Job description for a senior process engineer in oil refining?

I. Core Responsibilities — Senior Process Engineer (Oil Refining)

• I.1 Process monitoring and optimization: Lead daily technical stewardship of assigned units (e.g., crude/vacuum, hydrotreating, reforming, FCC, hydrocracking, sulfur recovery). Track KPIs (throughput, yields, energy intensity, hydrogen balance, product qualities) and optimize against planning targets and constraints using reconciled data and rigorous models. Key balances: mass: \( \sum \dot{m}_{in} = \sum \dot{m}_{out} + \frac{dM}{dt} \); energy: \( \dot{Q} + \sum \dot{m} h = \frac{dU}{dt} + \dot{W} \).

• I.2 Troubleshooting and debottlenecking: Diagnose bottlenecks (hydraulics, heat transfer, reaction kinetics, fouling, coking) and execute quick-win adjustments and medium-term modifications. Typical checks: heat duty \( \dot{Q} = \dot{m} C_p \Delta T \); exchanger rating \( \dot{Q} = U A \Delta T_{lm} \); pressure drop \( \Delta P = f \frac{L}{D} \frac{\rho v^2}{2} \); flow regime via \( \mathrm{Re} = \frac{\rho v D}{\mu} \).

• I.3 Process design and revamps: Produce/design check process deliverables (PFDs, P&IDs, H&MBs, equipment datasheets, line hydraulics, PSV sizing, control narratives) for brownfield revamps and capital projects; ensure design basis aligns with crude/product slate and margin drivers. Distillation quick estimates: Fenske \( N_{min} = \frac{\ln\left(\frac{x_D/(1-x_D)}{x_B/(1-x_B)}\right)}{\ln(\alpha_{avg})} \); VLE (ideal): \( y_i P = x_i P_i^{sat}(T) \).

• I.4 Safety, risk, and compliance (PSM): Own process safety fundamentals for units: perform/lead HAZOP, LOPA, SIL verifications, relief and flare system calculations, MOC technical reviews, safeguard validation, and operating envelope stewardship. Typical relief sizing form (vapor): \( A = \frac{\dot{W}}{C K_d P_1 K_b K_c \sqrt{\frac{T Z}{M}}} \) [symbols per applicable codes; unit-consistent].

• I.5 Startups, shutdowns, and turnarounds: Develop procedures, define readiness criteria, staff field/console support, and lead technical troubleshooting during heat-up, catalyst sulfiding/activation, and ramp-up. Define TA scope (cleaning, bundle pulls, tray/cat change-out) and post-TA performance tests.

• I.6 Advanced controls and automation enablement: Define control strategies, multivariable APC constraints/objectives, inferentials, soft sensors; partner with controls specialists to commission and sustain APC benefits and alarm rationalization.

• I.7 Energy and emissions performance: Drive fuel, steam, and power optimization; manage furnace excess O2 and draft, preheat trains, condensate recovery, and flare minimization. Track EIIs and unit OPEX; quantify abatement projects (e.g., waste heat recovery, heat-integration pinch). Combustion efficiency: \( \eta \approx 1 - \frac{\text{stack losses}}{\text{fuel LHV}} \).

• I.8 Catalyst and reactor stewardship: Monitor activity/selectivity/run length, deactivation rates, poison loading, delta-P; recommend cycle length, regeneration/change-out timing, and operating severity windows based on kinetic models and test runs.

• I.9 Quality assurance and product blending: Resolve off-spec incidents, adjust cutpoints and hydrogen severity, maintain product pool qualities (RVP, sulfur, octane/ cetane). Support blend models and giveaway minimization within specs.

• I.10 Documentation and training: Maintain operating envelopes, normal/abnormal operating procedures, and unit health reports; mentor junior engineers and coach operations on best practices.

II. Required Technical Skills, Soft Skills, and Physical Demands

II.A Technical skills

• II.1 Refinery unit expertise: Deep know-how in at least two major units (e.g., FCC/hydrocracker/hydrotreater/reformer/crude-vacuum/amine–sulfur/SWS), with working knowledge across the complex and utilities/offsites.

