Senior Engineer - Process
Saudi Methyl Acrylate Company - Samac
Total years of experience :16 years, 7 Months
I am currently working as a Senior Engineer at Methyl Methacrylate (MMA) monomer plant of 250K tons annual capacity, Alpha Technology, an ethylene-based MMA production process licensed by Lucite International, a subsidiary of MRC.
Following are the highlights of my job description:
Developed MMA Weekly Critical Operating Parameters (COP) Report covering Plant Performance Evaluation (Capacity, Production, Technical Evaluation of Catalyst performance & Equipment efficiency etc.) & by providing recommendations accordingly.
Formulated & carried out trial to increase plant capacity MMA & MeP plant load to 105% load. Upon successful completion of trail, provided detailed process guidelines for operation at 105% capacity.
Water column Pluggage is one of the major issue in plant, which has been interrupting production for almost 5-6 days/year since commissioning in 2018. Provided short-term solution and long-term solutions.
Stewardship to ensure implementation of all short-term actions related to WRC that has not allowed water column pluggage since last 02 years. Estimate production saving of 4000 MT ($ 0.28 Million)
Initiated “Organic Vent scrubber” project to implement the proposed modification & prepared all the documentation for project initiation that comes under CDP for Organic Vent scrubber project.
Carried out Hydraulic calculations, Sizing of new & existing PSVs, Control valves, Rating of Exhangers related to project, prepared the data sheets, mark-up the P & IDs, and update the logics and interlocks in Process Control documents to submit Process Design Package for detailed engineering.
Participated in the selection of contractors, reviewed Tie-In Package/ DEP Package prepared by contractors and participated in technical review meetings. Ensure that the process design is safe and suitable for operation. Assisted the Contractor in solving technical queries during the procurement, fabrication and site construction.
MMA Plant face load limitation in Sep-Oct 2018 due to Evaporator C-4201. Load remained limited to 80-85% load causing approx. 115 MT production lost /day (0.3 Million SAR/day). Initiated the idea of removing fouling of Evaporator by Hot Condensate and developed SOP in order to remove fouling from tubes as well as in bottom portion.
Led Process Hazard Analysis (PHA), Layer of Protection Analysis (LOPA) & Safety Integrity Level (SIL) determination studies for Management Of Change (MOC).
Issued Process Guidelines for Operation of different Units / Areas post trip event of any major equipment.
Identification of gaps in SHEMS (EHSS Management System) implementation at SAMAC & development of a roadmap towards achieving “Process Safety Excellence” based on the CCPS Risk Based Process Safety model.
Investigated ROG Pump frequent trip issue that caused 02 days SD (around 1300 MT production) in Aug 2020 and identified High caustic dosing as root cause; suggested to start Evaporator pH sample for early detection. Plant or ROG pumps didn’t trip afterwards due to high caustic.
Identified the reason of Product off-spec and provided guideline for early identification of slippage.
Successful R & D to resolve Azeo load limitation by identification of Tar accumulation, carried out laboratory tests to prove it & then provided guideline to flush the section with MeP online.
Provided process support during Catalyst loading and unloading activity of MMA main reactor & pre-bed. Ensured that all outages at critical points recorded.
Carried out the study related to effect on MMA reactors catalyst life cycle due to postpone of turnaround from Nov-2020 to Feb-2022 & recommended suitable solution based on cost benefit analysis.
Worked as part of a core team for planning, executing, controlling and close out of Annual turnarounds and outages as well as provided coverage and services for the on-call system.
I worked in Technical Service Department of Chemanol as a Process Engineer at MD-section and responsible for Methanol, CO, MethylAmines (MA) & Di-Methyl-Formamide (DMF) Plants along with Utilities that includes Steam Turbine Generator, MP-steam Boilers, Cooling Towers, Instrument Air Compressors and Water Treatment Plant. Following are the highlights of my job description:
Reviewed and evaluated technical documents & reports, new process design studies prepared by external engineering companies, validate process engineering related modifications through MOC cycle and ensure that process operating windows adjustments are implemented accordingly.
Optimized the plant capacity by monitoring production and consumption data to find any deviations from the design. Identified the reasons for deviation and formulated corrective actions.
Provided process coverage in the start-up of units, shutdowns and process inspections. Provided technical advice on new projects/installations analyses, such as HAZOPS, Process Flow Diagram (PFDs), Piping and Instrumentation Diagram (PIDs), safety assessment, and management of change (MOC).
Working as Focal Point for technical clarifications & catalyst performance evaluation with Licensor’s M/S Haldor Topsoe & Davy Process Technology, Ltd.
Selection & Sizing/Rating of Heat exchangers, pumps, compressors etc. Preparation of specification sheets for Control valves, orifices and pressure relief valves.
Participated actively in troubleshooting activities, enhanced load risk assessment and cyclic PHA to develop solutions to accommodate critical troubleshot problems and provide feedback accordingly.
Developed the methodology for Emission monitoring programme from Methanol Auxiliary Boiler, MADMF Boiler and Reformer’s Stack to ensure RCER (Royal Commission Environment Regulations) compliance.
