Meet Process Engineer Abhishek Sharma

Welcome to the latest in a series of AIChE blog posts profiling process engineers, a diverse group of professionals spanning multiple industries and regions. In this series, we profile process engineers who work in a wide range of fields, including petrochemicals, pharma, bulk chemicals, food, or any process-intensive industry.

Are you a member and process engineer interested in being profiled? We’d love to hear from you via this volunteer opportunity. Please also check out our online discussion group specifically for process engineers. You can find out about these initiatives and join our efforts by visiting https://www.aiche.org/processengineering.

This month, we introduce you to Abhishek Sharma, who works as an engineer at HPCL-Mittal Energy Ltd. He discusses his passion for process engineering, overcoming challenges, and the importance of his work.

Tell us a bit about your work as a process engineer.

Currently, I work as an engineer at HPCL-Mittal Energy Ltd. I make sure the process plant runs smoothly, economically, efficiently, and safely at maximum production rate. My plant is currenlty in the construction phase, but will soon enter start-up.

To make this happen, I meticulously review the drawings and datasheets of the equipment, including the distillation column, heat exchangers, and process vessels. Additionally, I carefully check the controlling of the DCS (PLC logic and actions of P&ID controllers along with tuning) and PLC. I also prepare the standard operating procedures that help the operators to commission the plant safely. Lastly, I review the P&ID, and perform the hazard identification of the plant.

Learning from your own experience is good but learning from the mistakes of others is wise. It will help to avoid any perilous event before it happens.

Why did you become a process engineer?

I wanted to become a doctor since childhood but my father’s dream was that I become an engineer. I chose chemical engineering to make my father’s dream come true while also fulfilling mine. As a process engineer, I can scrutinize processes and inspect the process equipment to find any ailment or issue. Once the problem is identified, I treat and correct it economically – just as a doctor would treat and heal his patients. This is called troubleshooting, which is necessary in order to run the process plant smoothly and efficiently.

What are some of the biggest challenges you face in your role as a process engineer?

It was a delight to become part of one of the biggest ethylene plants yet in India. Theoretical knowledge will only give us an understanding, but a practical approach will enhance how you analyze different chemical engineering concepts. Being a part of a grassroots unit provided me with an opportunity to review technical documents as a part of my job role.

During my tenure, I came across many challenges that I took on and found efficient solutions for most concerns in my area.

Listed below are examples of some of the challenges I faced:

1. Line hydraulics were altered based on pressure drop calcuations in order to route material to appropriate locations.
2. DEC had provided elevations for equipment, and the same information had also been cross-checked with respect to NPSH calculations. A few vessels, however, were found to be incorrectly placed, so I resolved the issue with DEC.
3. Controlling issues were rectified thanks to discussions with the licensor during the DCS system configuration.
4. Controller tuning challenges: I helped engineers better understand the hazard and speed of reaction for most controls.

What aspect of your work as a process engineer is most critical to your particular job assignment or industry?

As a project process engineer, certain things need to be addressed vigilantly and effectively for the industry. These include making sure critical activities are carried out, such as environmental clearances with respect to air, water, and concerned approvals required at the district level. As a PSM lead, I must ensure that everything is upheld and adhered to throughout the complex. This includes permit audits, standard operating procedures, and process safety.

It is also critical that I efficiently perform equipment inspections and piping checks in order to avoid any catastrophic incident during plant start-up. I also must prepare SOPs for smooth commissioning. Timely review of all technical documents is crucial to ensure that any changes made will be carried out in earlier stages. This is done in order to avoid a delay in the commissioning schedule.

What do you think is most important about what you do as a process engineer?

I have made a bridge between academic knowledge (chemical engineering) and process industries. This is the best way to fly over any issues or troubles you may encounter. I have learned a lot from many case studies of the distillation column, compressor, and furnace from experienced seniors. Learning from your own experience is good but learning from the mistakes of others is wise. It will help to avoid any perilous event before it happens. I have inspected the distillation columns, tray, and exchangers. I have implemented all the lessons I learned from other plants related to the safety of the plant as well as the safety of the people within the plant.

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