TRAINING MANUAL

Process Engineering

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Introduction

This KLM Technology Group training manual is designed to introduce new and
experienced engineers in the field of process / chemical engineering to their
engineering responsibilities and their interactions with other areas of engineering. It
also outlines the tasks they will undertake while working for an engineering
contracting company or operating company.

Additionally, the manual serves as a reference and quick look-up for a range of
standards applicable to their everyday process engineering tasks, such as the
Kolmetz Handbook of Process Equipment Design, and KLM Technology Group
Project Standards. It also aims to provide an understanding of process engineering
tasks for engineers from other disciplines.

This manual aims at providing professional industrial training & exposure to various
Process Engineering design principles for Process / Chemical Engineers. The training
program provides knowledge to candidates starting from explaining the roles &
responsibilities of Process Design Engineer to development of final process design
engineering document i.e., Piping & Instrumentation Diagrams (P&IDs). This program
is designed to cater to the needs of fresh graduates as well as experienced
professionals. Process Engineering involves developing new processes, project
engineering and troubleshooting.

This Manual will assist Chemical Engineers to enter industry as Process Design
Engineer and Operations Engineer. Chemical / Process engineers are found in vast
range of industries, such as;

Oil & Gas,

Upstream Processing / Offshore,
Natural Gas Processing – Midstream,
Ammonia,
Refining,
Ethylene,
EB / Styrene,
Polymers,
Petrochemical,
Chemical Plants,
Mineral Processing,
Food,
Palm Oil,
Pharmaceutical,
Biotechnological industries.
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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

The goal of this Manual is to introduce the basic concepts of the process Design
Engineering. The Style and approach of the training manual is to provide insight view
of the Process techniques to Chemical Engineers.

“Kolmetz Universal Law of Project Stupidity”.

Kolmetz Universal Law of Project Stupidity: a law strictly followed by most

engineering projects.

“Save money and poorly design the process equipment by awarding it to the
low- cost bidder. Loose money for the next twenty years on plant capacity,
maintenance reliability, and excess energy.”

According to this law, awarding a process equipment contract to the lowest

bidder may save you money in the short term, but it can cost you heavily in
the long run. You may end up losing money for the next twenty years on plant
capacity, maintenance reliability, and excess energy. So, next time you are
tempted to cut corners, remember the Kolmetz Law of Project Stupidity.

Typically, process equipment is awarded to the lowest bidder with very low
standards of guarantees. Typical guarantees by the manufacturers are
hydraulic capacity only, and this test must be carried out within three to six
months, while the process equipment is still clean and new. Typical process
guarantees are by the process engineering company which includes capacity
and energy, again the performance test must be carried out within three to six
months.

Imagine buying a car and receiving a three-to-six-month warranty and only

good gas milage for the first six months. You would think the car
manufacturer was taking advantage of you, yet this is what we do for process
equipment, and cars are much more complex than heat exchangers.

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

What are things that should be included in process equipment design that are
not being utilized because of the sweetheart guarantees and low-cost
bidders.

1. KLM is a recognized expert in Process Equipment Design, only

utilize groups with technical expertise.
2. KLM only partners with high quality suppliers, often from the same
factories as the Original Equipment Manufacturers (OEM) and has
senior inspectors to ensure your equipment is installed correctly
3. Anti Fouling Designs to improve the process equipment over the life
of the run length
4. Ensure correct metallurgy.
5. Review Galvanic Corrosion Potential for extended life. If you have
polar liquids (water, acids, caustics) and a carbon steel vessel,
stainless steel demister pads will experience bi-metallic corrosion
with reduced life.
6. Review the failures of the non-technical suppliers.

KLM can assist your team in providing Senior Engineering and Operations
Staff to provide support for your local team in many areas including demister
pads, distillation towers, heat exchanger and pump design.

