Process Plant Services

LoopCalTech provides a wide range of services for refineries and process facilities. We have been providing detail engineering services to refineries for almost 20 years, performing a variety of projects for which our organizational structure, capabilities and expertise are the right fit.

In addition to projects involving process units, LCT completes many projects that are required in order to meet new safety standards, environmental regulations, supply and distribution logistics, storage and blending needs, feedstock flexibility, maintenance and replacement needs, and infrastructure improvements. Our smaller, versatile teams provide quicker development and presentation of options and estimates for client approval.

LoopCalTech provides planning, engineering, procurement services, and project management for natural gas production, processing, and distribution systems, from the wellhead to the end user. Natural gas system clients include natural gas producers, gas utilities, gas transmission companies, gas compressor packagers, gas-turbine power generation companies. Services provided are based on the needs of the client and range from the preliminary assessment or study through development and engineering design of completely new systems.

LoopCalTech Services provides a full range of technical support to oil and gas producers in southern and central California. Our services generally fall under the following three categories:

● Process assessment and optimization, and project scoping/planning
● Execution of detailed engineering and design
● Project services, including construction management, procurement, permitting, and project controls

LoopCalTech delivers pipelines that transport oil, natural gas, petroleum products, and industrial gases for utilities and private customers. Our services include planning, engineering, and project management.

LoopCalTech has been working with pipeline operators in California and the greater southwestern USA for more than 15 years and is the leading provider of pipeline engineering and design services for high pressure, welded steel pipelines in the region. We have the expertise to assist clients in the front end planning and development stages of projects to determine the optimum solution, and to carry through with effective execution of the detailed engineering and project management to achieve project success.

New Pipelines and Relocations (both urban and rural): planning, route studies and selection, GIS exhibits and data management, cost estimating, survey/mapping, subsurface utility research, design, alignment sheet preparation, permitting, right-of-way acquisition, traffic control plans, construction and material specification, construction management.

Stress Analysis: hot oil pipelines, settlement, geotechnical hazards, fault crossing design.

GIS: hazardous classification studies, high consequence areas, risk assessment, feature studies, route planning, data management.

Pipeline System Modeling: surge analysis, batching, thermal transient analysis, pressure relief and protection systems.

Pump and Compressor Stations: new stations, rate increases, efficiency improvements, upgrades.

Station Facilities: storage and relief tanks: control, relief, metering and proving systems, shipping, delivery, and receiving systems.

EXPERTISE

● Pump and compressor stations
● Gas compression, dehydration and injection facilities
● Condensate stabilization
● Crude storage tank systems
● Receiving terminals

our expertis

Once we’ve helped define the automation engineering service requirements in the front-end project phases, our systems group is comprehensive in its capability to provide transmitter-to-valve engineering.

Our industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Safety Instrumented Systems (SIS),Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas Systems (FGS). The result is a totally integrated automation lifecycle, from project inception to operation.

Feasibility Study:

We are here to do Conceptual Study for any oil, gas and petrochemical industry at the very early stage of a greenfield projects to identify all the possibilities and conditions to develop the project.

Our efforts in feasibility study :

● Investigate the multiple control system technologies to be used for your project.
● Evaluate the costs of each solution, especially during the total life cycle of the project including capital expenditure for the construction (CAPEX) and operational expenditure (OPEX) to run the plant
● Estimate construction challenges versus benefits in operations and vice versa.
● Draft planning corresponding to each solution to identify critical items.
● Identify potential risks on the project and hazards for personnel.
● List all the required offsites and utilities.
● Determine all the infrastructures needed to bring in the feedstock and to export the production.

Front End Engineering Design (FEED):

Once Feasibility study completed and validated, the conceptual study will be the base for the front-end engineering and design (FEED) of the project.

We design Front End Engineering and Design‚FFED‚ or Basic Design in more details the different technical and financial options considered during the feasibility study. The „FEED„ will define the over requirement of process control, the plot plan, Control System architecture block diagram, the long lead items, most of the key requirements, and the preliminary vendors list. For the large projects involving multiple production units, it will also prepare the break-down of the different packages to be posted for bid to the engineering companies and contractors at the execution phase.

We can also help you on process design on:

1• Process design basis development
2• Unit operations computer process simulation (as applicable) and process design
3• Process flow diagrams (PFDs) preparation
4• System process control design
5• Equipment specifications preparation
6• Instrument data sheets preparation
7• Capital cost estimate development.

