Project/Process Engineer III (BSChE)

GMM Pfaudler Systems Sr. Process/Project Engineer Job Description SUMMARY OF BUSINESS & POSITION GMM Pfaudler US Inc. is a leading supplier of highly engineered, critical equipment and process systems for energy, chemical and industrial markets. The Systems Group within GMM Pfaudler designs and fabricates complete modular process systems including Reactor Systems, Wiped Film Evaporator (WFE) Systems, Distillation Systems, and other special process design systems. Pfaudler is seeking an experienced chemical process engineer to fill the position of Sr. Process Project Engineer (SrPE) 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 SrPE’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. DETAILED DUTIES AND RESPONSIBILITIES Essential duties for the SrPE position are listed below. The duties may be modified and/or other duties may be assigned, as necessary. For small projects, the SrPE performs all the typical process and project engineering activities required for the successful execution of the project plus the project management responsibilities. For middle-to-large sized projects, the SrPE manages the project and also reviews/approves the work done by other support Project Engineers (PE) assigned to the project. Typical project 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. Project Management Activities Schedule and participate in internal and customer project meetings, model reviews, hazard reviews, etc. and generate meeting reports. Maintain the Technical Query Register (TQR) which is the project open issue list. Maintain the project schedule and ensure all project activities are completed on time to ensure the project is complete on time. Execute customer and vendor document transmittals, review customer specifications, maintain project files, etc. Define, cost estimate and implement customer change requests and project change orders. Complete post project reviews for knowledge of process design changes or system improvements and leverage this knowledge for future proposals and orders. 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 work completed by other supporting Project Engineers for the project and 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 (