Sector 01 ยท Energy, Oil & Gas

Energy, Oil & Gas

We engineer energy and process facilities end to end: upstream and gas processing, refining and petrochemicals, hydrogen, storage and terminals, with the power, distribution and utilities that keep them running. New units, revamps and expansions, from FEED to start-up.

Upstream & gas processingRefining & petrochemicalsStorage & terminalsPower & utilities
The challenge

What makes these projects hard

Energy projects combine licensed process technology, demanding operating conditions, strict international standards and complex logistics, and increasingly need to be delivered faster, in modules, with less site construction. Power, utilities and gas systems are too often engineered late, as isolated packages, after the process is fixed

  1. Licensed process technology that must be integrated exactly to licensor requirements
  2. Hydrotreating, desulphurisation and product-specification upgrades on operating sites with tight turnaround windows
  3. Storage, terminal, flare and gas-recovery systems facing tighter emissions limits
  4. Power and utility systems sized late, delivered as scattered vendor packages
  5. Equipment that must be manufactured to code and inspected before shipment
How we help

From concept to an executable project

We support clients in transforming process concepts into engineered, manufacturable and executable projects, across the whole value chain, with power, utilities and gas systems considered as part of the complete facility. Our methodology is aligned with internationally recognised standards and the requirements of major licensors, including projects incorporating Honeywell UOP process technologies

  • Upstream and gas processing, gas treatment, hydrogen systems and process units
  • Crude oil refineries, hydrotreating, desulphurisation, naphtha processing and isomerisation
  • Petrochemical facilities, process units and modular refinery systems
  • Storage, terminals and offsites, tank farms, loading, metering and firewater
  • Flare and gas-recovery systems and utilisation
  • Power generation and distribution, MV/LV systems, MCCs and substations
  • Industrial utilities, steam, cooling, compressed air and water, with energy-efficiency studies
  • Pressure vessels, columns and exchangers designed for manufacture
  • Brownfield modifications, revamps and upgrades
  • EPC technical support, procurement and commissioning
Services

Scope of services

Six service lines, each delivered as a study, an engineering package or as part of a complete project

01

Refining & petrochemical process units

Process engineering for new units, capacity or yield upgrades and product-specification projects, integrated to licensor requirements

  • Hydrotreating, desulphurisation and naphtha processing
  • Catalytic reforming, isomerisation and hydrogen management
  • Heat and material balances, simulation and PFDs
  • Equipment sizing, datasheets and process safety inputs
  • Licensor design-basis integration and interface management
02

Upstream & gas processing

Treatment, conditioning and compression facilities from wellhead to export specification

  • Gas sweetening, dehydration and dew-point control
  • Separation, stabilisation and condensate handling
  • Compression, metering and export systems
  • Hydrogen production and purification
  • Modular and skid-mounted process trains
03

Storage, terminals & offsites

Tank farms and logistics facilities designed for safe, efficient and expandable operation

  • Atmospheric and pressurised storage layout and sizing
  • Loading, unloading, metering and custody transfer
  • Vapour recovery, blending and transfer pumping
  • Firewater, foam and fire-protection systems
  • Hazardous-area classification and plot plans
04

Flare, relief & gas recovery

Safe disposal of process upsets and recovery of gases that would otherwise be burned

  • Relief scenarios, PSV sizing and relief-load summaries
  • Flare header hydraulics and knock-out drums
  • Flare-gas recovery and utilisation
  • Emissions and monitoring studies
  • Debottlenecking of existing flare systems
05

Power, utilities & electrical

Power and utility systems engineered with the process rather than added afterwards

  • Load lists, load-flow and short-circuit studies
  • MV / LV distribution, MCCs, substations and earthing
  • Steam, cooling water, compressed air and nitrogen
  • Hazardous-area electrical and lighting design
  • Energy-efficiency and heat-integration studies
06

Brownfield, revamps & EPC support

Modifications on operating sites, where tie-ins, access and shutdown windows decide the schedule

  • Site surveys, laser scanning and as-built verification
  • Tie-in strategy and shutdown work packages
  • Constructability and modularisation studies
  • Procurement support and vendor evaluation
  • Construction supervision, commissioning and start-up
Featured concept ยท modular NHT + CCR

A modular naphtha hydrotreater and reformer, in 3D

A reference concept from our refining work, designed for 12,000 BPD of naphtha feed: two identical 6,000 BPD hydrotreating trains built as shop-fabricated modules, a common stripper, a catalytic reformer with three reactors in series, stabiliser and hydrogen management, and one set of shared utilities. Drag to rotate, tap a station to see its function and what CAC engineers there.

