Process Engineer

Description

1. JOB DETAILS :

Position Title : Process Engineer

2. JOB PURPOSE :

Act as the functional expert and technical authority for and provide process engineering support for the assigned Vinyl operations including the delivery of process engineering design for assigned plant revamps in order to enhance long term efficiency, productivity, and safety of the assigned QAPCO facilities, in line with defined industrial standards and QAPCO�s quality policies and procedures.

4. KEY ACCOUNTABILITIES :

Supervision

Organize and supervise the activities and work of service providers to ensure that all work within a specific area of the process engineering activity is carried out in an efficient manner which is consistent with operating procedures and policy.

Budgets and Plans

Monitor the financial performance of a given area of activity versus budgets so that areas of unsatisfactory performance are identified and rectified promptly, and potential performance improvement opportunities are capitalized upon.

Ensure effective execution of process engineering schedules of the assigned unit in line with the overall approved budgets in accord with defined HSE and quality standards.

Provide economic evaluation for proposed investment budgets to assure compliance with defined guidelines and facilitate the selection of best fitted initiatives.

Process Engineering for assigned Unit

Conduct feasibility studies for debottlenecking of plant process facilities and conditions control systems projects, as assigned by Supervisor. Includes but is not limited to preparing economic comparisons of alternative schemes, preparing preliminary cost estimates and necessary engineering calculations, assisting consultants, contractors and / or concerned company personnel in scoping, defining, and planning such projects for the assigned plant.

Lead in conducting detailed technical evaluation and / or safety audits of various critical plant areas and equipment to identify cost saving opportunities, deficiencies or hazards and recommend remedial solutions. Includes but is not limited to leading / assisting a team comprising of senior representatives from maintenance, operations and sometimes outside consultants, as required.

Assist in the preparation of appropriate recommendations for improvements / upgrades.

Prepare conceptual and detailed process engineering designs and process specifications for in-house design projects related to modifications, improvements, debottlenecking, and pollution control, as per international codes and practices.

Review tenders for plant process engineering designs and specifications submitted by engineering consultants and contractors, and comment on technical and financial aspects of such submissions.

Liaise with other departments to monitor general performance of QAPCO facilities and provide support to these entities as required to ensure optimum safety, productivity, and minimum environmental pollution from the organization�s facilities.

Validate and ensure all modifications are engineered and implemented in compliance with company safety and environmental and other standards, initiating HAZOP studies as necessary.

Supports Engineering, Production and Environmental Section on process issues as per defined procedures.

Ensure the updating of all process documentation (PID, PFD, Material Balances, process data sheets) for all modifications. Prepare process data sheets and scheme to formulate capital expenditure and cost justification.

Responsible to conduct performance tests of equipment and units to optimize plant variable costs and assists production to select the best chemicals and catalyst in terms of process.

Develop and carry out industrial trials for replacement of catalysts or chemicals to improve process and environment in compliance with regulatory authorities.

Review, develop and update the specification of raw materials, chemicals and catalysts and finished products to comply with new regulations.

Assist in preparation scheme to formulate capital expenditure and cost justification for approval using the GATED process for CAPEX approval.

Review technical offers from selected bidders for evaluation of new catalysts, chemicals, equipment and packages.

Prepare enquiry document and coordinate basic engineering studies / feasibility studies carried out by consultants (outsourced) to ensure compliance with company, that requirements are met and recommendations are technically acceptable.

Use software programs for simulation, heat and material balances and those to perform chemical engineering calculations.

Liaise with the Process Licensors and Equipment manufacturers to ensure that the assigned plants is updated with the latest developments.

Act as a deputy for Head of Process (Vinyl) in his absence in order to support effective administration of process engineering activities.

Facilitate the training and improvement of skills of all process engineers in the section to support national development.

Policies, Systems, Processes & Procedures

Provide inputs and implement departmental policies, systems, and procedure across the plant so that all relevant procedural / legislative requirements, fulfilled while delivering a quality, cost-effective service.

Quality, Health, Safety & Environment

Ensure compliance to all relevant quality, health, safety and environmental management procedures and controls within a defined area of activity to guarantee employee safety, compliance, delivery of high-quality products / service and a responsible environmental attitude.

Collaborate with HSE and Quality on related issues such as process safety, maintaining and updating system documentation and continuous improvement systems, etc. to achieve and exceed target standards.

Participate in incident investigation and root cause analysis and recommend corrective actions for improvement.

Lead process safety studies like HAZOP, LOPA, HAC, and Fire Risk Analysis to support compliance with world class HSEQ standards.

Statement and Reports

Provide inputs in the preparation of timely and accurate departmental statements and reports to business coordination unit to meet QAPCO�s and department requirements, policies and standards.

5. COMMUNICATIONS & WORKING RELATIONSHIPS :

Internal

Department management to discuss critical process engineering issues

Operations for continuous improvement of the plants

Maintenance Planning & Turnaround to review maintenance issues and for all equipment reliability / performance issues.

Engineering Services Department for all process issues

Materials department to ensure selection of new raw material supplies.

Human Capital

External

Contractors

Government / statutory organizations

Vendors

Service and technology providers

Consultants

6. CONTEXT & WORK ENVIRONMENT :

The Process Engineer shall be responsible for the effective conducting of process engineering programs in line with the defined plans and quality standards, shall work according to established company policies and procedures, industry norms and best practices using own initiative in a variety of ways to answer technical queries / resolve problems within the defined policies and procedures.

The Process Engineer shall determine work methods from alternative existing methods in accordance with established specialized policies and professional standards. This role shall be responsible to lead a team of contractors to fulfil unit objectives in line with HSE and quality standards.

Completed work assignments are subject to review by the Head of Process (Vinyl).

8. QUALIFICATIONS, EXPERIENCE & SKILLS :

Minimum Qualifications

Bachelor�s degree in Chemical Engineering or a relevant engineering discipline.

Minimum Experience

5 years of related experience in the assigned field of process engineering with at least 3 years of growing supervisory / team leadership responsibilities and experience using major process engineering & Process Control Standards and Process Control practices.

Job-Specific Skills (Generic / Technical)

Knowledge of ethylene processes

Original thinking, judgment, critical analysis, and problem-solving ability.

Capacity to effectively prioritize and execute multiple tasks in a high-pressure environment.

Knowledge of industry, regulatory guides, and codes.

Knowledge of process engineering methodologies and tools

Knowledge of downtime analysis and good knowledge of problem-solving tools

Project Management

Mentoring, coaching and people management skills.

Knowledge of the operations in petrochemical plants and of QAPCO operations and products

Employee relations skills

IT proficiency

Strong performance management skills

Health, Safety, and Security Management skills

Strong planning, organizing, and integration skills

High level of integrity

Meticulous attention to detail

Conceptual and analytical skills

Achievement orientation and result oriented skills

Strong time management skills

Customer orientation skills

Decision making and problem-solving skills

Inventory management skills

Strong interpersonal, relationship building, negotiations, verbal, and written communication skills