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Improve the Technical Competency of the Staff

One of the yearly items of the Manufacturing Work Plan is to improve the technical competency of the staff.  One way to accomplish this task is to develop Competency Work Plan and then a path to meet the Plan.  What competency (ability to solve assigned tasks) should a one, three or five years engineer possess?

Process Engineer - One Year Competency

1. Have the ability to size and rate equipment for potential use in the process unit  (Process Equipment Design Course).

A.  Piping
B.   Control Valves
C.  Flow Orifices
D.  Pumps
E.   Compressors
F.   Relief Valves
G.  Flares
H.  Drums
 I.  Heat Exchangers
J.   Tanks
K.  Cooling Towers

2.  Understand Piping Codes, Specification and Temperature Limits.

3.  Understand Pressure Relieving and Flaring Systems (Advanced Pressure Relieving and Flaring Systems Training Course)

3.  Understand Distillation Operation Fundamentals (Introduction to Distillation Course)

4.  Have the ability to Simulation Simple Distillation Columns

5.  Have the ability to participate as a HAZOP Team Member. (Hazard Analysis Course)

6.  Understand furnace and boiler oxygen requirements, efficiencies, and utility cost.  (Furnace and Boiler Overview Course)

7.  Understand Cooling Tower Water Treatment Operations

8.  Understand Boiler Water Treatment Operations.

9.  Understand Waste Water Treatment Operations.

10.Understand Basic Process Control (Introduction to Process Control)

11.Understand the plant steam systems; build a detailed model of the system for process monitoring and improvements.  (Intro to Energy Optimization Course).


Third Year Competency

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

1.  Have the ability to calculate a rigorous heater efficiency for process monitoring and improvements (Advanced Energy Optimization Course)

2.  Have the ability to calculate a rigorous compressor efficiency for process monitoring and improvements (Advanced Energy Optimization Course)

3.  Understand the plant steam systems and steam turbine efficiency relationships.  (Advanced Energy Optimization Course)

4.  Have the ability to simulate complex distillation systems.  (Process Simulation Course

5.   Understand Distillation Column Tray and Packing Design Parameters.  Have a working knowledge of vendor hydraulics programs. (Advanced Distillation Course)

6.  Have knowledge of unit economics.  Understand Return on Investment and Net Present Value (Finance for Non Financial Professionals Course).

7. Have the ability to review commissioning and start up procedures. (Safe Commissioning of Process Units Course)

8.  Begin to understand the relationship between people, equipment, process and safety.  (Building Operational Excellence Course)

9. Have knowledge of reactor design and catalyst functions. (Catalytic Processes)

10. Obtain general costing of heat exchangers, pump, compressor, and distillation equipment.

11.Obtain general maintenance cost of cleaning and repairing heat   exchangers, compressors and distillation equipment.

12. Be a team member in a project. (Project Management)

13. Have knowledge of Advanced Process Control (Advanced Process Control)

14. Begin to be at least 20% self directed.                          


Five Year Competency

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

1. Have the ability to write commissioning and start up procedures. (Safe Commissioning of Process Units)

2. Have the ability to lead a HAZOP Team.  (HAZOP Team Leader)

3. Be able to lead a project from conception through construction, commissioning to startup.  (Projection Management)

4. Develop project lists and prioritize projects for optimum project execution.

5. Understand critical safety design guidelines by reviewing past safety incidents.  (Achieving Zero Accidents)

6. Be at least 30% self directed.


Training Guide Lines for Process Engineers

Here is Potential List of Courses for Process Engineers

Year One

1.       Process Equipment Design Course

2.       Advanced Pressure Reliving and Flare Systems

3.       Introduction to Distillation Course

3.       HAZOP Team Leader

4.       Furnace and Boiler Overview Course

5.       Introduction to Process Control

6.       Introduction to Energy Optimization


Third Year

1.       Projection Management

2.       Advanced Distillation Course

3.       Distillation Simulation Course

4.       Finance for Non Financial Professionals

5.       Advanced Energy Optimization Course

6.       Safe Commissioning of Process Units

7.       Building Operational Excellence Course

8.       Catalytic Processes

9.       Advanced Process Control


Fifth  Year

1.       Safe Commissioning of Process Units

2.       HAZOP Team Leader

3.       Projection Management

2.       Achieving Zero Accidents




 Engineer Training Goals

Core Competency


KLM Training Course Brochure


Certificate in Process Equipment Design