Lead Process Safety Engineer in Rāniganj, India

POSITION: LEAD PROCESS ENGINEER

JOB DESCRIPTION:

Qualification: B.E./B.Tech. or M.E./M.Tech., preferably in Chemical Engineering.

Minimum 10–20 years of relevant experience as a Lead/Senior Process Engineer with leading and reputed Engineering / EPC companies operating in Oil & Gas, Refinery, Petrochemical, Chemical, Fertilizer, Energy, Renewable Energy, and related industries.

Software Proficiency: Good working experience in Aspen HYSYS, Aspen Plus, , PIPENET, Flarenet or equivalent process engineering software. Working knowledge of AutoCAD, SPPID, AVEVA P&ID, MicroStation, MS Office, and engineering document management systems is preferred.

Responsibilities

1. Lead and oversee Basic Engineering, FEED, and Detailed Process Engineering activities for projects.
2. Manage a team of in-house Process Engineers/Designers responsible for Process Design, Process Simulation, Hydraulic Analysis, Utility Systems, Relief & Flare Systems, and Process Documentation.
3. Manage process engineering activities subcontracted to third-party engineering agencies as and when required.
4. Review and optimize process schemes and systems to achieve CAPEX/OPEX optimization, energy efficiency, operability, and maintainability.
5. Integrate HSE, process safety, and inherently safer design principles into the process design of plants and associated facilities.
6. Review the Client's Design Basis, Process Design Criteria, applicable codes and standards, project specifications, and statutory/local regulations, and incorporate the requirements into the Process Design Basis.
7. Develop and review Process Design Basis, Process Flow Diagrams (PFDs), Heat & Material Balances (HMBs), Piping & Instrumentation Diagrams (P&IDs), Utility Flow Diagrams, Process Datasheets, Equipment Datasheets, and Process Specifications.
8. Perform and/or review process simulations, hydraulic calculations, line sizing, equipment sizing, control valve sizing, PSV/PRV sizing, relief and flare system studies, and utility system calculations using appropriate engineering tools.
9. Provide technical guidance and expertise in process selection, process optimization, equipment sizing, operating philosophy, material selection, and process control requirements.
10. Ensure proper development and review of process engineering deliverables and provide technical guidance to Process Engineers for preparation of project documents.
11. Coordinate with Piping, Mechanical, Civil & Structural, Instrumentation & Control, Electrical, HSE, and other engineering disciplines to ensure proper integration of process requirements into the overall plant design.
12. Define Process Engineering activities and deliverables, establish schedules, and coordinate with other disciplines during BID, FEED, Basic Engineering, and Detailed Engineering phases in accordance with contractual requirements.
13. Manage the Process Engineering team, define deliverables, review process calculations, equipment datasheets, line lists, utility summaries, and material/energy balances, and ensure timely completion.
14. Act as an effective Team Leader/Team Player and provide technical direction, mentoring, and training to Process Engineers and Designers.
15. Manage preparation and review of Process Datasheets, Equipment Datasheets, Utility Summaries, Instrument Data, Process Requisitions, Technical Bid Evaluations (TBE), and Vendor Document Reviews related to process engineering.
16. Ensure proper workflow, interdisciplinary interfaces, technical reviews, quality checks, document control, and approval of Process Engineering deliverables.
17. Monitor and control Process Engineering progress, productivity, man-hour budgets, resource loading, and project schedules.
18. Support project management in identifying and managing changes, deviations, technical clarifications, and potential variations to the contract scope.
19. Coordinate with process licensors, vendors, contractors, suppliers, and technology providers to ensure compliance with project requirements and timely resolution of technical issues.
20. Participate in Client, PMC, Process Licensor, Engineering Subcontractor, Vendor, HAZOP/HAZID, SIL/PHA, and other internal and external stakeholder meetings.
21. Lead and/or participate in HAZOP, HAZID, SIL/LOPA, PHA, Design Reviews, Operability Reviews, and other process safety studies, as applicable to the project.
22. Review and provide technical input for statutory and regulatory approvals, including process-related documentation and submissions to relevant authorities.
23. Support commissioning, start-up, performance testing, site engineering, inspections, troubleshooting, and technical queries related to process systems, as required.
24. Further develop and strengthen the Process Engineering department, including development of engineering procedures, standards, templates, tools, and technical competencies to support business objectives.

Additional Skills & Competencies

1. Strong knowledge of process engineering principles, process design, process simulation, heat and material balance, fluid flow, thermodynamics, and equipment sizing.
2. Proficiency in relevant process codes, standards, engineering practices, client specifications, and statutory/regulatory requirements applicable to Oil & Gas, Refinery, Petrochemical, Chemical, Fertilizer, and Energy projects.
3. Strong experience in preparation and review of PFDs, P&IDs, HMBs, Process Design Basis, Process Datasheets, Equipment Datasheets, Line Lists, Utility Summaries, and Process Calculations.
4. Good knowledge of process hydraulics, pump/compressor selection, control valve sizing, PSV sizing, relief and flare systems, utility systems, and equipment sizing.
5. Experience with process simulation and engineering software such as Aspen HYSYS/Aspen Plus, UniSim, PRO/II, PIPE-FLO, PIPENET, Flarenet, or equivalent.
6. Strong understanding of process safety engineering, including HAZOP, HAZID, SIL/LOPA, relief system design, hazardous area considerations, and inherently safer design principles.
7. Strong leadership and team-management skills, with the ability to guide, mentor, and develop Process Engineers and Designers.
8. Ability to independently review engineering deliverables, identify technical issues, provide practical solutions, and take technical decisions within the project requirements.
9. Excellent communication, presentation, coordination, and stakeholder-management skills.
10. Strong analytical and problem-solving capability with high attention to technical accuracy, quality, schedule, and cost.
11. Ability to coordinate effectively with Clients, PMC, Licensors, Vendors, Contractors, and multidisciplinary engineering teams.
12. Knowledge of QEHS requirements, process safety standards, environmental regulations, and industry best practices.
13. Ability to work under project deadlines and manage multiple projects/priorities with minimum supervision.
14. Adaptability and willingness to adopt digital engineering, process simulation, automation, data analytics, and other emerging engineering technologies.
15. Experience in EPC/EPCM projects from conceptual/BID stage through FEED, detailed engineering, procurement, construction, commissioning, and start-up will be an added advantage.