Process Engineer role for design and engineering job
- 1. Training Program on Basic Process Engineering Practices Module - 2 Process Engineer’s Role
- 2. Project Life Cycle - Recapitulation Feasibility Study Basic Design Engineering Construction Operation Maintenance Revamp Concept Concept Let us recapitulate the project life cycle. Process Engineers have very important role to play in each of the stages.
- 3. Process Engineers Role – EPC – Phase I • Project Leader – Process Engineer - Dream Plant built & Operated as per his dream ! • Conceptual - Definition • Naphtha cracker • Bhopal Pesticide Plant • ONGC LPG Recovery Plant - Market Information • Plastics IPCL case • Bhopal Pesticides Plant • ONGC Uran Plant - Technology Selection • LPG Recovery - Oil Absorption Process - Refrigeration Process - Expanded Cycle
- 4. • Feasibility Study - Capex - Opex - Economic viability - Sensitivity Parameters • Capex • Taxation Parameters • Raw Material Cost • Opex • Utility Cost - Sensitivity Analysis Process Engineers Role – EPC– Phase I
- 5. • Key Parameters / Process Package - Process Optimization - Heat & Mass Balance - Translate to Process Package • Process Flow Diagram • P&I Diagram • Plot layout • Equipment specification, etc. Process Engineers Role – EPC– Phase I
- 6. Engineering (Support role) • Equipment Selection - Compressors - Column Packing - Package Units • Tender enquiry • Receive offers • Comparative Statement • Evaluation Process Engineers Role – EPC– Phase II
- 7. Engineering (Support role) Fabricated Equipment Pressure Vessels, Columns • Mechanical - Nozzle size, orientation - Nozzle location - Reboiler type – skirt height Heat Exchanger • Mechanical Drawing - Type - # of passes - nozzle orientation Fired Heater/Furnaces - Configuration - General arrangement Process Engineers Role – EPC – Phase II
- 8. Engineering (Support role) • Piping Design - Lay out drawing - Model Review - Isometric check • Stress Analysis • Supports - Hydraulic check – critical loops • Revise P&I Diagrams as necessary • Other Disciplines - Support as required Essentially monitoring & hand holding Process Engineers Role – EPC– Phase II
- 9. Plant Check out and Pre-commissioning • P & I Check • Pipe /Equipment - Flushing, Cleaning, Purging and Testing • System identification • Equipment Running in • Refractory Drying • Catalyst Reduction • Chill Down Process Engineers Role – EPC– Phase II
- 10. Commissioning • Check plant operating parameters • Quality of Product Streams - Specifications met? - If not? • Equipment Performance - Compressors - Furnace • Trim operations to ensure performance test - Dream come true ! Process Engineers Role – EPC– Phase II
- 11. General Plant Management * * * Production Plant Engineering Technical R&D Services - Keep plant - Maintenance - Efficiency - Support running - Modifications - SHE innovations - Innovations - Technology development * Checks & Balances Process Engineers Role – Operating Company–Phase III
- 12. • Plant Operations - Ensure desired / optimum level of production • Shift Supervision • Technical Services - Plant house keeping - Plant efficiency - Plant capacity • Debottlenecking • Modifications • SHE - Technology monitoring and application - Interface with R&D • R&D tech. Developer Process Engineers Role – Operating Company– Phase III
- 13. Research & Development • Who is best suited? • New Technology - Same Products (Fundamental) • Catalyst Development • Reactor design (Reaction kinetics and the Thermodynamics) - Engineering modifications • Heat Recovery Systems • New methodology allows higher temperatures • New types of packing - New & Related products Example: Refining companies, (UOP) etc. Process Engineers Role – Operating Company– Phase III
- 14. Process Engineers Role – Consulting & Operating SUMMARY • Chemical Engineer by education • Process Engineer by experience - Vast canvas • Process Engineering skill can contribute in many ways: - Concept to commissioning - Plant performance Continuity Efficiency • R&D - Technology Development (Equipment / Catalyst / Reactor) • Cracking Furnace Reactor yield • New Product