Mechanical Engineer — Pyrolysis Plant

Engineering / Maintenance — Pyrolysis Operations

Job ID: 20260820

Open Positions

8–10 years

Shadnagar , Hyderabad

Position Summary

The Mechanical Engineer is responsible for the safe, reliable and efficient mechanical operation and maintenance of the pyrolysis plant, including the feeding system, main reactor, catalytic tower, hot-air heating system, oil condensing system, carbon-char discharging system, distillation section, and associated utilities (cooling water, nitrogen, instrument air, raw water and effluent handling).

The role covers planned preventive maintenance, breakdown response, reliability improvement, spare-parts management, vendor coordination, and active participation in turnarounds, commissioning, and incident investigations. The position works closely with Operations, HSE, Electrical, Instrumentation and Process Engineering teams.

Key Responsibilities

Maintenance and Reliability

Plan, schedule and execute preventive, predictive and breakdown maintenance for all mechanical equipment — rotary kiln / reactor, screw conveyors, catalytic towers, condensers, heat exchangers, pumps, blowers, compressors, storage tanks and piping.
Maintain reliability of critical rotating equipment including oil transfer pumps, residue transfer pumps, ID/FD blowers, root blower, screw air compressors and water-jet vacuum pump.
Develop and update equipment maintenance strategies, criticality assessments and spare-parts catalogues.
Drive root-cause analysis (RCA) for repeat failures, vibration issues, seal leaks, mechanical-seal failures, bearing failures and shaft-alignment problems.
Monitor equipment condition through vibration analysis, thermography, oil analysis, ultrasonic testing and visual inspection.
Maintain mechanical integrity of high-temperature equipment (reactor at 400–450 °C, combustion chamber at 750 °C, hot-air preheater) including refractory, insulation and expansion-joint inspections.
Manage mechanical performance of the pyrolysis reactor including reactor rotation drive, seals, internals, jacket integrity and feed/discharge mechanisms.
Maintain reverse-screw and spiral slag (carbon-char) discharge system across the four cooling stages, ensuring no choking, leakage or seal failure at the sealed feed silo and sealed carbon silo.
Oversee oil condensing train (primary and secondary condensers, shell-and-tube heat exchangers) including tube cleaning, gasket replacement, leak testing and fouling control.
Support distillation section operations — main furnace, catalytic tower, fractionation, oil tanks, residue transfer.
Maintain combustion chamber, burners and dual-fuel changeover (LDO / PyGas) systems including burner overhauls, fuel-train integrity and refractory inspections.
Ensure mechanical integrity of nitrogen-blanketed storage tanks (PyOil, LDO) including PVRVs, flame arrestors, emergency relief vents, earthing jumpers and rupture-disc / burst-sensor assemblies (e.g. decanter 1V1401).
Coordinate hydrostatic tests, pneumatic tests, NDT (RT, UT, MPI, DPT) on pressure parts and piping.
Participate in pre-commissioning, commissioning and performance-guarantee runs of new equipment including OEM-supplied packages (nitrogen generator, air compressors, dryers, condensers, cooling towers).
Comply with all site HSE rules; ensure all mechanical work is performed under valid permits (work-at-height, hot work, confined-space entry, LOTO).
Enforce Lockout-Tagout (LOTO) procedures on all rotating, pressurised and energised equipment before mechanical intervention.

Documentation and Reporting

Maintain equipment history cards, maintenance logs, breakdown records, lubrication schedules and shutdown reports.
Maintain mechanical drawings, GA drawings, P&IDs, datasheets, isometrics and Bill of Materials in current revision.
Generate daily / weekly / monthly maintenance KPIs — MTBF, MTTR, equipment availability, planned vs. breakdown ratio, maintenance cost per tonne.

Qualification and Experience:

Education

Bachelor’s Degree (B.E. / B.Tech.) in Mechanical Engineering from a recognised university. Diploma in Mechanical Engineering with more than 5 Years of relevant experience.
Desirable: Postgraduate qualification in Maintenance Engineering, Reliability Engineering, Energy Management or Project Management.

Experience

Engineer : 2–5 years of mechanical maintenance / operations experience in a continuous process plant — pyrolysis, petrochemical, refinery, chemical, fertiliser, cement, power or similar hydrocarbon-handling industry.
Hands-on experience with mechanical-seal pumps, screw conveyors, blowers, compressors, heat exchangers, fired heaters and pressure vessels is essential.
Exposure to commissioning of a green-field or brown-field plant is highly desirable.

Technical Knowledge

Sound understanding of pyrolysis / thermal-cracking process flow, equipment behaviour and failure modes.
Reading and interpretation of P&IDs, GA drawings, isometrics, datasheets, vendor manuals and welding procedure specifications (WPS / PQR).
Working knowledge of relevant codes and standards — ASME Section VIII, ASME B31.3, API 610, API 682, API 650 / 620, TEMA, IBR, OISD-STD-117, NFPA 30.
Familiarity with mechanical-seal selection (API 682 plans), pump seal-pot operation, nitrogen blanketing and PVRV / flame-arrestor selection.
Knowledge of refractory linings, ceramic-fibre insulation, expansion joints and high-temperature gasket selection.
Working knowledge of CMMS / EAM tools (SAP PM, Maximo, or similar) for work-order management.
Familiarity with DCS / interlock logic from a maintenance interface perspective is desirable.