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.
Requirements
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
Benefits
Best In the Industry

Work arrangement
No