Process Engineering Services
Safety, efficiency, and reliability are at the forefront of our services. Cognascents Consulting Group provides integrated engineering services that help organizations design and improve processes, manage overpressure risks, and give operators the information they need to operate safely and effectively.
PROCESS ENGINEERING SERVICES
Six services, one engineering basis.
From a new capital project to an operating unit that needs a closer look to support safer and optimized operation, our engineers bring process design, simulation, relief and flare system analysis, procedures, and alarm management solutions to solve the challenges in front of you.
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RELIEF SYSTEM DESIGN
Pressure Relief System Design and EvaluationIdentify credible overpressure scenarios, evaluate relief devices and systems, and document a relief design basis supported by engineering calculations. |
FLARE & DISPOSAL SYSTEMS
Flare System DesignFlare load determination, header hydraulics, and radiation analysis per API STD 521 and 537, designed to satisfy both the relief system and the environmental permit. |
ALARM MANAGEMENT
Alarm RationalizationReview alarms with your team to establish their purpose, priority, setpoint, and operator response, reducing nuisance alarms and helping operators focus on what matters. |
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PROCEDURES
Operating Procedure GenerationOperating procedures written by process engineers, not technical writers, so every step, limit, and safeguard matches how the unit actually runs. |
PROCESS MODELING
Process Simulation & Modeling ServicesBuild and validate process models to troubleshoot operating issues, evaluate process changes, identify bottlenecks, and support design decisions. |
PROCESS DESIGN
Process Engineering Design ServicesProcess engineering support from concept and FEED through detailed design and commissioning, with the same team accounting for the brownfield constraints of the operating unit already running around your project. |
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Why Cognascents
Why choose Cognascents for process engineering services
INTEGRATED ENGINEERING TEAM
Process Engineering and Process Safety Together
Cognascents combines process engineering and process safety expertise in one integrated team. Relief and flare design draws on the same scenarios evaluated in your PHA and LOPA studies, SOLs are developed alongside the alarms and procedures that enforce them, and process models built for simulation feed directly into relief sizing and design work, so the numbers stay consistent across disciplines. |
PRACTITIONER-LED EXPERTISE
An Experienced Team That Helps Shape Industry Practice
Our engineers have experience across multiple industries, and participate in multiple API Standards Subcommittees, AIChE Design Institute for Emergency Relief Systems (DIERS), and the CCPS Technical Steering Committee, carrying that standards-level involvement into the work we support our clients with across refining, petrochemical, chemical, and midstream facilities. |
AI-ACCELERATED DELIVERY
Faster Analysis, Same Engineering Depth
Our in-house proprietary AI tools accelerate calculations, documentation, and data-heavy work, from reconstructing heat and material balances to organizing alarm and relief records, so our engineers spend more time evaluating scenarios and applying judgment. Every study is still independently reviewed and signed off by senior engineers, with no change to technical rigor or accountability. |
Standards & Codes We Work To
The industry standards and regulatory frameworks that govern process design, relief, flare, and operations.
Pressure Relief & Flare Systems
API STD 520 (Parts I & II)API STD 521API STD 537API STD 2000API RP 576ASME BPVC Section VIII Division 1 (UG-150–UG-156) and Section XIII
Alarm Management
ANSI/ISA-18.2IEC 62682EEMUA Publication 191
Process Safety Management (Design Basis)
OSHA 29 CFR 1910.119(d) and (f)EPA 40 CFR Part 68
Flare Emissions & Environmental
40 CFR 60.1840 CFR 63.1140 CFR 63.670–63.671 (Refinery MACT Subpart CC)40 CFR 60.103a (NSPS Subpart Ja)
Safe Operating Limits & Functional Safety
API RP 754API RP 584IEC 61511
Engineering Practice Guidelines
CCPS Guidelines for Initiating Events and IPLs in LOPACCPS Guidelines for Writing Effective Operating and Maintenance ProceduresCCPS Guidelines for Risk Based Process Safety
PROCESS ENGINEERING AND PROCESS SAFETY, ONE FIRM
Talk through your design basis or operating limits with an engineer who has built one.
Tell us where your process design, relief system, or operating limits need another look. We will tell you which of these services actually fits, with no sales process in between.
Want background first? Keep reading for articles and case studies from the engineers who do this work. ↓↓
Related Content
Process engineering articles and case studies
Technical articles and case studies from the engineers who lead these engagements.
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ARTICLE | PROCESS ENGINEERING
Economics and Process EngineeringWhy the small decisions made during process engineering design can have an outsized influence on a capital project’s bottom line. |
CASE STUDY | FOOD & BEVERAGE
Pressure Relief Device (PRD) Evaluation for Ethanol Processing TankOverpressure scenario identification and PRD sizing for a new molecular sieve surge tank and column system in ethanol-based specialty chemical production. |
CASE STUDY | REFINERY
Enhancing Refinery Safety with a Strategic Safe Operating Limits (SOL) FrameworkEstablishing an SOL framework and specific operating boundaries for a refinery client, built to scale facility-wide. |
Talk to a process engineer about where to start
Tell us what is happening with your process design, relief system, or operating limits. One of our engineers will give you a straight answer about where to start.