Process/Mechanical Design

Process Engineering for New & Existing Facilities

Process and mechanical design support new facilities, plant expansions, equipment integration and production upgrades.

Process Engineering for Industrial Facilities

Process and mechanical design define how materials move, how equipment operates, and how systems integrate within an industrial facility.

At Cortex, process engineering drives system definition, production targets, operating conditions, equipment sizing, and utility loads. Mechanical systems, utilities, and supporting infrastructure are then developed around that process basis to produce a coordinated, construction-ready design package.

Process System Definition

Process flow diagrams and piping & instrumentation diagrams establish material flow, equipment requirements and utility demand.

Capabilities include:

  • Process Flow Diagram (PFD) development
  • Piping & Instrumentation Diagram (P&ID) development
  • Equipment identification and preliminary sizing
  • Throughput and production rate analysis
  • Utility load development

Mechanical System & Piping Design

Mechanical design translates process requirements into coordinated piping and equipment layouts ready for construction. Systems are developed with tie-in strategies, shutdown planning and integration requirements within active, operating facilities.

Capabilities include:

  • Piping system design, including CIP systems
  • Piggable piping system design
  • USP-grade piping applications
  • Vessel design and specification
  • Pipe stress analysis (Caesar II)
  • Structural steel platforms and equipment supports
  • Pipe racks, bridges, and mechanical support systems
  • Civil foundation design and containment systems

Utility Integration & Infrastructure Coordination

We specify and design steam systems, compressed air, water pretreatment and wastewater treatment, gas and other utility systems to support both current production and future expansion requirements.

Capabilities include:

  • Utility capacity verification against process load requirements
  • Utility routing and distribution design
  • Integration with existing electrical and control infrastructure
  • Evaluation of infrastructure upgrade requirements
  • Coordination of utility expansion with process loads

Coordinated Layout & Constructability Development

3D modeling may be used to validate routing, equipment placement, access and maintenance clearances before construction begins. Final drawing packages are developed to support fabrication and installation.

Capabilities include:

  • Integrated layout coordination
  • Clash detection across disciplines
  • Access and maintenance clearance validation
  • Construction-ready drawing package development
Industries

Who This Service Supports

Process & Mechanical Design supports:

Testimonials

Why Clients Choose Cortex

I have worked with Cortex for about 15 years. They have done lots of 3D design work, including for an $11MM HDPE reactor debottleneck and a $30MM waste treatment plant. They bring a great skill set to these projects and are agile and able to adjust to changing conditions."
Principal Project Manager
Their use of the latest technology in producing these packages across multiple disciplines provides exacting details to reduce scope changes and field busts thus reducing the total installed costs of projects. The long-term relationship that we have developed with Cortex provides an experienced background that is influential in bringing project to a successful conclusion."
Project Manager
They provide timely updates, openly discuss challenges and options, and make it easy for stakeholders to understand.They proactively identify cost-saving opportunities without compromising system performance or reliability."
Project Engineer
Most recently, I had Cortex develop FEL2/3 estimates for six Turnaround projects (three MCC replacements and three piping/ structural projects). All of these projects were well within the error band comparedto when we developed estimates after detailed engineering. I have been pleased with the work that Cortex has performed for me over the years."
Principal Project Manager
Working with Cortex has been exceptional across every phase of the project. Their dedication to transparency, thorough scope development, and clear communication builds confidence from day one.They take the time to understand every operational requirement, clearly define deliverables, and lay out realistic expectations to minimize risk, prevent scope creep, and ensures everyone starts the project aligned."
Project Engineer
Cortex has a long history of being instrumental in developing both turnaround and non turnaround capital projects. We have used Cortex to develop competent IFC drawing packages and estimates from scope descriptions."
Project Manager
They have a strong understanding of our internal engineering standards. They consistently uphold internal specifications, industry best practices, and quality expectations in every aspect of design, programming, documentation, and implementation."
Project Engineer