Process Engineering Excellence

Engineering Certainty
in Process Design and Safety

Katalysers delivers world-class process engineering solutions combining rigorous design methodology with comprehensive safety analysis. We provide technical excellence in process design, safety assessments, and SIL verification for critical industrial facilities.

Our Services

Comprehensive Process Engineering Solutions

From conceptual design to safety verification, we deliver integrated engineering solutions that optimize performance while ensuring the highest safety standards across the entire project lifecycle.

01

Process Design Engineering

Complete process design from concept through detailed engineering, delivering optimal performance and operational excellence.

  • Process Flow Diagrams (PFDs)
  • P&IDs Development
  • Mass & Energy Balance
  • Equipment Sizing & Selection
  • Process Simulation
  • Debottlenecking Studies
  • Process Optimization
  • Retrofit Engineering
02

Process Safety Management

Systematic safety analysis ensuring regulatory compliance and operational integrity throughout facility lifecycle.

  • HAZOP Studies (IEC 61882)
  • Process Hazard Analysis (PHA)
  • Layer of Protection Analysis (LOPA)
  • Reliability, Availability & Maintainability (RAM)
  • Bow-Tie Analysis
  • Fire & Explosion Analysis
  • Consequence Modeling
  • Emergency Response Planning
03

SIL Assessment & Verification

Expert Safety Integrity Level determination and verification per IEC 61508/61511 standards.

  • SIL Determination Studies
  • SIL Verification & Validation
  • SIS Design & Architecture
  • Safety Requirements Specification (SRS)
  • Proof Test Development
  • SIL Selection & Classification
  • Functional Safety Audits
  • SIS Lifecycle Support
04

Quantitative Risk Assessment (QRA)

Comprehensive quantitative evaluation of risks enabling informed decision-making and risk-based design.

  • Individual & Societal Risk
  • Frequency Analysis
  • Consequence Modeling
  • Risk Contour Development
  • ALARP Demonstration
  • Risk Reduction Measures
  • Cost-Benefit Analysis
  • Regulatory Compliance
05

Fire & Explosion Risk Analysis (FERA)

Detailed fire and explosion consequence analysis with mitigation strategy development.

  • Fire Scenario Modeling
  • Explosion Overpressure Analysis
  • Thermal Radiation Assessment
  • BLEVE Analysis
  • Vapor Cloud Explosion (VCE)
  • Fire Protection Strategy
  • Passive Fire Protection (PFP)
  • Escape, Evacuation & Rescue
06

Relief & Flare Systems

Specialized design and analysis ensuring compliance with API standards for overpressure protection.

  • Pressure Relief Valve Sizing
  • Flare System Design
  • Relief Load Calculations
  • API 520/521 Compliance
  • Dispersion Modeling
  • Thermal Radiation Studies
  • Blow-down Analysis
  • Flare Network Modeling
Technical Expertise

Specialized Engineering Capabilities

Our multidisciplinary team combines deep technical knowledge with practical industry experience across critical engineering domains.

⚙️

Advanced Process Simulation

Utilizing industry-leading software including Aspen HYSYS, Aspen Plus, and CHEMCAD for comprehensive process modeling and optimization.

🛡️

Safety Analysis Tools

Expert application of PHA-Pro, PHAST, ALOHA, and SAFETI for rigorous hazard identification and consequence assessment.

📊

Regulatory Compliance

Comprehensive knowledge of international standards including OSHA PSM, API, IEC, ISO, and regional regulatory frameworks.

🔬

Consequence Modeling

Advanced dispersion, fire, and explosion modeling using validated methodologies and industry-standard software platforms.

📐

Equipment Design

Detailed mechanical design including pressure vessels, heat exchangers, columns, and rotating equipment per ASME codes.

💡

Lifecycle Engineering

Complete project support from feasibility studies through detailed design, commissioning, and operational optimization.

Industry Sectors

Cross-Sector Experience

Delivering specialized engineering solutions across diverse industrial sectors with proven track record of technical excellence.

Oil & Gas

Upstream, Midstream & Downstream

Petrochemical

Refineries & Chemical Plants

Pharmaceuticals

API & Formulation

Specialty Chemicals

Fine Chemicals & Intermediates

Power Generation

Conventional & Renewable

LNG & Gas Processing

Liquefaction & Regasification

Mining & Minerals

Processing & Extraction

Food & Beverage

Processing Facilities

Professional Development

Training & Knowledge Transfer

Comprehensive training programs designed to enhance technical competency and ensure effective implementation of process safety management systems.

Process Safety Training

  • HAZOP Facilitation Training
  • LOPA Practitioner Certification
  • Process Hazard Analysis (PHA) Methods
  • Incident Investigation Techniques
  • Management of Change (MOC)
  • Pre-Startup Safety Review (PSSR)
  • Operating Procedures Development
  • PSM Regulatory Compliance

SIL & Functional Safety Training

  • IEC 61508 Functional Safety Overview
  • IEC 61511 SIS Lifecycle Management
  • SIL Determination Methodology
  • SIL Verification Techniques
  • SRS Development Workshop
  • Proof Testing & Validation
  • Safety Instrumented Functions
  • Common Cause Failure Analysis

Consequence Modeling Training

  • Dispersion Modeling Fundamentals
  • Fire Modeling & Analysis
  • Explosion Assessment Methods
  • QRA Methodology & Application
  • Risk Assessment Software Tools
  • Consequence Analysis Techniques
  • Risk-Based Inspection (RBI)
  • Risk Matrix Development

Process Design Training

  • Process Simulation Software (HYSYS/Plus)
  • P&ID Development Standards
  • Mass & Energy Balance Techniques
  • Equipment Design & Sizing
  • Relief System Design (API 520/521)
  • Flare Network Analysis
  • Process Optimization Methods
  • Inherently Safer Design
Standards & Regulations

International Compliance

Our work complies with globally recognized standards and regulatory frameworks ensuring technical excellence and legal compliance.

IEC 61508/61511

Functional Safety Standards

IEC 61882

HAZOP Studies

API 520/521

Pressure Relief Systems

OSHA PSM

Process Safety Management

ISO 31000

Risk Management

API RP 754

Process Safety Performance

ASME Section VIII

Pressure Vessels

CCPS Guidelines

Process Safety Best Practices

About Katalysers

Engineering Excellence Delivered

Your Trusted Process Engineering Partner

Katalysers is a specialized process engineering consultancy dedicated to delivering world-class solutions in process design and process safety. Our team combines rigorous engineering methodology with extensive industry experience to provide technically excellent and economically optimized solutions.

We understand that every project presents unique challenges requiring tailored approaches. Our systematic engineering methodology ensures delivery of designs and safety systems that are not only compliant with international standards but optimized for operational excellence and long-term reliability.

Our commitment extends beyond project delivery. We partner with our clients to build internal capability through knowledge transfer and training, ensuring sustained operational excellence.

100+
Projects Delivered
15+
Countries Served
25+
Industry Sectors
50+
Certified Professionals
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Get In Touch

Start Your Project Today

Contact our team to discuss your process engineering requirements. We provide responsive consultation and tailored solutions for your specific needs.

Contact Information

Email

info@katalysers.com

Phone

+92 XXX XXXXXXX

Location

Serving clients globally

Based in Pakistan

Business Hours

Monday - Friday

9:00 AM - 6:00 PM PKT

Thank you for your inquiry. We will respond within 24 hours.