Production Engineer
IOCL Mathura Refinery
Total years of experience :23 years, 6 Months
I Responsible for control room panel operation through Distributed Control System of
assigned Petroleum Refinery Units (SRU, ARU, SWS, BBU) during normal operation, start-up, shut down and emergency situations.
I Operates and manages process parameters of number of units at the same time.
Takes fast and accurate actions to keep the units under optimum conditions minimizing wastage of hydrocarbon through slopping and flaring.
I am in a central contact point and all communications to the field is made through me.
My role is extremely critical during emergencies (Like leak or fire) whereby all announcements information is passed by me through the radio.
DCS Operation:
Operates computerized Distributed Control System (DCS) from Central Control Room) of assigned units to control and monitor operating parameters of various operating facilities SRU, ARU, SWS, BBU units under my assigned area.
Work Co-ordination:
As Panel operator myself is the main link between the field operations and the control room operations. Establishes communication through radio or telephones with Field Operators, Supervisor, upstream I downstream panel operator and maintenance for operational activities.
I am Responsible to maintain the plant at optimum throughput ensuring unit safety.
Shift Handover:
Routine Tasks:
Controls process start-up, shutdown and emergency situation.
Take corrective actions to normalize alarms and adjust process parameters to keep the unit streamlined.
Process upsets or process changes in his assigned areas are immediately communicated to upstream or downstream panel operators and to shift supervisor.
Instructs the field operator to adjust the equipment, manual valves, chemical injections and changeover of equipment as per the process demand & schedule.
Log critical readings of the main process parameters like pressure, temperature
and flow. Deviations from the normal readings are brought to the attention of
shift supervisor.
Implementation of Instructions:
Implement the instructions from shift supervisor. Any observation or problems are referred back. End results are logged.
Handling "Emergency Situations":
I am responsible for handling all types of emergencies which may include tripping of an equipment, gas or hydrocarbon leak, fire and natural calamities (like earthquake, typhoons, high wind).
Monitoring of Alarms and Interlock Trips:
As Panel operator myself is the first person to know about any abnormal alarm, trip or
stopping of equipment.
I am the first line defence of the shift team and immediately takes actions to nominalise the process.
Checks alarm summary on continuous basis and reports abnonnalities to shift supervisor.
Optimizing Process Parameters:
As Panel operator myself is constantly alert to the process. Monitors process parameters
and Advance Process Control graphics on continuous basis.
Make accurate changes to the process parameters if any measured or control variables are
hindering the unit optimisation.
Analysing Lab results:
Uses Refinery Information System (RIS) to check routine or non-routine Lab
analysis. Updates and implements the Lab results in respective APC modules.
Based on lab analysis make parameter adjustments to keep the process stream
and product specifications on spec.
Maintenance work & Permit tracking:
Take actions to handover closed control loops and ESD loops.
For all ESD related maintenance, as panel operator I ensure that ESD is bypassed
before maintenance crew starts working on the designated equipment Make special notes on the control loops that are kept in manual mode and ESD bypassed.
Controls "Slopping and Flaring":
As Panel operator I adjusts process parameters to ensure that hydrocarbon "slopping
and flaring" is minimized subsequently increasing the product yield and
minimizing environmental hazards, Informs to shift supervisor of such conditions.
To communicate and follow instructions of the Shift Controller to carry out duties efficiently and safely.
To check process parameters and coordinate with the Panel Operator to correct any deviations.
To carryout routine checks on equipment for abnormalities and inform Superior for prompt action.
Checks for any malfunctions, such as line ruptures, valve breaks and blown gaskets, estimates degree of seriousness and takes action accordingly.
Participate in process start-ups, shut-downs and isolations
Prepare process units and equipment for routine maintenance
Participate in safety programs and maintain a safe work environment
To sign work permits, follow on-going jobs and monitor Contractors activities ensuring adherence to safety regulations and procedures.
Takes Sample products like LPG, NAPHTHA, KEROSENE, LGO, HGO, DIESEL, VR etc, perform tests, record data and maintain a log of process conditions, changes and upsets.
To receive chemicals, maintain the stock/consumption register and prepare chemical batches required for the process ensuring adherence to procedures.
I am responding immediately to AVU plant process upsets/emergencies and safety emergencies, which can include gas leaks and fires etc.
I Responsible for the entire field operations of all equipment of AVU in my assigned area,
I am the first person to observe and react to any field equipment abnormalities.
With a mechanical aptitude and basic knowledge of process instrumentation and DCS Operations.
Heavy water plant experience Period: June 2004 to Sep. 2005
(A unit of Department of Atomic Energy)
• I have worked in heavy water plant Baroda as Scientific Assistant, a unit of department of atomic energy, heavy water used as moderator and coolant in nuclear reactor in nuclear power plant,
• Deuterium extracted from water with Ammonia Water Exchange Process and produced as heavy water.
• Heavy Water Plant operating at 405 Ksc and capacity 24 Kgs/day With DM Water, Steam Generation and Cooling Water Units.
Heavy water plant consists of the following section:
Ammonia water exchange Section
Ammonia crackers Section
Ammonia (liq.)-Synthesis (gas) Exchange Section
Ammonia Converter Section
Compressor Section
Oswal Chemicals & Fertilizers ltd. experience: Period: Oct. 2000 to June 2004
HYDROTREATING UNIT (Removal of Sulphur):
PROCESS: IIP-IFP (INSTITUTE FRANCAIS DU PETROL, FRANCE)
DESIGN: 27 TPH
• This unit is an oil processing Unit where the sulphur content is reduced from 1500 ppm to 0.5 ppm based on IIP-IFP Process.
• I have the operating experience of this unit, where we have two natural draft FIRED HEATERS fuelled by fuel gas and Naphtha using 4 burners, COMOX and ZnO catalyst reactors,
• Two reciprocating Hydrogen Compressors, Separators and Distillation Column and necessary pumps and heat exchangers.
CATALYTIC REFORMING UNIT:
PROCESS: ICI STEAM NAPHTHA REFORMING PROCESS
• This unit is a gas cracking unit based on ICI Steam - Naphtha reforming process. This unit is having 90 nos. of top fired burners and a furnace, two sets of induced and forced draft fans.
• Vapour Naphtha is mixed with steam and enters at 4570C to a Nickel catalyst bed. The outlet gas contains CO, CO2, H2, H2O and CH4 is cracked into CO and H2 using Nickel with Alumina and Silica catalyst. Preheated air at 5380C is burned with process gas to 9700C.
• The gas is cooled in reformed gas boiler to raise 106KSC pressure steam. Routine observations of skin temperature, gun cleaning and explosive check are done here.
Acid Gas Removal (Absorption and Regeneration):
• CO2 is removed (41, 127 Nm3/Hr) from process gas by GIMMARCO VETROCOKE DUAL ACTIVATED HOT POTASSIUM CARBONATE SOLUTION SYSTEM which involves operation of high capacity pumps, high pumps, high pressure absorber and two regenerators (Dual Pressure System).
• Acid gas purification involves the regeneration of acid gas from Vetrocoke solution (K2CO3 & Glycine and Di-Ethanolamine). Purification by water scrubbing resulting 99.8% purified gas, which is supplied to downstream of the urea plant.