Upstream Simulation Services

Process safety studies

Integrated process safety approach

Oil & gas operators, EPCs and consultants companies
Process safety studies
Process safety studies

Taking into account safety consideration by looking holistically at production wells, pipelines, risers, process facility and the flare system


Process safety studies are often carried out with interlinked multiphase flow and dynamic process simulator. The dynamics of the wells, flowlines, topside process and the flare system are simulated under a common and integrated approach (from well to flare tip).

The approach complies with API Standard 521 regarding relief contingency cases, such as inadvertent valve opening, choke valve failure, gas blowby, blocked outlet and emergency de-pressuring.

A typical process safety study is powered by industry-standard simulators and BPT-developed efficient workflows​ driven by our production/process safety domain experts.

The following simulator extension Sim-Apps are normally included in such studies:

  • BPT-OLX - link between OLGA and HYSYS / UniSim / Petro-SIM
  • BPT-PSX - relief valve design and rating (API 520 compliant)
  • BPT-ROX - restriction orifice design and rating
  • BPT-FSG - extraction of flare data from process simulator to flare system design tool
  • BPT-EXT - excel based data processing and reporting


Reference use cases:

  • Choke optimization/verification studies
  • Overpressure protection of inlet arrangements
  • Flare optimization/verification studies
  • HIPPS studies
Benefits and key findings:
  • The approach ensures consistency between plant, report and prediction tools
  • PSV sizing & verification is handled in accordance with API Std 520
  • The piping loads are verified (for both process as well as flare system piping)
  • The instrumented safety system responses / requirements are verified
  • Optimized utilization of existing installation, by establishing the envelope for maximum operability and production flexibility within the process safety integrity limits
  • Optimized utilization of existing flare system during emergency depressuring to reduce escalation hazards during fire & gas events
  • Avoid overly conservative assessments, that may reduce the business potential of a new prospect, such as new tie-in to an existing platform
  • Avoid early phase simplified assessments, that may later reduce the business potential by requirement for late modifications, or even lost production

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