Lead Engineer Process (Hydrogen Production, Acid Gas Recovery, Sour Water Strippers, Sulfur Recovery & Tail Gas Treatment Units)

Main Tasks and Responsibilities:

Scope:

Process Optimization:

The systematic approach of analyzing data, identifying areas for improvement, and implementing changes to optimize production (improving efficiency and effectiveness) of various processes including hydrotreating, hydrogen production, amine treatment, sour water stripping, sulphur recovery and blending, among others, to improve their performance by minimizing energy consumption, reducing operating costs, and maximizing production.

Process Control:

Real-time monitoring, simulation, modelling, and data analytics to enable the identification process inefficiencies, reduce waste and emissions, and optimize the use of raw materials, energy, and other resources.

Product Quality:

Data analytics that aim to meet regulatory requirements for product quality in process installations, upgrades, and maintenance

SR Hydrotreating:

Hydrotreaters: Hydro-desulfurization (HDS) to remove sulfur and nitrogen compounds from natural gas and other refined petroleum products like diesel, gasoline, and jet fuel.

Hydrogen Generation Unit: Pre-desulfurization section, followed by desulfurization, reforming and process gas cooling with high temperature shift conversion to increase the hydrogen content of the process gas. Hydrogen purification by PSA included.

Amine treatment: Regeneration and keeping Amine used as solvent on-specs for H2S absorption in different processes.

Sour Water Stripping: Remove H2S, NH3 and keep Sour Water on specs for final disposal.

Sulphur Recovery: Destroy Nh3 and Convert all H2S generated in Refinery into Sulphur with subsequent granulation.

Main Optimization Strategies:

Process Modeling and Simulation:

Utilize advanced process simulation software to create dynamic models of Hydrotreating (Hydrotreaters, HGU & SRU) operations. Simulations can help identify bottlenecks, optimize operating conditions, and predict the impact of changes without disrupting the actual operations.

Advanced Control Strategies:

Support on implementation of advanced process control (APC) strategies to optimize the control of various parameters such as temperatures, pressures, and flow rates. Model Predictive Control (MPC) can be particularly effective in optimizing the entire hydrotreating, HGU & SRU processes in real-time.

Feedstock Analysis and Blending:

Perform detailed analysis of incoming crude oil feedstock to understand its composition. Adjust blending ratios of different crude oil sources to optimize the feedstock composition for better yields and reduced processing challenges.

Heat Integration:

Implement heat exchanger networks and pinch analysis to optimize the heat integration within the units. Recover heat from hot streams and utilize it in processes requiring heating. This reduces energy consumption and improves overall efficiency.

Tray and Packing Design:

Optimize the design of trays and packing inside distillation columns to enhance separation efficiency. Computational Fluid Dynamics (CFD) simulations can be used to study the flow patterns and optimize tray and packing geometries.

Fouling and Corrosion Management:

Support on implementation of effective fouling and corrosion management strategies. Regular cleaning schedules, monitoring of fouling rates, and selecting corrosion-resistant materials can prevent the degradation of equipment performance over time.

Real-Time Monitoring and Predictive Maintenance:

Implement real-time monitoring systems to collect data from various sensors and instruments. Utilize predictive analytics and machine learning algorithms to predict equipment failures and perform maintenance proactively.

Energy Efficiency Improvements:

Evaluate energy usage patterns and implement energy-saving measures, such as installing variable frequency drives (VFDs) on pumps and fans, optimizing steam usage, and utilizing waste heat for other processes.

Process Safety and Environmental Compliance:

Support Process Safety on Technical Evaluation of MOCs, Alarm Rationalization, Hazop, among others and ensure that optimization strategies also prioritize process safety and environmental compliance. Implement safeguards to prevent operational deviations that could lead to accidents or environmental violations.

Continuous Training and Workforce Development:

Invest in the continuous training and development of the operating staff.

Accountabilities:

Process Engineering SR:

Lead the Engineering processes and procedures implementation to assure that the team completes the technical assessments, recommendations, tasks, and activities as per objectives and ensures that the technical support requirements for all the Maintenance and operations assets are performed in a timely manner in order to minimise the down time.

Cooperates on contract management, interacting with the Vendors/ OEM management, coordination with Engineering/ Assets Development/ Inspection, FATs & SATs support, RCM Management, HAZOP, and other departments,

Provides input into the assigned budget for the department and advises on red flag budget over spend.

Identifies and execute opportunities to optimize operations within and across process for SR and process optimization in terms of Yield, Feedstock for Secondary Units, Fractionation and Heavy Oil Processing.

Supervises and verify design work performed by internal/ external engineering resources, which results in process optimization for SR assigned Units.

Prepare data for Heat and Material Balances, Process Flow Diagrams, designs minor plant modifications, and follows through to the project completion.

Review details of the refinery turn around process scope of work.

Analyses the documentation related to Scope of Work for MOC (Management of Change) requests raised for process improvement.

Performs Root Cause Analysis (RCA) and proposes corrective actions for performance improvement.

Participates in HAZOP studies for any modification of existing facilities/plants.

Gather preliminary documents for tender submissions.

Prepare technical procedures in line with modifications and new systems implemented.

Resolves issues that have a direct operational business impact, using problem-solving tools and techniques and balancing multiple considerations (e.g., economic, operating, maintenance, technical).

Analysis the design, analysis or findings of engineer’s analyses data and identifies opportunities to optimize operations within and across process units or equipment.

Recommends improvements to department procedures so that all procedures are fulfilled while delivering a quality, cost effective service managing budget and quality control.

Monitoring:

Monitoring and executing process engineering Services to look after short to long term plant solutions, RCAs & FMEAs, spare parts reviews & optimizations, Area Reliability Committee involvements, PM reviews, TA scopes, cost optimization

Coaching & guidance:

Provides coaching and guidance to develop technical engineering strength within the SR technology.

Provides technical support and guidance to the operating team on daily basis and longer term based on operating tactics and demands in order to ensure that all staff can complete their tasks and responsibilities.

Education Requirements: Minimum Qualifications for this position are bachelor’s degree in engineering preferably in Chemical Engineering.

Background and Experience:

8-10 years of relevant experience

Relevant experience in similar role within the Oil & Gas / Refinery / Petrochemical industry,

Related experience in Refinery main processes / Units Hydrotreating (Hydrotreaters, HGU & SRU).

Experience and well versed in field investigation, inspections, troubleshooting, performance checks, data compilation, etc.

Understanding of Process Plant (P& ID / PFD) & Engineering drawings and OEM manuals.

Experience in benchmarking studies like Solomon.

Experience in Asset Master Data governance, field materials specifications and international standards.

Expertise for budgeting and cost control.

Familiar with techniques for ensuring data integrity with various integration of information/ reports.

Experience in Process Engineering for refinery optimization strategies:

Process Modelling and Simulation

Advanced Control Strategies

Feedstock Analysis and Blending

Heat Integration

Tray and Packing Design

Fouling and Corrosion Management

Vacuum System Optimization

Real-Time Monitoring and Predictive Maintenance

Energy Efficiency Improvements

Process Safety and Environmental Compliance

Continuous Training and Workforce Development