Principal Engineer – Mechanical Design

Job Description: Principal Engineer – Mechanical Design Engineering

Reporting To Head – Engineering

Position Summary

The Principal Engineer - Mechanical Design Engineering is responsible for leading the mechanical design, development, analysis, and optimization of Tubular Reactors (Plug Flow Reactors - PFR) used in chemical, petrochemical, fertilizer, refining, and specialty process industries. The role provides technical leadership across the complete equipment lifecycle, including concept design, detailed engineering, manufacturing support, installation, commissioning, troubleshooting, and continuous improvement.

Key Roles & Responsibilities

Mechanical Design & Engineering

• Lead the mechanical design and development of Tubular Reactors and Plug Flow Reactor (PFR) systems.
  
• Prepare and review equipment specifications, datasheets, engineering calculations, and fabrication drawings.
  
• Design high-pressures and high-temperature reactor components in compliance with applicable design codes and standards.
  
• Perform mechanical calculations related to:
  
• Internal and external pressure
  
• Thermal expansion
  
• Stress analysis
  
• Fatigue analysis
  
• Creep assessment
  
• Structural integrity
  
• Optimize designs for safety, reliability, manufacturability, and cost-effectiveness.
  

• Evaluate reactor performance under severe operating conditions involving high pressures and temperatures.
  
• Analyze flow distribution, pressure drop, thermal gradients, and heat transfer characteristics.
  
• Ensure reactor designs meet process requirements and performance guarantees.
  

Mechanical Integrity & Stress Analysis

• Conduct detailed stress analysis of reactor components.
  
• Perform Finite Element Analysis (FEA) for critical equipment.
  
• Evaluate thermal stresses caused by process and startup/shutdown conditions.
  
• Assess fatigue life, creep behavior, and equipment durability.
  
• Support Fitness-for-Service (FFS) and remaining life assessments.
  

Materials Engineering

• Select suitable materials for:
  
• High-temperature service
  
• Corrosive environments
  
• Hydrogen service
  
• High-pressure applications
  
• Review material specifications and metallurgy requirements.
  
• Investigate material failures and recommend corrective measures.
  
• Work closely with metallurgists on material upgrades and qualification activities.
  

Process & Multidisciplinary Coordination

• Collaborate with Process Engineering teams to:
  
• Understand process requirements
  
• Review operating conditions
  
• Evaluate reaction kinetics impacts
  
• Optimize reactor performance
  
• Coordinate with:
  
• Piping Engineering
  
• Structural Engineering
  
• Instrumentation & Controls
  
• Project Engineering
  
• Manufacturing Teams
  

Vendor & Manufacturing Support

• Review vendor proposals and technical submissions.
  
• Participate in supplier qualification and technical evaluations.
  
• Support procurement activities involving reactor systems and critical components.
  
• Review fabrication procedures, welding specifications, and inspection plans.
  
• Resolve manufacturing and fabrication-related technical issues.
  

Quality, Inspection & Compliance

• Ensure compliance with:
  
• ASME Section VIII
  
• ASME B31.3
  
• API Standards
  
• PED Requirements
  
• Company Engineering Standards
  
• Review inspection and testing requirements.
  
• Support Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT).
  
• Ensure quality standards are maintained throughout project execution.
  

Commissioning & Plant Support

• Provide engineering support during:
  
• Installation
  
• Pre-commissioning
  
• Commissioning
  
• Startup
  
• Troubleshoot reactor operational issues including:
  
• Tube failures
  
• Hot spots
  
• Excessive pressure drop
  
• Mechanical distortions
  
• Thermal stress problems
  
• Conduct Root Cause Failure Analysis (RCFA).
  

 Innovation & Continuous Improvement

• Lead design improvement initiatives for enhanced reactor performance and reliability.
  
• Evaluate emerging reactor technologies and advanced materials.
  
• Support R&D activities for new process applications.
  
• Develop engineering standards, design practices, and lessons learned documentation.
  

Leadership Responsibilities

• Act as Subject Matter Expert (SME) for Tubular Reactor and PFR technologies.
  
• Mentor and guide mechanical design engineers.
  
• Review and approve critical engineering deliverables.
  
• Lead technical reviews and client engineering discussions.
  
• Support business development activities by providing technical expertise during proposal and bid stages.
  

Experience

• 6+ years of experience in Mechanical Design Engineering.
  
• Minimum 6-7 years of specialized experience in:
  
• Tubular Reactors
  
• Plug Flow Reactors (PFR)
  
• High-pressure process equipment
  
• Chemical, Petrochemical, Fertilizer, or Refining Industries
  

Technical Skills

Engineering Software

• AutoCAD
  
• SolidWorks
  

Design & Analysis

• Pressure Vessel Design
  
• Thermal Analysis
  
• FEA & Stress Analysis
  
• Fatigue and Creep Assessment
  
• Mechanical Integrity Evaluation
  
• Weld Design & Fabrication Engineering