Detail Design:

The detailed engineering phase is the final design stage of a project and typical outputs include procurement specifications, construction drawings, and evidence of design verification. This package can form the basis for EPC tender material, authority approvals and/or certification by a third party.

We can develop the entire detail design package for you and make the project ready for procurement and construction. Based on our extensive experience, we design the entire PC package as a design book for client and ready for any support service during for procurement and construction period.

Control System design

● Safety Instrumented Systems (SIS)

● Fire and Gas Systems (F&G)

● Basic Process Control (BPCS) )

● Burner Management Systems (BMS) )

Critical decisions made after the PHA/LOPA and before detailed design have significant impacts later in the lifecycle; LoopCalTech can reduce your financial risk of late discoveries on capital projects with safety instrumented systems, or SIS engineering.

LoopCalTech has a unique process to design and implement ISA84/IEC 61511-compliant industrial safety instrumented systems. We integrate intimate knowledge and experience in PHA/LOPA along with control system hardware and field instrumentation to ensure that Safety Instrumented Functions (SIFs) are clearly defined.

In addition to industrial safety instrumented systems, LoopCalTech works with clients in all aspects of the process safety lifecycle. We understand that critical decisions made in the analysis phase have significant impacts later in the lifecycle, and we will help you reduce the financial risk of late discoveries on your capital projects. Our full understanding of the process safety lifecycle prevents rework, saves time, and produces a more effective safety program, resulting in an overall cost savings to you.

Corporate SIS Project Standards Development:

For clients who do not yet have standards and procedures for the implementation of Risk Assessment and SIS on your projects, LoopCalTech can consult with your team to collect pertinent data and develop Risk Assessment Standards, SIL Selection Standards, Functional Safety Assessment Templates, and SIS Design and Implementation Standards. We have worked with many companies to enhance their existing standards or develop new standards. We supplement the standards development with training of your staff at all levels ─ from executive management, to divisional management, to onsite management, operations, maintenance, and engineering staff.

Independent Protection Layer (IPL) Validation of Credits:

When appl:ying protection layers to a LOPA scenario, it is important to validate these layers against the five requirements for all IPLs; specific, independent, dependable, and auditable, and secure. By performing and documenting how IPLs perform for each of these criteria, requirement gaps can be identified and closed. IPL validation will also bolster the auditability of the IPLs by providing auditors with the information required to confirm that an IPL is still performing at least as well as required by the LOPA. LoopCalTech can provide you with a standard validation form and report, or work with you to customize the validation effort to be more specific to your corporate IPL requirements.

Safety Integrity Level (SIL) Verification:

During the SIL Verification process, the type of equipment specified, voting architecture, diagnostics and testing parameters are verified by calculation, producing the Probability of Failure on Demand, and Spurious Trip Rate for each SIF. Additionally, we consider Hardware Fault Tolerance (HFT) required. The SIL Verification calculation reports are provided from all tools and calculations we perform. A Design Verification Report (DVR) details the calculation parameters, assumptions, limitations, and sources of data for SIL calculations performed. Recommendations for optimized SIF performance (taking into account both safety integrity and spurious trip evaluation), are also reported in this document.

LoopCalTech’ SIS Engineers are trained and experienced in the fundamentals and the advanced parameters of SIL Verification Calculations. Our engineers, many of which have CFSE, CFSP, and ISA84 Expert certifications, work with our clients to evaluate the SIS options for optimized investment

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Safety Instrumented Function (SIF) Architecture Options Analysis (Redundancy, Diagnostics, Hardware Selection and Test Intervals):

The SIF List is a comprehensive list of all the Safety Instrumented Functions with their identification number, description, target, test intervals, and achieved RRF and IL. The SIF list encompasses sensor, logic solver, and final element voting, and provides a quick-reference to the Risk Assessment, SIL Verification Calculations, and Safety Requirement Specification data. LoopCalTech provides this list as an efficient, single-document summary of safety functions. We also provide a BPCS IPL List for Basic Process Control System (BPCS) Independent Protective Layers (IPL), used generally in the same manner.

