Ehab Salama

Advanced Polyolefin petrochemical company Saudi Arabia
Senior process engineer
2023- 2025

The industry belongs to petrochemicals plant to produce Homopolymer and copolymer grades of polypropylene (PP) using Spheripol technology and Spherizone technology which depends on liquid tubular reactor and gas phase reactor, pelletizing by Coperien extruder, DCS operating system is Siemens, 400KTA.
• Follow up the proper plant startup to produce PP in a petrochemicals plant and shutdown with high safety standard.
• Implement and review Pre commissioning and Commissioning map, tasks, and Schedule.
• Lead loop and function testes.
• Develop and review system and sub systems commissioning procedure.
• Development and review general and detailed procedures.
• Communicate with vendor and contractor for performing work.
• Troubleshoot the obstacles, technical or administration.
• Share in evaluation to hire the operator’s staff.
• Review 3D modules, P&ID, PFD, mass and heat balance, review gasket and piping specification, review materials data sheet, review equipment specification and its data sheet for MTR (mechanical test run), punch listing and process safety studies, Hazid and Hazop study and Yokogawa DCS graphics and SIS graphics.
• Planning of purchasing raw materials and packaging requirements
• Perform technical and engineering studies for the necessary modification to improve the plant performance.
• Implement monthly, quarter, and yearly presentations for key performance indicators and put the road map for improvement.
• Manage the performance and training programs for plant operation staff.
• Develop the standard operating, Commissioning procedures and emergency procedures.
• Implement the daily production instructions.
• Follow the claims received from the customers and take the necessary actions to eliminate these claims.
• Share with maintenance to schedule the maintenance plan and prepare the spare parts list.
• Develop HAZOP and PHA
• Provide required calculation.
• Cooperate with vendors for commissioning packages.
• Develop required MOCs.
• Mass and heat balance

The industry belongs to petrochemicals plant to produce Homopolymer and copolymer grades of polypropylene (PP) using Spheripol technology which depends on liquid tubular reactor and gas phase reactor, pelletizing by JSW extruder, DCS operating system is Siemens, 350KTA.

• Follow up the proper plant startup to produce PP in a petrochemicals plant and shutdown with high safety standard.
• Troubleshoot the obstacles, technical or administration.
• Optimize plant production to meet the required quality and rates.
• Issue daily plant operation instructions for production and quality tuning.
• Preparing the production plan according to sales and marketing plan.
• Plan the raw materials and chemicals delivery schedule according to the production plan.
• Prepare and monitor the consumed resources and improve for a achievement the optimum production costs.
• Perform the plant key performance indices(KPI) to evaluate the plant performance.
• Share in evaluation to hire the operator’s staff.
• Troubleshooting the emergency shutdown with trends and DCS historical reports aid.
• Perform technical and engineering studies for the necessary modification to improve the plant performance.
• Implement monthly, quarter and yearly presentations for key performance indicators and put the road map for improvement.
• Manage the performance and training programs for plant operation staff.
• Develop the standard operating and emergency procedures.
• Development of engineering studies to get an adequate quality, production rates and economy.
• Follow the claims received from the customers and take the necessary actions to eliminate these claims.
• Share with maintenance to schedule the maintenance plan and prepare the spare parts list.

The industry belongs to petrochemicals to produce Homopolymer and copolymer grades of polypropylene (PP) from polymerization of propylene and mixed ingredients using Spheripol technology which depends on liquid tubular and gas phase reactor, pelletizing by JSW extruder, DCS operating system is Yokogawa, 500KTA.
Study and develop the required plant, PID, DCS and SIS modification for safe startup
Review and develop standard operating procedures and emergency procedures
Share with licensor and equipment vendors startup and shutdown activities
Pre-startup safety review (PSSR) leader
Troubleshooting the operation troubles using root cause analysis(RCA) methodology using DCS trends and historical reports
Implement job safety analysis for critical works to keep HSE
Share in planning and performing of commissioning activities
Perform the calculation required for operation and for chemicals delivery plan
Side responsibilities for operators class room and on job training(OJT)
Dry and wet logic function test of SIS and DCS interlocks
Review and study the operating manuals, logic diagram and process design package for production improvement
Optimize production rates, catalyst yield and operating parameters
Optimize the production wheel and the required resources
Determine the design basis for equipment, production and row materials specifications
Perform economics study and key performance indicators( KPI) analysis for the plant production optimization

