctly requires balancing gas capacity, liquid retention time, and water droplet settling — and knowing which constraint governs your design.
Running an Effective HAZOP: Ten Lessons from the Field
A HAZOP study is only as valuable as the quality of its findings — and a poor facilitation can turn a critical safety exercise into an expensive rubber stamp. Here are ten lessons from years of leading and participating in HAZOP workshops across onshore and offshore projects.
Early Production Facilities: Design Principles for Fast-Track Upstream Projects
An Early Production Facility is not simply a smaller, simpler version of a full field development. It is a different type of engineering problem — one that demands a different set of design decisions, trade-offs, and delivery priorities.
SIL Determination Using LOPA: A Practical Guide for Process Engineers
Safety Integrity Level determination is a core requirement for any Safety Instrumented Function protecting against a major hazard. LOPA provides the quantitative link between the hazardous event frequency and the risk reduction required from the SIS — but applying it correctly requires understanding several concepts that are frequently misunderstood.
Why Peng-Robinson EOS is a Good Choice in HYSYS
The Peng-Robinson equation of state is the go-to thermodynamic model in Aspen HYSYS for hydrocarbon systems. Here's why it earns that position — and where its limits lie.
Why Routine Maintenance for Pressure Relief Valves (PSVs) is Non-Negotiable
A PSV that passes its installation inspection is not a PSV that will perform reliably five years later. Here is why routine maintenance is a safety-critical obligation, not a scheduled inconvenience.
How to Size a Token Relief Pressure Relief Valve (PSV)?
Token relief PSVs protect systems against minor, predictable overpressure scenarios. Sizing them correctly requires understanding the specific relief case — and why an oversized valve can be just as problematic as an undersized one.
When is a Token Relief PSV Needed?
Not every overpressure scenario requires a full-scale relief valve. Understanding when a token relief PSV is the right engineering solution — and when it is not — is a fundamental process safety skill.