Model viewNHT + CCR ยท MODEL 002
Rotate ยท explore
LinesNaphthaHโ‚‚Fuel gasSteamCWFlare
Assembling the plant

Design basis: 12,000 BPD total naphtha feed, split across two 6,000 BPD hydrotreating trains so that either train can be taken offline for catalyst change-out while the other keeps the reformer running at reduced charge. The reformer, stabiliser and shared utilities are sized on the combined 12,000 BPD of hydrotreated naphtha. Configuration follows publicly documented naphtha hydrotreating and catalytic reforming practice; it is a reference concept, not a licensor design, and uses no proprietary catalyst or process data.

Discuss a modular unit

Approach

How a refining project runs

A staged, gated approach that lets the client stop, adjust or proceed at each decision point

01

Define

Scope, feedstock and product basis, capacity, site constraints and licensor requirements captured in a design basis and a Class 5 cost range

02

Develop

Concept and FEED, process design, simulation, PFDs, equipment list, plot plan and a Class 3 estimate for the investment decision

03

Engineer

Detailed multidisciplinary design with a 3D model, P&IDs, isometrics, datasheets and specifications issued for procurement and fabrication

04

Deliver

Vessels, skids and modules fabricated to code with inspection, followed by installation support, commissioning and performance testing

Outputs

Typical deliverables

  • Feasibility and FEED packages
  • Process design, simulation, PFDs, P&IDs and datasheets
  • Multidisciplinary detailed engineering across all disciplines
  • Electrical and utility design packages, load studies and single-line diagrams
  • Fabricated vessels, skids and modules
  • Technical specifications and tender documents
  • Site, commissioning and start-up support
Disciplines

Related expertise

Process engineeringPipingElectricalPressure vessels & modular systemsLicensor integration

Every scope is staffed from the same multidisciplinary team, so process, mechanical, piping, electrical, civil and control engineers work from one model and one design basis.

Compliance

Codes and standards we engineer to

API 521 ยท pressure-relieving and depressuringAPI 650 / 620 ยท storage tanksAPI 610 ยท centrifugal pumpsAPI 560 ยท fired heatersAPI 661 ยท air-cooled exchangersASME VIII ยท pressure vesselsASME B31.3 ยท process pipingTEMA ยท shell-and-tube exchangersIEC 61511 ยท functional safetyIEC 60079 ยท explosive atmospheresATEX 2014/34/EUPED 2014/68/EUNFPA 15 / 20 / 24 ยท fire protectionIEC 61439 ยท LV assemblies

Applicable codes are confirmed with the client and licensor at the start of every project

Experience

Typical engagements

Representative scopes drawn from the work we take on

Process unit

Modular naphtha hydrotreater

Two shop-fabricated hydrotreating trains with a common stripper and a catalytic reformer, designed as transportable modules to cut site construction time

OutputDesign basis, BFD / PFD, equipment list and modular plot concept
Brownfield

Gas-recovery and flare upgrade

Relief-load and flare-header review on an operating site with tighter emissions limits, followed by a recovery unit tied in during a planned shutdown

OutputRelief study, tie-in packages and shutdown work scopes
Storage & offsites

Terminal expansion

New storage tanks, loading bays and firewater system added to an existing terminal without interrupting operations

OutputLayout, hydraulics, hazardous-area drawings and tender package
Questions

Frequently asked

Can't find your question? Send a short brief and an engineer will reply within one business day.

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Can you work with our process licensor?

Yes. We integrate licensed technology to the licensor design basis and review requirements, and we manage the interface between the licensor package and the rest of the plant design. We do not replace licensor design or guarantees, and we do not claim licensor approval for concepts that have not been reviewed by them

Do you design for modular construction?

Yes. Modularisation is considered from the concept stage, module limits, lifting and transport envelopes, structural frames and interfaces, so that equipment, piping, instrumentation and electrical can be integrated and tested in the factory before shipment

Can you support a project on an operating site?

Yes. Brownfield work starts with a survey and an as-built verification, followed by a tie-in strategy that fits the available shutdown windows, so that most work can be prepared and prefabricated while the plant runs

What do we receive at the end of a study?

A written report with the design basis, options compared on technical and cost criteria, an estimate with a stated accuracy class, a schedule and a recommended route, enough to take an investment decision or to start FEED

Do you manufacture the equipment?

Pressure vessels, skids and modules are fabricated through our manufacturing partners under CAC-managed inspection and test plans, so the design office and the workshop work to the same drawings and acceptance criteria

Learn how CAC can help you engineer, build and run your next water, energy or industrial project.

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