Against the backdrop of digitalization and intelligent transformation in the oil and gas industry, refined process system design and optimized operations have become key to ensuring efficient, safe, and low-carbon energy utilization. FAC Institute, leveraging its strong foundation in engineering practice and advanced simulation platforms, now offers Process Simulation and Optimization Services for oil and gas production, transportation, and processing, helping clients enhance process performance and control costs throughout the full lifecycle.
✅ Service Overview
The Process Simulation and Optimization Service aims to build dynamic or steady-state simulation models based on actual operating conditions, analyze the material and energy transfer characteristics at key nodes in the process flow, identify system bottlenecks, optimize operating parameters, and evaluate the impact of different operating conditions on system performance — thus achieving the goals of “design equals operation” and “operation equals optimization.”
🔧 Service Modules & Technical Features
1️⃣ Real-time Virtual Metering System (Hybrid Model Based)
Based on dynamic multiphase flow mechanisms and field-collected data, hybrid models are constructed to calculate real-time oil, gas, and water three-phase flowrates. Compared to traditional separation metering methods, this system features low maintenance, low cost, and high adaptability, with metering errors controlled within ±5%~±10%, widely applicable to commingled well metering, mature field retrofits, and more.
2️⃣ Gathering & Subsea Pipeline Operation Simulation
Using multiphase transient simulation models combined with predictive algorithms for hydrates, wax deposition, and slugging, we model the full process of oil & gas field gathering and subsea pipelines. The model can integrate real-time data to dynamically forecast flow assurance risks and support operational strategies and risk warning for complex networks.
3️⃣ Integrated Process Chain Digital Twin Platform
A simulation-integrated platform is developed to cover the entire process from wellbore–gathering–export–stations, integrating control strategies, real-time data, and 3D visualization to achieve closed-loop control for production, incident prediction, and operational training. It is a vital tool for building intelligent oil & gas facilities.
4️⃣ Process Simulation & OTS Operator Training System
Based on real process models, a 3D scene-based simulation interface is developed, supporting training scenarios such as routine operations, abnormal responses, and emergency handling, effectively enhancing operator skills and improving operational safety and compliance.
5️⃣ Long-distance Pipeline Operation Optimization
For long-distance liquid/gas pipelines, we provide modeling and analysis on unsteady flow conditions, batch optimization, blended oil tracking, and elevation drop control, meeting the needs of complex terrain and long-haul operations. Supports both online and offline simulation modes to enhance dispatch and operational efficiency.
💻 Software & Tools Platform
FAC Institute utilizes a range of industry-leading and self-developed tools to build its simulation platforms:
Aspen HYSYS / Aspen Plus: General platforms for steady-state and dynamic modeling
Unisim Design: Simulation of oil & gas processing and refining
ProMax / VMGSim: Natural gas dehydration and special processes
FA Master Process Module (self-developed): Fast modeling, modular deployment, tailored for customized requirements
Data Integration: Supports integration with DCS/SCADA/PI systems for real-time model-data fusion
🚀 Service Advantages
Accurate modeling, field-aligned: From boundary conditions and property databases to control logic, all aspects are considered to ensure high model-to-field consistency
Data fusion, intelligent analysis: Supports integration of historical, real-time, and predictive data to enable smart O&M and fault forecasting
Cross-platform compatibility, flexible deployment: Customizable for domestic and international platforms, adaptable to various IT architectures
Multi-scenario coverage, rich industry experience: Suitable for offshore platforms, arctic pipelines, desert oilfields, LNG plants, and more
📦 Deliverables
Full-process simulation models and technical documentation
Process bottleneck identification and optimization recommendations
3D simulation platforms or digital twin visualization interfaces
Operator training system and user manuals
Continuous O&M and upgrade support services
📞 If you are facing challenges in process design, station upgrades, operational optimization, or training system development in the oil & gas domain, please contact FAC Institute.
With our engineering logic + digital technology, we offer scientific, practical, and actionable solutions for your process simulation and optimization needs!
