Process Engineer
Maersk Oil Kazakhstan, a company of Total
Total years of experience :13 years, 3 Months
Responsibilities:
 Process support to Engineering Projects and Asset Development departments for Dunga Field in Mangystau region;
Initiation and development of small to medium scale field modification projects, including writing justification documents, scopes of work, guiding and managing engineering contractors, participation in safety reviews and HAZOP;
Troubleshooting of field units, assessment of operating criteria;
Root cause analysis of process incidents.
Dunga Phase 3 Project
Project’s aim: Expansion of the Dunga Oil Field, to connect 61 new wells, increase production to 21900
bopd and increase oil, produced gas and water handling capacity of the plant and its reliability. Personal involvement: Preparation of the project for DEFINE stage review.
Development of the Basis of Design;
Update of the HYSYS simulation and simulation report, including sensitivity checks for options; Publishing Heat and Material Balances;
Coordination of the Wax study of the representative well samples for criteria;
Preparation of presentations for Review Team;
Close-out of review actions.
Responsibilities and deliverables:
Preparation and process input to documents and drawings, including:
o Technical and economic feasibility studies;
o Pipelinehydrauliccapacity/stresscalculations;
o Plotplansandpipinglayouts;
o Design basis reports (explanatory notes);
o Process diagrams;
o Technical reglaments;
Managing the subordinates’ work load;
Liaising with engineering disciplines and management.
Project portfolio:
Fuel gas pipeline for Halliburton complex in Aktau
Gas export pipeline for Tasbulat Oil Corporation
Field gas utilisation program for Maersk Oil Kazakhstan
Desalinator plant feasibility study (TEO) for Astana-Kyzmet
Responsibilities and deliverables:
Equipment sizing, Line sizing, Storage Tank, Pump and control valve sizing calculations, providing sizing data to mechanical team;
Engineering calculations using various software including Fluor Proprietary Software for Line sizing and Horizontal and Vertical Vessel Sizing, Aspen HYSYS, Mathcad;
PFD and P&ID development;
Preparation and process input to various engineering deliverables such as Equipment and Instrument datasheets, Hazardous area classification, Environmental release summary, etc.;
Pressure Relief Valve sizing calculations;
Participation at design and safety reviews, scribing at HAZOP studies.
Future Growth Project (FGP), Location: Kazakhstan; UK
Project’s aim: The next major expansion of the Tengiz Oil Field operation, which further expands
production capacity by 12 million tonnes per year.
Was involved in development of following areas of the project:
Steady state hydraulic study for Tengiz - Atyrau pipeline pump station upgrade/debottlenecking scope. The study looked at increasing the export capacity of the pipeline and the impact on DRA injection, pipeline size, main and booster pump capacity and impeller replacement, vortex formation in export tanks, LACT meter operation and protection against transient pressure surges in the pipeline.
Water Injection Facility design. A facility consisting of storage tanks, booster and main pumps to inject
stripped sour water to underground.
Tie-ins scope for major update of the field gathering system. Tie-ins were provided to minimize
construction scope to connect the new gathering pipelines and provide fuel gas from the field high pressure fuel gas system. Tie-ins schedule was executed to utilise available planned shutdown windows.
New gathering system design including pipelines network and metering stations. Metering station design included multiphase flowmeters, gathering manifolds and flare system. Major component of the scope was to ensure stable field production output. It was achieved by initially constructing meter stations and operating them on high pressure mode, while allowing time for construction of future facilities. When the well production started to fall due to failing reservoir pressure, the gathering system would be converted to low pressure mode. I was also involved in the input to conversion strategy, which defined the sequence of switching the field units to LP mode, as well as establishing safe operating regimes during conversion period with both HP and LP systems running at the same time.
Second Generation Enhancement (SGE) Project, Location: Kazakhstan; UK
Project’s aim: Substantially increase processing capacity and reliability of the Second Generation Plant at Tengiz, Kazakhstan to achieve and maintain higher production of crude oil product.
As a member of the Kazakh Projects Joint Venture FEED and detailed design engineering team participated in various design subprojects including:
Sour gas dehydration unit with molecular sieves. The aim was to achieve less than 10 ppm wt water content, to protect downstream Sour Gas Injection compressor from water condensation which could cause a catastrophic event.
Butane polishing unit. The aim was to capture excess mercaptans in the butane product with molecular sieves to reduce sulphur content to 15 ppm wt. This would increase the stabilised crude production rate as the prior solution to reduce sulphur content was by intentionally letting more butane through the column overheads to dilute sulphur compounds in the butane product, thus decreasing the more valuable crude production.
Mercaptan treater caustic carryover elimination. The aim was to improve caustic entrainment prevention from the MerOx Unit via installing an enhanced separation system. The entrained caustic created basic environment downstream resulting in process upsets, such as increased stress corrosion cracking risks and breakdown of disulphides into mercaptans.
Responsibilities and deliverables:
Equipment selection;
Engineering support for client queries with technical notes and sketches;
Process flow sketching of minor units, such as waste cementation, lead smelter feed blending.
New Metallurgy Project, Location: Kazakhstan
Project’s aim: Development and Construction of Copper and Lead Smelters, and a Copper Refinery at Ust-Kamenogorsk Metallurgy Complex.
Personal involvement: Assistance in various areas of the project during commissioning of Xstrata’s ISASMELT Copper Smelter and ISAPROCESS Refinery including:
Assistance and interpreting for contractor engineers during commissioning of processing units including: Foster Wheeler Waste Heat Boiler, Outotec Anode Casting Machine, Mesco Cathode Stripping Unit, ISAPROCESS Refinery cells;
Daily site visits while assisting contractors.
Final year project: “Design of a Waste-to-Energy plant in the UK”. This project consisted of two parts. In the first group part the overall design of the plant was decided and calculations of mass and energy balances were done by group. In the second individual part a Bubbling Fluidised Bed Boiler had to be fully designed.