Safety Requirements Specification (SRS):

The SRS defines the integrity and functional requirements of SIFs. LoopCalTech provides a detailed SRS datasheet for each SIF and a general SRS document for the project, logic solver, and/or facility. Together, they meet the requirements defined in Clause 10 of IEC 61511. Since many of our SIS Specialists have configuration, instrumentation, and operations experience, we have the expertise to specify feasible solutions to complex SIF implementation.

SIS/SIF Equipment Specifications:

The solicitation of quotes and procurement without knowing all of the equipment requirements can be very costly. LoopCalTech works with clients and multiple manufacturers to assure that all equipment manufacturers know their requirements in meeting the Safety Lifecycle standards, regulations, and codes that may apply.

We assist in identifying these requirements and develop specifications to be used in comparison of competitive quotes to ensure compliance with project requirements, standards and code compliance. As an additional benefit to our clients, we provide code assessment services.

LoopCalTech offers industrial control system (ICS) cybersecurity risk assessment services in every phase of the process automation/process safety lifecycle. We guide clients through our unique cyber-safety risk assessment methodology

Industrial Network Architecture Design:

A properly designed and configured network is fundamental to achieving the required performance, reliability and security of an industrial control system. LoopCalTech can provide the engineering services to plan and design or redesign complete industrial networks.

Industrial Firewall Design/Commissioning:

Firewalls are a great tool to segment networks and prevent unauthorized access to critical ICS assets. However, a firewall is only as good as its configuration. LoopCalTech has extensive experience in designing, configuring and commissioning firewalls in industrial applications. We have experience in all major brands of firewalls, whether they be general-purpose IT firewalls used to partition the ICS networks from company business networks or industrial firewalls used to protect individual zones and conduits.

ICS Intrusion Detection Design:

Just like IT networks, ICS networks should be monitored for suspicious or potentially malicious events. Minor security issues may go undetected and become critical security incidents if an organization does not have the means to detect suspicious events. Unfortunately, most Commercial Intrusion Detection (IDS) and Security Incident and Event Monitoring (SIEM) solutions are not appropriate for the ICS environment.

LoopCalTech can help design and implement intrusion detection solutions that make sense for the ICS environment.

At LoopCalTech, we’re committed to serving clients throughout the process lifecycle through ′ even after commissioning ′ with our process safety operations and maintenance services. Whether we’re designing maintenance plans, performing functional testing, or documenting process safety compliance, our trained and experienced experts work closely with our clients to develop maintenance safety programs to ensure safe, efficient, and sustainable operation throughout the life of the facility.

Our commitment to safety, integrity, quality, innovation, and respect drives our passion to offer world-class process safety operations and maintenance services to our clients. Our deep understanding of the IEC 61511 / ISA 84 standards supports our ability to make these programs effective and sustainable.

Maintenance Plans:

Maintenance Plans are an ongoing process that evolve as best practices emerge based upon design, benchmarking, root cause investigations and employee communications. Our team can help develop effective plans for operations and safety departments that utilize both predictive and proactive approaches to maintain critical equipment.

Proof Test Procedures:

Test Procedures include detailed steps to fully test for undetected failures for either a full function or for the individual devices that comprise that function, depending on customer requirements.

The limitations and constraints of testing are explored and documented during the development of the Proof Test Philosophy and taken into account in the Safety Requirement Specification.

Management of Change (MOC) Program Development & Implementation

Changes often occur in facilities that produce, use, handle and store hazardous materials.

Managing these changes to ensure that failures are not introduced are essential to ensuring the safety of the employees and functional systems of a facility.

LoopCalTech can provide leadership in developing and improving your Management of Change system. It is essential that leadership supports the Management of Change process and provides the necessary stewardship to ensure proper system integrity and ongoing regulatory compliance.

Corporate SIS Project Standards Development:

For clients who do not yet have Standards and Procedures for the implementation of Risk Assessment and Safety Instrumented Systems on your projects, LoopCalTech can consult with your team to collect pertinent data and develop Risk Assessment Standards, SIL Selection Standards, Functional Safety Assessment Templates, and SIS Design and Implementation Standards. We have worked with many companies to enhance their existing standards, or develop new standards. We supplement the standards development with training of your staff at all levels ─ from executive management, to divisional management, to onsite management, operations, maintenance, and engineering staff.

We Design Security, CCTV, complying with your industry standards.

● Oil and Gas

● Cryogenic and LNG

● Refinery

● Power plant / Steam Generation

● Food & Beverage

● Plastics/Packaging