The document outlines the vital role of process engineers throughout the project life cycle, emphasizing their responsibilities in the phases of engineering, construction, operation, and maintenance. It discusses their involvement in key activities such as feasibility studies, technology selection, equipment design, and plant commissioning. Additionally, it highlights the importance of research and development for continuous improvement in efficiency and innovation within the industry.

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