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 Page 5 of 46
KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Contents

i Introduction
1. Process / Chemical Engineering
2. One, Three and Five Year Engineering Goals
3. Process Engineering Projects
4. Role of Process Engineer
5. Interface with Other Discipline Engineers
6. Phases of Project
7. FEED
8. Basic Design
9. EPC Proposals
10. Detailed Design
11. Basis of Design
12. Process Selection
13. Process Simulation
14. Flow Assurance Evaluation
15. Process Flow Diagram and Heat and Mass Balance
16. Piping and Instrumentation Diagram
17. Line Sizing
18. Pump Hydraulics Calculation
19. Vessel Sizing
20. Heat Exchanger Thermal Design
21. Relief Valve Sizing
22. Blowdown and Depressurizing Study
23. Flare Design
24. Hazop, LOPA and Safety Integrity Level
25. Sustainability (Reduce, Recycle, Recover, Renewable)
26. Environmental

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

1. Process / Chemical Engineering

Chemical engineering is a branch of science that applies physical

sciences (physics and chemistry) and life sciences (microbiology and
biochemistry) together with applied mathematics and economics to
produce, transform, transport, and properly use chemicals, materials
and energy. Essentially, chemical engineers design large-scale
processes that convert chemicals, raw materials, living cells,
microorganisms and energy into useful forms and products.

Process engineering design involves the use of chemical, petroleum,

and gas technologies, along with mechanical, instrumentation, and
other engineering skills, in the development, planning, design, and
decision-making processes necessary for the economical and efficient
execution of a process project.

The process design engineer actually engineers the process

chemistry into appropriate hardware (equipment) to accomplish the
process requirements. His task is to find the best way to produce a
given quality product, safely and economically.

Process engineer has the following responsibilities:

1. Studies process systems for manufacture of a product or to

implement improvements / changes in existing production units.
2. Prepares economic studies associated with process performance.
3. Evaluates operating data of existing or new equipment.
4. Designs and/or specifies items of equipment required to define
the process flowsheet or flow system.
5. Evaluates competitive bids for equipment.

The process engineer must understand the interrelationship between

the various research, standards, engineering, purchasing, expediting,
construction and operational functions of a project. He must
appreciate that each function may and often does affect or influence
the process design decisions.

In a consulting or engineering contractor organization, process design

and/or process engineering is usually a separate group responsible
for developing the process with the customer or presenting the
customer with a turnkey proposed process.
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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Process Engineering is the application of Chemical, Mechanical, Petroleum,

Gas and other engineering disciplines in the Development, Design,
Construction, Efficient, Safe and economic operation of a plant / processing
facility meeting customer’s Specifications
 In a Consulting or Engineering contractor Organization, Process Design and
/ or Process Engineering is usually a Separate Group Responsible for
Proposing / Developing / Designing a Process plant / facility for the
customer.
 In an Operating or Production Company, Process Design and / or Process
Engineering is involved in Research and Development, Technical Services
or Engineering Department for developing new projects and processes.
Introduction to Chemical Engineering Guideline
https://www.klmtechgroup.com/PDF/EDG-KNO/ENGINEERING-DESIGN-
GUIDELINES-introduction-to-chemical-engineering-Rev1.2web.pdf

2. One, Three and Five Year Engineering Goals

A fresh graduate engineer is typically taught the fundamental principles
necessary to solve complex engineering problems but may not receive
guidance on applying these concepts in the field. It is essential for them to
be trained in using these fundamental concepts to evaluate and size
process equipment.
The Kolmetz Handbook of Process Equipment Design was developed for
this purpose and includes chapters on various types of process
equipment. The International Association of Certified Practicing Engineers
offers certification to teach the content of the Kolmetz Handbook. What
competencies (abilities to solve assigned tasks) should engineers with
one, three, or five years of experience possess?

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Process Engineer - One Year Competency

A. Have the ability to size and rate equipment for potential use in the
process unit (KLM Process Equipment Design Course).
 Piping
 Control Valves
 Flow Orifices
 Pumps
 Compressors
 Relief Valves
 Flares
 Drums
 Heat Exchangers
 Distillation Towers
 Tanks
 Cooling Towers

B. Understand Piping Codes, Specifications and Temperature Limits.

C. Understand Pressure Relieving and Flaring Systems (KLM Advanced
Pressure Relieving and Flaring Systems Training Course)
D. Understand Distillation Operation Fundamentals (KLM Introduction to
Distillation Course)
E. Have the ability to Simulation Simple Distillation Columns
F. Have the ability to participate as a HAZOP Team Member. (KLM Hazard
Analysis Course)
G. Understand furnace and boiler oxygen requirements, efficiencies, and utility
cost. (KLM Furnace and Boiler Overview Course)
H. Understand Cooling Tower Water Treatment Operations
I. Understand Boiler Water Treatment Operations.
J. Understand Wastewater Treatment Operations.
K. Understand Basic Process Control (KLM Introduction to Process Control)
L. Understand the plant steam systems; build a detailed model of the system
for process monitoring and improvements. (KLM Intro to Energy
Optimization Course).