The industry belongs to petrochemicals to produce Homopolymer grades of polypropylene (PP) from polymerization of propylene and mixed ingredients using Spheripol technology which depends on liquid tubular reactor and gas phase reactor, pelletizing by JSW extruder, DCS operating system is Honeywell, 400KTA.
Manage the shift team to achieve the desired production target and product specification
Perform pre-commissioning, commissioning, startup and performance acceptance of the plant
Develop lecture guide lines and implement class room and On job training(OJT) for operators
Develop standard operating procedures for the process and vendors machinery
Implement SIS and DCS functions with contractors
Develop and implement sequence startup chart for smooth startup
Develop raw materials calculation sheets for smooth production planning
Perform DCS operation activity in case of shortage
Apply 5S methodology for smooth operation
Prepare daily, monthly and yearly production and key performance reports
Share with maintenance team in job safety analysis(JSA), tool box and safe work meetings
Implement the required maintenance requisition in MAXIMO
Prepare and follow up incident reports
Alarm suppression, PID tuning responsibility
Confirm performing of HSE standards and procedures
Implement PTW requirement and confirm that all the jobs follow PTW
Participate in training program development to build up operation team to ensure the competence
Perform safety counter measurement before perform operation and maintenance tasks
Lead implementing of emergency plan in case of emergency or disaster

The industry belongs to petrochemicals to produce Homopolymer and copolymer grades of polypropylene (PP) using Spheripol technology which depends on liquid tubular reactor and gas phase reactor, pelletizing by JSW extruder, DCS operating system is Siemens, 350KTA.
Troubleshoot the operation and process technical troubles
Analyze the shutdown root cause and put the recommendation for future elimination
Review and modify P&ID to match the actual process
Prepare shutdown reports with historical events and necessary DCS trends
Issue the purchasing requisition for raw materials and follow with laboratory the analysis results
Lead the safety and environment committee and issue the recommendation
Guide the operation staff for safe and successful operation
Review and evaluate modifications performed by the process department

The industry belongs to petrochemicals to produce Homopolymer and copolymer grades of polypropylene (PP) using Spheripol technology which depends on liquid tubular reactor and gas phase reactor, pelletizing by JSW extruder, DCS operating system is Siemens, 350KTA.
Follow up the proper plant startup and shutdown with high safety standard
Troubleshoot the obstacles whither technical or administration
Share in evaluation to hire the operators staff
Planning of purchasing raw materials and packaging requirements
Perform technical and engineering studies for the necessary modification to improve the plant performance
Implement monthly, quarter and yearly presentations for key performance indicators and put the road map for improvement
Manage the performance and training programs for plant operation staff
Develop the standard operating procedures and emergency procedures
Implement the daily production instructions
Follow the claims received from the customers and take the necessary actions to eliminate these claims
Share with maintenance to schedule the maintenance plan and prepare the spare parts list

The industry belongs to gas processing to liquefy natural gas and produce liquefied natural gas (LNG) at -178C using Main cryogenic heat exchanger and 78M turbo compressors, DCS operating system is Yokogawa.
Perform punch listing at the field as a part of mechanical completion process
Follow up commissioning activities and starting of gas turbine(Mark6) from the field and PLC
Perform ready to start safety review
Prepare safety and operation punch lists and follow it with safety and maintenance departments
Operate and monitor natural gas metering unit, gas compression unit, Mercury removal unit(MRU), Sulfur removal unit(SRU), dehydration unit, hot oil furnace unit, propylene and mixed refrigerant unit, turbo expander, fractionation unit and main cryogenic heat exchanger
Operate LNG plant from DCS and PLC with continuous monitoring the operating parameters and laboratory analysis to keep smooth operation and the required specifications
Review and implement the required PTW
Apply HSE standard during all production phases
Perform shift handover using the standard methods

The industry belongs to petrochemicals to produce Homopolymer grades of polypropylene (PP) using UNIPOL technology which depends on gas phase reactor, pelletizing by coperion extruder, DCS operating system is Honeywell, 120KTA.

Operate and monitor propylene storage spheres, deoxo bed, dehydration molecular sieves, ingredient loading and purification, gas phase reactor, Hydrogen manufacturing unit (HMU), additives stations, extrusion, Nitrogen manufacturing cold box
Operate the plant from DCS and PLC startup and shutdown with optimizing the operating parameters to keep smooth and safe operation
Responsible to receive the imported propylene shipments to berth in the company jetty, measuring the shipment drafts, connection with loading arm, review BOL, Laboratory analysis and perform the required inventory calculations then start pumping.