Process & Engineering Support
Delivering rigorous process design verification, PFD/P&ID audits, and HAZOP support for EPC contractors.
Independent Technical representation & Field Support
During the detailed engineering phase of an EPC project, minor design oversights or configuration conflicts can lead to major field modifications, schedule slippage, and performance failures. EPC process teams are often under pressure to deliver drawings without operational validation.
Kafaah provides expert process engineering support that integrates directly with EPC design offices. We review PFDs, P&IDs, hydraulics, and equipment specifications to ensure they conform to operational reality and licensor standards.
Scope of Deliverables & Core Execution
Deliverable 01
Detailed review of Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs)
Deliverable 02
Verification of process calculations, hydraulic line sizing, control valves, and pressure relief systems (PSVs)
Deliverable 03
Critical equipment data sheet review (reactors, absorbers, boilers, Mannheim furnaces)
Deliverable 04
Active participation and technical support during HAZOP, SIL, and HAZID studies
Deliverable 05
Technology licensor interface management and design compliance audits
Deliverable 06
Material selection and corrosion management review for highly corrosive process lines
Service Engagement & Execution Workflow
Design Basis Verification
Review process design bases, meteorological data, and feed conditions against project specifications.
PFD & P&ID Optimization
Conduct detailed reviews of PFDs, P&IDs, control logic, start-up loops, and bypass lines.
Hydraulics & Sizing Audit
Re-calculate lines hydraulics, pressure drops, control valve CVs, and safety relief valve capacities.
HAZOP & Safety Integrity
Participate in HAZOP sessions, bringing operational risk scenarios and validating interlocks.
Licensor Compliance Audit
Cross-check detail drawings against the technology package requirements to secure licensor approval.
Proven Field Capabilities & Technical Depth
Design for Operability: We review process designs based on how they will behave in transient states (startup, shutdown, trip) and not just steady-state.
Corrosive Media Expertise: We specialize in handling highly corrosive fluids (concentrated sulfuric, phosphoric, and hydrochloric acids).
Critical Risks Managed & Mitigated
Lines Piping Bottlenecks
Prevent high backpressures or pipe vibrations caused by undersized lines, wrong fittings, or poor layouts.
Process Safety Hazards
Identify runaway reactions, gas pocket accumulation, or toxic backflows during HAZOP reviews before fabrication.
Licensor Warranty Violations
Ensure detail engineering changes do not inadvertently violate licensor process guarantees and void warranties.
Applicable Plant Technologies
Sulfuric Acid — H₂SO₄
Contact process · Converter design · Absorption tower
Phosphoric Acid — H₃PO₄
Wet process · Dihydrate & hemihydrate · Filtration
NPK Compound Fertilizers
Blending · Granulation · Coating · Quality control
Ready to Secure Your Process & Engineering Support Deliverables?
Partner with independent technical advisors to safeguard your construction phase, pre-commissioning readiness, or operational efficiency.
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