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Third Year Competency

A third-year engineer should have mastered all of the one year competency
requirements along with the additional items.

A. Have the ability to calculate a rigorous heater efficiency for process

monitoring and improvements (KLM Advanced Energy Optimization
Course)
B. Have the ability to calculate a rigorous compressor efficiency for process
monitoring and improvements (KLM Advanced Energy Optimization
Course)
C. Understand the plant steam systems and steam turbine efficiency
relationships. (KLM Advanced Energy Optimization Course)
D. Have the ability to simulate complex distillation systems. (KLM Process
Simulation Course)
E. Understand Distillation Column Tray and Packing Design Parameters. Have
a working knowledge of vendor hydraulics programs. (KLM Advanced
Distillation Course)
F. Have knowledge of unit economics. Understand Return on Investment and
Net Present Value (KLM Finance for Non Financial Professionals Course).
G. Have the ability to review commissioning and start up procedures. (KLM
Safe Commissioning of Process Units Course)
H. Begin to understand the relationship between people, equipment, process
and safety. (KLM Building Operational Excellence Course)
I. Have knowledge of reactor design and catalyst functions. (KLM Catalytic
Processes Course)
J. Obtain general costing of heat exchangers, pump, compressor, and
distillation equipment.
K. Obtain general maintenance cost of cleaning and repairing heat
exchangers, compressors and distillation equipment.
L. Be a team member in a project. (KLM Project Management Course or
IACPE Project Management Certification)
M. Have knowledge of Advanced Process Control (KLM Advanced Process
Control)
N. Begin to be at least 20% self directed.

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Five Year Competency

A five year engineer should have mastered all of the one and three year
competency requirements along with the additional items.

A. Have the ability to write commissioning and start up procedures. (KLM Safe
Commissioning of Process Units or IACPE Commissioning Certification)
B. Have the ability to lead a HAZOP Team. (KLM HAZOP Team Leader Course
of IACPE Safety Certification)
C. Be able to lead a project from conception through construction,
commissioning to startup. (KLM Projection Management Course or IACPE
Project Management Certification)
D. Develop project lists and prioritize projects for optimum project execution.
E. Understand critical safety design guidelines by reviewing past safety
incidents. (KLM Achieving Zero Accidents Course)
F. Be at least 30% self directed.

3. Process Engineering Projects

Project management is the application of knowledge, skills, tools, and

techniques for project activities in order to meet or exceed
stakeholder needs and expectations in a project. A project is a
temporary endeavor undertaken to create a unique product or service
that is different in some distinguishing way from all similar products or
services.

A project management certification like Certified Practicing Project

Management (CPPM ) will assist in gaining the knowledge needed to
manage projects. Knowledge will assist your carrier by increasing
you ability to interview and speak in meetings.

https://www.iacpe.com/cppm-program.html

For any typical process related project, the process engineer begins
by gathering all the data / information he can about the process and
the physical & chemical information of the substances involved in the
process.

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

The initial goal of the preliminary process study is to obtain an

economic evaluation of the process, with the minimum expenditure of
time and money. During this stage, all information necessary to obtain
a reasonably accurate cost estimate for building and operating the
plant is determined.

In the design and evaluation of a process, the process engineer takes

the following activities. These are the selection of a site, the writing of
the scope (definition of project), the choosing of the process steps, the
calculation of material and energy balances, the listing of all major
equipment with its specifications, the development of the physical
layout of the plant, the instrumentation of the plant, the development
of a cost estimate, and finally the economic evaluation of the process.

If the techno-economic evaluation appears promising, then this

process must be compared with all other alternatives to determine
whether taking the proposed action is really the best course to follow.
All these feasibilities must be economically evaluated to determine the
best course of action to take.

If, after comparing alternatives, a project is approved by the

management, the project is returned to process engineering for the
detailed process design. Now the process engineer must provide all
the information necessary to the project engineering specialists, so
that equipment can be designed and specified.

