Process Engineer at Sappi

Job description:

Sappi Saiccor Mill requires a Process Engineer who will be responsible for reviewing the effectiveness of processes in single plants in the operation from end to end and design process improvements to ensure higher production, less waste and improved consistency of quality standards for specific product lines.

This role reports to the Senior Process Engineer.

The main responsibilities of this job are:

• Ensure that all Piping and Instrumentation Documentation, Process Flow diagrams and Mass and Energy Balances for the area are kept updated, published and communicated to all impacted parties in the process.
• Update product specifications for the area and ensure that it’s communicated to the plant personnel.
• Review start-up procedures, shut-down procedures, best-operating practices and training manuals prepared by process technicians. Coach them on the quality improvements required and sign them off.
• Review results of daily process audit performed by process technicians (Once per Month). Identify patterns that could indicate opportunities to improve processes going forward. Develop recommendations on which areas should be investigated further.
• Conduct detailed root cause analysis by gathering input from multiple sources including alarm data, production floor operators, managers and technical reports. Ensure that documentation is updated and approved.
• Develop high-level process designs for single plants based on the priorities defined in the projects list for the mill or as assigned by technical managers. Ensure that engineering standards are met in all aspects.
• Provide process input into pre-feasibility studies with a focus on technical parameters and testing assumptions that are put forward by project teams.
• Participate in feasibility studies by developing draft processes and providing technical advice.
• Develop detailed process designs for specific processes in one or more parts of the production facility. This includes mass and energy balances, valve sizing and tuning, pump sizing and other technical specifications designed to make processes more efficient.
• Lead design review meetings by collaborating with other process engineers to conduct peer reviews of new designs. Run through design details to determine if the design elements are complete, controls are adequate and if they are likely to achieve the improvements that were scoped.
• Present own designs to colleagues for their input and review. Review longer-term control strategies and advanced control opportunities. Ensure measurement and mass and energy balance accuracy.
• Create an understanding of environmental standards and engineer improvements with current and future legislative requirements in mind.
• Lead risk studies (Structured What If Technique – SWIFT, Hazard and Operability Study – HAZOP) for the plant.
• Review detailed designs prepared by other process engineers from a control effectiveness point of view. Provide input to colleagues on areas of improvement. Present own designs to colleagues for their input and review. Review longer-term control strategies and advanced control opportunities. Ensure measurement and mass and energy balance accuracy.
• Work with production teams to create simulations or test environments. Closely monitor the outcomes of the tests. Update process designs based on test results and obtain new approvals for updated processes.
• Determine the impact of the process changes on people, processes and systems in place in the plant. Develop actions to address the changes. Work closely with project managers to draw in support from other areas (for example Sappi Learning if there is training required).
• Work closely with project managers to scope out the change management actions, determine the stakeholders and contribute to the development of communication and training materials.
• Oversee the commissioning of new equipment or changed processes. Provide the subject matter expert input into the drafting of training material and work with learning teams to develop learner guides and assessments.
• Work with project managers throughout the implementation of the new processes to obtain feedback on successes and risks. Adjust process designs if required. Measure the outcome of the process changes to determine if the efficiency improvements have been achieved.

The ideal candidate should have:

• Degree or BTech in Chemical Engineering with pulp and paper experience
• 3 - 5 years of process experience in a heavy manufacturing environment