ENHANCING YOUR TECHNICAL SKILLS

In a previous post entitled How to “Become a Good Chemical Engineer”, I listed 5 key steps. They were:

? Defining Success

? Developing Relational Skills

? Using Your Technical Training

? Enhancing Your Technical Skills

? Putting Safety First

My last post discussed “Using Your Technical Training”. This post deals with “Enhancing Your Technical Skills”. As I have reviewed my career and the people that I have been fortunate to be associated with, I have reached three conclusions:

? There is always something new to learn.

? Regardless of how much academic training one has or how much experience that one may have he/she will always be encountering projects that require new learning. 

? While Continuing Education is a vital part of being a good chemical engineer, there is no “one size fits all” approach. I can only write about what worked for me. 

Too often the individual challenged with lack of knowledge in a technical skill reacts by suggesting that management should get someone trained in the required technical skills. This reaction is evident in statements such as “I am not a mechanical engineer”, “You need an advanced chemistry degree for that”, or “That is above my pay scale”. While there are times, when an expert should be utilized, these challenges should always be viewed as opportunities to expand one’s technical skills. This expansion of technical skills can be done by learning from an expert and also by individual action to acquire the new skill -learn by doing or learn by studying. An example of this is the application of thermodynamics to compression. Academic training is generally limited to consideration of compression as either being isothermal or adiabatic. In a real-world scenario, compression is neither. For example, most compressors are either cooled by a jacketed cylinder or lose heat to the atmosphere. In these industrial scenarios, compression is referred to as “polytropic compression”.

The knowledge of polytropic compression can be achieved by multiple approaches such as:

? Discussions with an equipment engineer that can explain the differences between polytropic and adiabatic compression.

? Literature references-A Goggle search is a sure way to gain knowledge on almost any subject. A search on “polytropic compression” produced over 200,000 articles.

? Once one obtains a basic knowledge of polytropic compression, a whole new field becomes apparent. The general field of how does the compression work opens up a need for more knowledge. Take the case of a polytropic compression with a reciprocating displacement type of compressor. One needs to know the meaning of polytropic efficiency and how to use this variable. Polytropic efficiency can be measured by the absolute suction and discharge temperatures. Knowing this efficiency (generally provided by the compressor supplier) and the suction temperature, the design engineer can estimate the outlet temperature The chemical engineer working in a plant environment can determine the operating efficiency knowing the suction and discharge temperatures. In addition to being able to estimate polytropic efficiency, a chemical engineer in this position, needs to understand the terms of compression – ribbon valves, double acting compression or cylinder displacement. While these are mechanical details, it is often a chemical engineer that must determine if a compressor needs to be shut down for repairs.

Another type of learning is associated with a new technology. Often a chemical engineer will find that he/she is assigned to a technology that he/she is not familiar with. This might be in the role of an engineer in the plant, in a design team or in a research project. How does one learn this new technology or to what degree does he/she have to learn it to be able to make a contribution? In order to make a contribution the following must be learned:

? The chemistry – The amount of time that one must take to master this phase of learning obviously depends on the complexity of the process. This can range from simple storage facilities to production of pharmaceuticals. Recent safety events in India illustrate the need to understand the chemistry of simple storage facilities. Many times, this material is covered in a technology manual. Most new technologies whether they represent in-house development or licensed technology will have a technology manual. This will have a discussion of the chemistry, process correlations, and a heat and material balance. An in-depth review of these documents especially the heat and material balance is mandatory in learning new technology.

? The equipment – Again this need can cover the entire spectrum of operations and design. This is often the area where inexperienced engineers need to spend the most time. For example, when considering a fractionation column, fractionation simulations must be understood. In addition, analysis of poor operation requires detailed knowledge of tray dynamics, or line sizing for a thermo-siphon reboiler. These are some of the areas that might require additional study. A similar list could be developed for reactors, centrifuges, and the large number of equipment pieces used in the process industry. 

? The procedures – One of the best sources of information that can be used to develop understanding of new technology is the operating, startup and shutdown procedures that are written for the operation of the technology. These procedures can be studied while asking the question – Why is it done this way? Answering this question will allow development of a great deal of hidden know-how.

Another type of learning is associated with new calculation techniques – Chemical engineers at all phases of their careers will encounter a need to develop or utilize new calculation techniques. These new techniques can occur in two ways. They may come as a software package with minimal or complicated explanation or they may occur because there is a need to develop a new technique that may not be available as a reasonable priced package. Examples of these needs are pneumatic conveying of solids, two phase flow, or removing of volatiles from a solid. Whether one is using a new software package or developing a new calculation technique, it is mandatory that one understands the technical basis for the program. For example, a retail software program for two phase flow of gas and liquid utilizes the Lockhart-Martinelli expression for determining pressure drop and flow regime. This approach is described in the literature and should be thoroughly understood before using the program. In a similar fashion, the stripping of volatiles from a polymer is often modelled using an available flash program with polymer simulated as the heaviest component in the data base. This is a risky technique since the removal of the volatile from the polymer will often require residence time to approach equilibrium. In addition, there maybe polymer-volatile interaction that reduces the effective vapor pressure of the volatile. 

It is also important to keep up with new developments in your field of expertise. This might involve chemistry, engineering, safety or whatever field one is active or interested in. The question is – How does one do this? There are several sources such as:

? Courses in academic settings – Even before the current pandemic, on-line classes allowed for enhanced training with skilled instructors without having to commute. Many of these courses are available On-Demand and would be available to fit the participant’s schedule.

? Free Webinars – While these courses are not usually part of a planned program to obtain an advanced degree and often have a component of marketing, they can provide valuable information. They will often provide information on niche areas such as dust explosions or static electricity.

? Literature – Both books and magazines provide valuable information that can enhance an engineer’s knowledge of his/her profession. The traditional literature searches have been greatly enhanced by the vast sources of information available on the internet.

? Short concentrated courses – Courses that are presented in a full-time environment for a short time (4-5 days) can be a source of valuable specialized material. These courses might deal with such specialized areas as pneumatic conveying, gas phase reactors, or spray drying. These courses can be presented in several different modes – at a training center, as an in-house course or On-Demand.

Two final thoughts seem to be of value:

Regardless of how one is enhancing technical skills, these new skills are not fully incorporated until they are practiced. One can visualize this by considering these new skills like a new athletic move. They must be practiced multiple times until the application becomes “second nature”. The medical field is another example of practicing new learning. This practice can be done by different techniques such as:

? Performing a practice case with a software program.

? Doing a manual calculation to confirm the accuracy of a software program which will also allow understanding what are the important parameters. 

? Making a careful examination of the new learning to understand how it could be applied to your current job.

When considering enhancing skills, the question “Is this effort and cost worth it to me?” often occurs. To many that ask this question what they mean is “Will it increase my salary?” I have had the opportunity to examine these questions from both the management side and the engineering side. From the engineering side, it is my belief that while it may not increase one’s salary in the short range, it will “pay off” in the long range. In addition, there will be a greater sense of accomplishment that will be derived by both knowing that the job has been done well and as the fact that you are regarded as an expert in your field of engineering. From the management side, it is important that those that you might be managing find a good balance between studying and doing.