• II.2 Process modeling: Steady-state and dynamic simulation, rigorous column/reactor models, heat exchanger rating, hydraulic networks, relief/flare calculations, and data reconciliation.

• II.3 Controls and instrumentation: PID tuning concepts, APC constraint management, inferential development, alarm management, and interlock/safeguard logic understanding.

• II.4 Codes and standards: Familiarity with applicable refinery standards for pressure relief, piping, fired equipment, and process safety management requirements.

• II.5 Data and analytics: Time-series analysis, mass/energy closure, regression, M&V of benefits, and uncertainty treatment.

II.B Soft skills

• II.6 Operational leadership: Lead cross-shift decision-making, balance safety/operability/economics, and drive consensus under time pressure.

• II.7 Communication: Clear, concise shift notes, technical reports, and field/console briefings; translate complex trade-offs for non-specialists.

• II.8 Risk-based thinking: Prioritize by risk and value; apply bow-tie thinking, causal analysis, and barrier health concepts.

• II.9 Mentoring: Coach less-experienced engineers and operators; lead knowledge capture and lessons learned.

II.C Physical demands

• II.10 Field presence: Regular unit walkdowns; climb towers/ladders up to 50–80 m; work around heat, noise, rotating equipment, and elevated platforms.

• II.11 PPE and fitness: Wear FR clothing, hard hat, gloves, eye/hearing protection; respirator use and fit testing; ability to work in high ambient temperatures near furnaces and during turnarounds.

• II.12 Emergency response support: Participate in drills and provide technical support during abnormal situations.

III. Typical Tools, Software, and Equipment

• III.1 Process simulators: Industry-standard steady-state/dynamic simulators for refinery units; reactor/column and thermodynamics packages; property methods selection and VLE modeling.

• III.2 Heat exchanger and networks: Thermal rating and network pinch tools; fouling assessment and cleaning optimization.

• III.3 Data systems: Plant historians, laboratory information systems, DCS/SCADA HMIs, advanced control suites, and analytics dashboards.

• III.4 Engineering design tools: CAD/CAE for PFDs/P&IDs, instrument databases, hydraulic calculators, PSV/flare network tools.

• III.5 Field instruments: Portable gas analyzers, IR thermometers/thermal cameras, ultrasonic flow/level thickness gauges, explosion-proof cameras, sample cylinders, digital manometers.

IV. Work Environment

• IV.1 Location: Onshore refinery complex; mix of control room, office, and field work within process units and offsites.

• IV.2 Schedule: Typically weekday day-shift; after-hours/weekend call-outs for upsets, startups, and turnarounds; extended shifts during TAs and major commissioning.

• IV.3 Travel: Occasional travel to engineering offices, labs, offsite terminals, or OEM shops for inspections and FAT/SAT.

• IV.4 Conditions: Exposure to hydrocarbons, H2S, steam, hot surfaces, and noisy environments; strict adherence to safe work permits and unit entry protocols.

V. Reporting Lines and Cross-Functional Interfaces

• V.1 Reporting line: Reports to Process Engineering Manager or Refinery Technical/Technology Manager.

• V.2 Internal interfaces: Operations (console/field), Maintenance, Inspection/RBI, Reliability, Projects/Capital, Planning & Economics, Laboratory, HSSE, Turnaround, Instrumentation/Controls, Utilities/Power.

• V.3 External interfaces: Engineering contractors, catalyst/chemical technical support, equipment suppliers, testing/inspection service providers, and regulatory authorities as required.

VI. Career Ladder and Progression

• VI.1 Next roles: Lead Process Engineer, Process Engineering Supervisor, Unit Technology Lead, Principal/Consulting Process Engineer, Technical/Technology Manager, or Operations Superintendent for assigned units.

• VI.2 What it takes to move up: Proven delivery of multi-million-dollar optimizations and debottlenecks, leadership of HAZOP/LOPA and MOC portfolios, successful APC deployments, turnaround readiness/execution leadership, high-quality process designs for revamps, and strong mentoring impact.

• VI.3 Professional credentials: Relevant professional licensure/charter and advanced certifications in process safety and controls are valued (estimated).