Project Management Guideline

https://www.klmtechgroup.com/PDF/EDG-PRO/ENGINEERING-DESIGN-
GUIDELINES-project-management-Rev1.2web.pdf

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 Page 12 of 46
KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

4. Role of Process Engineer

In an engineering consultancy or owner’s representative, process engineers

are usually involved to varying degrees in different phases of a project.
Process engineers should try to adapt to the phase of the project, while
doing their work.

 Study (Concept and Feasibility) – Generates Design Data /

Information
 Engineering (Basic/FEED and Detail) – Validates and Disseminates
the Design data / Information
 Procurement – Evaluation of Technical Bids / Discussion with
vendors
 Construction – Response to Site Queries
 Commissioning / Start-up – Prepare procedures and assist in smooth
/ trouble –free commissioning

In a nut shell, the role of a process engineer is to provide services from

concept to commissioning.

Additional Responsibilities of a Chemical / Process Engineer

 Business Development
 Gathering knowledge on technologies (from Principals, Licensors,
Vendors)
 Developing design capabilities in new areas
 Development of design tools, calculation procedures, technical
database
 Training other engineering disciplines on general / specific process
design aspects
 Site services - Data collection for revamping (brown field
engineering), commissioning assistance
 Maintaining good customer relations and providing opportunities for
repeat orders

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

Capabilities of a Chemical / Process Engineer

 Carrying out Simulation Study to develop Mass & Heat Balance and
to establish fluid property databank.
 Performing Equipment (Vessels, Pumps, etc.) Sizing calculations
 Performing Line sizing and Hydraulic calculations
 Developing and updating Process Engineering deliverables
 Carrying out Effluent study to develop suitable Flare, Vent and
Drain Systems for the facility
 Carrying out Utility System Design
 Participating in HSE (Health, Safety and Environment) studies like
HAZOP (Hazard v/s Operability), SIL (Safety Integrity Levels) to
record the design changes and to implement in Engineering
 Technical Assistance for Procurement
 Vendor offer review & clarifications
 Assistance in Technical Bid Evaluation
 Final Vendor data incorporation

Process Design Engineering Deliverables

Some of the major process design engineering deliverables are:

 Process Design Basis

 Process Simulation Study
 Process Flow Diagrams (PFDs)
 Equipment Design and specifications
 Line sizing and hydraulics
 Instrument sizing and specifications
 Piping and Instrumentation Diagrams (P&IDs)
 Utility consumption summary
 Cause and Effect Diagrams

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KLM Technology KLM Technology Group
Group Process / Chemical Engineer Rev: 01
Practical Engineering
Training Manual
Guidelines September 2024
for Processing Plant Solutions
www.klmtechgroup.com

The process engineer must be able to perform the following activities to build a
basic design package.

a. Prepare heat and material balance studies for a proposed process,

with and without use of software applications.
b. Prepare rough cost economics, including preliminary sizing and
important details of equipment, factor to an order of magnitude
capital cost estimate, prepare a production cost estimate, and work
with economic evaluation representatives to establish a payout and
the financial economics of the proposed process.
c. Participate in layout planning for the proposed plant.
d. Prepare operating, control and safeguarding philosophies of the plant.
e. Prepare and supervise drafting of process flow diagrams (PFD).
f. Prepare and supervise drafting of piping and instrumentation
diagram (P&ID), with necessary preliminary sizing of all piping,
equipment and representation of all instrumentation for plant
monitoring, automation and protection.
g. Prepare detailed sizing of all process equipment and utility systems,
with and without use of software applications.
h. Prepare process datasheet for all equipment and package systems.
This is used by mechanical engineers to prepare a detailed
equipment specification.
i. Determine size and specifications for all safety relief valves.
j. Select piping specifications from existing company standards for
the fluids and their operating conditions for incorporation in P&ID.
k. Select from company insulation standards the insulation codes to
be applied to each hot or cold pipe or equipment as applicable.
l. Prepare line schedule, equipment summary schedules, summary
schedules for safety relief valves and rupture disks.
m. Perform technical evaluation of bids and recommendation of qualified
vendors.

Basic Design Package Standard

https://www.klmtechgroup.com/PDF/ess/PROJECT_STANDARDS_AND_SPE
CIFICATIONS_basic_design_package_Rev01.1.pdf

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