Process/Project Engineer

Job Description

SUMMARY OF POSITION

Pfaudler is seeking an experienced chemical process engineer to fill the position of Process/Project Engineer (PE) in the Systems Group located at GMM Pfaudler in Rochester, NY.

Every process system that our Systems Group designs is custom-designed for each client's specific needs. We work with a broad range of processes for many different industries including Specialty Chemicals, Pharmaceuticals, Nutraceuticals, Petrochemicals, Polymers, and others. Our clients rely on our Systems Group to design complete chemical process systems for their new products and for their capacity expansions of existing processes or products. For the new product systems that we design, we take the client's pilot test data, or our own pilot test data, and scale up to design commercial scale production systems. For the systems that we design for client capacity expansions, our clients rely on our Systems Group to evaluate their existing processes and improve the designs for increased capacity, improved quality and ease of operation.

The high-level summary of the PE's responsibilities: 1) develop the chemical process system design, 2) engineer the equipment, instrumentation and piping systems required for the process, 3) project engineering responsibilities of specifying and procuring the various components of the system, 4) work with the CAD Design Group to develop the detailed layout and drawings of the system, 5) manage the construction of the modular process system and 6) field commission the processing systems at our clients' facilities.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Essential duties include those listed below. The duties may be modified and/or other duties may be assigned, as necessary.

For all projects, the PE supports the Project Manager and/or Senior Process/Project engineers and performs typical process/project engineering activities for the successful execution of projects. Activities include but are not limited to the following:

Process Engineering Activities

• Work with the customer representatives and Systems Application Engineers to define the project requirements such as applicable standards, regulations, and physical and process requirements to establish a Project Basis of Design.
• Develop Process Flow Diagrams (PFDs). Complete Mass & Energy Balance (MEB) calculations along with required utilities calculations (temperatures, pressures and flowrates) and tabulate results in an MEB. Guide a CAD Designer to develop the drawing(s).
• Develop Piping and Instrumentation Diagram(s) (P&IDs) for the process. Guide a CAD Designer to develop the drawing(s).
• Define/size the equipment required for the process, such as heat exchangers, evaporators, tanks, reactors, pumps, vacuum equipment, etc.
• Define the instrumentation required for the process, such as sensors, transmitters, gauges, switches, control valves and other final control elements, to measure/control temperature, pressure, flow, etc.
• Define/size the piping items required for the process, such as piping, valves, fittings strainers, expansion bellows, flex hoses, etc.
• Participate in customer Process Hazard Analysis (PHA or HAZOP), via Teams meeting or by traveling to the customer site, to provide engineering support.
• Complete pressure relief scenario assumptions and complete pressure relief device (pressure relief valves and/or rupture disks) sizing calculations.
• Travel to the customer site after installation of the process system to provide startup and commissioning engineering support.
• Provide post start-up support to customers as needed.

Project Engineering Activities

• Participate in project meetings, model reviews, hazard reviews, etc. (both internal meetings and customer meetings).
• Work with the GMM Pfaudler Equipment Engineering Group and with Operations to ensure any GMM Pfaudler equipment (reactors, WFEs) for the project are correctly specified, designed, fabricated and completed on schedule.
• Specify and procure the equipment, instrumentation and piping items required for the process: Develop specification sheets, prepare bid specification packages, obtain competitive vendor bids, evaluate potential suppliers by completing technical reviews of the quotations, and then procure the items.
• Guide a CAD Designer to develop the project 3D model of the process system to ensure proper layout for the process as well as ergonomic layout for ease of operation and maintenance. Guide a CAD Designer to generate all project drawings (Equipment Layout Drawings, Structural Steel Drawings, Orthographic Drawings, Piping Isometric Drawings, Bills of Material, etc.) and complete detailed checks of all drawings.
• Prepare specification packages for the construction of the modular systems, obtain bids for fabrication of the systems, and then select a fabricator for the project.
• Prepare project Factory Acceptance Test (FAT) and, if necessary, Site Acceptance Test (SAT) documents.
• Prepare project system operating manuals that include: Basis of Design, Installation Instructions, Process Description, Description of Operation, Equipment Index, Instrument Index, Line List, Valve List, Tie-Point List, Lubrication Schedule, Spare Parts List and all manufacturers documentation for purchased components.

Construction Management Activities

• Travel to local facilities of equipment suppliers and module fabricators to monitor and inspect the fabrication and construction of equipment and modular systems to ensure compliance with all requirements, specifications and drawings. Review supplier documentation to ensure accuracy and compliance with requirements.
• Complete factory acceptance test (FAT) and ensure all punch-list deviations are corrected.

Other duties:

A PE may from time to time assist a Systems Application Engineer (AE) with customer inquiries. The responsibilities include, but are not limited to, the following: equipment sizing and costing, instrument sizing and costing, and system fabrication layout and cost estimating.

SUPERVISORY RESPONSIBILITIES

No direct supervision responsibilities. Monitor/approve fabrication and construction work completed by contractors/vendors.

TRAVEL

While most customer communications are through email, phone and online meetings, occasional travel to customer sites, travel to travel to vendor and or customer sites is also required. Travel requirements are light (
QUALIFICATIONS

Required Relevant Experience: Minimum of 3 years of experience with chemical process system design (heat transfer, fluid flow, mass transfer, etc.) including equipment design, instrument design/selection and piping system design. Project engineering and project management experience is considered a plus.

Must be a self-starter and independent worker; however, must also be a team player and focus on customer service.

Excellent communications skills required, both verbal and written, for team, vendor, contractor and customer communications.

Must have ability to read and interpret customer technical documents such as engineering specifications and drawings including Piping and Instrument Diagrams and Process Flow Diagrams.

Computer skills:

• Required
• Word, Excel and PowerPoint for general use.
• Preferred and considered a plus
• Aspen Plus (or similar) for process simulations
• Aspen Exchanger Design (or similar) for heat exchanger sizing
• Microsoft Project (or similar) for project scheduling

EDUCATION

A BS in Chemical Engineering is required.

LANGUAGE SKILLS

Must speak and write English proficiently. Must have the following communication skills:

• Must be able communicate effectively (listen and speak) for technical discussions with customers, to understand their needs and explain GMM Pfaudler designs. Must also communicate effectively for technical discussions with vendors and contractors to define and discuss GMM Pfaudler needs.
• Ability to write technically sound mechanical specifications and instructions.

MATHEMATICAL SKILLS

Must have the ability to complete basic process design calculations (e.g. mass or volumetric flow rates, mass transfer, pressure, temperature, unit conversions, etc.).

REASONING ABILITY

Must have ability to apply common sense understanding to carry out instructions furnished in written, oral, or diagram form. Must have ability to deal with typical project problems and troubleshoot to resolve issues.

CERTIFICATES, LICENSES, REGISTRATIONS

None

PHYSICAL DEMANDS

All requirements are subject to possible modification to reasonably accommodate individuals with disabilities. This job posting in no way states or implies that these are the only duties to be performed for this position. Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their supervisor. This document does not create an employment contract, implied or otherwise.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an employee will encounter while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Primarily the work environment is a typical office environment. The employee will also be required to enter the GMM Pfaudler or vendor workshop environments to track job progress, inspect equipment and system components and accompany customers during inspections. The employee may also be required to visit customer plant sites to view existing or proposed equipment installations and/or commission new process systems. The customer plant sites are typical chemical and pharmaceutical operating plant sites where the employee will be required to follow the plant site safety regulations.