Working as Focal point from CHEMANOL for the Saudi Energy Efficiency Center (SEEC), one of the pillars of Saudi Energy Efficiency Program’s enforcement mechanism. Prepared scope of work for PTAI in order to conduct Energy assessment study to achieve 2019 energy targets.
Led Risk Assessment studies for Increased Load Operation for 02 production plants / units which include facilities for production of Methanol & Di Methyl Formamide
Led multiple PHA pertaining to proposed modifications according to MOC, including identifying potential operational and safety related problems and coordinating appropriate solutions.
Successful Trouble Shooting of Auxiliary Boiler High Stack Temperature by identification of Pre-heat coil leakage and gave practical solution to avoid re-occurrence.
Successful Trouble-Shooting of high supply temperature of Close Cooling water system & provided recommendations.
Focal Point of CHEMANOL with water treatment services provider (NALCO) for Open & Closed Cooling water treatment to avoid scale and fouling and ensure running the Utilities equipment smoothly without any problem by decreasing shutdown and maintenance Cost.
Carried out Study to increase COC for MADMF Cooling tower from 1.4 to 1.5 and for Methanol Cooling tower fro, 1.3 to 1.4 saving 3 Million SAR.
Led Alarm management study in order to fall in between Acceptable & Manageable alarms category according to “ANSI/ISA-18.2-2009 Management of Alarm Systems for the Process Industries” standard.
Led/participated in various Root Cause Analysis (RCA) on plant operational upsets & suggested recommendations to avoid recurrence.
Participated, contributed and provided technical input during the review and development of SOP, PSSR, Responsible care procedures and other plant related documents.
Prepares the specific schedules for testing, sampling and analyzing plant process/equipment under WAFER Programme by identifying definite requirements and implement in coordination with support groups.
Fatima Fertilizer Company Limited: (0ct 2007-July 2015)
Identification and evaluation of concepts for new projects. Implementing technical projects for cost/capacity enhancement, plant performance and efficiency improvement as per Management of change Procedure (MOC). Pre and Post Evaluation of realization of benefits from implemented modifications
Worked as PSM (Process Safety Management) Champion for implementation of PSM programme (22 elements) in accordance with DuPont Standards.
Initiated/Participated in Management of Change (MOC) by ensuring adequate review of all plant changes and technical projects in process engineering and process safety aspects
Extensive modifications involving de-bottle necking study of ammonia plant to achieve 1500 MTPD production figure. Contributed to Ammonia plant revamp study for capacity enhancement carried by Haldor Topsoe and KBR (Kellogg).
Major Projects as Process Engineer:
During the Project phase of plant, I worked as a Process Engineer and involved in Plant integration engineering, Procurement, Construction, Pre-commissioning, Commissioning and Plant operation. Particulars are as follows:
At Ammonia Plant :
Involved in Erection, Pre-Commissioning & Commissioning of 1500 MTPD Ammonia Plant, engineering by C.F.BROWN & re-engineering by M.W.KELLOG, (relocated from Kamira, Holland).
Successful commissioning of Deareator, Reforming, Catacarb, Methanation, Synthesis, and Expander for the cold box.
Independent In-charge of Chemical cleaning of process piping that includes BFW lines, Furnace coils (HP and ISOLATED STEAM), lube oil piping of all the compressors, Seal oil bottles, Synthesis loop, Catacarb system
Involved in Catalyst loading of all the reactors, Reduction of all catalysts, Steam blowing & Oil Flushing.
Planned & Conducted Hydro testing of vessel, exchangers & pipingSolo test Runs of all the motors, OST testing of all the turbines, condensing and non condensing, Load testing of all the pumps.
Commissioning of PIMS (Plant information Management system) and DCS under Yokogawa experts.
Shared meetings with Dresser Rand and GE experts for troubleshooting of critical problem of compressors. Participated in performance Evaluation and guarantee test runs of compressor and gas turbines.
At Nitric Acid:
Involved in Erection, Pre-Commissioning & Commissioning of Nitric Acid Plant (Dual Pressure) at FFCL.
Independent In-charge of Erection, Pre-Commissioning & Commissioning of CDM Plant (NOx and N2O Abatement System) located at Fatima Fertilizer Company Ltd. to control Air Pollution.
Independent in charge of Pre-Commissioning & Commissioning of Compressor Train (that includes 6.8 MW Steam Turbine, 9MW Centrifugal NOx-Compressor, 18.3MW Axial Air Compressor & 20 MW Tail Gas Expander.
Involved in Pre-Commissioning & Commissioning of High Pressure Waste Heat La Mont Boiler(70tons/hr)
Done Modifications in Nitric Acid plant through MOC at Fatima site to counter especially the warm weather conditions in comparison to UK.
Technical assessments of Pt/Rh catalyst purchases & follow-up. Loading & unloading of J & M’s Catalyst.
Successful development of technical evaluation of Pt/Rh catalyst by suggesting to use catalyst pack of HERAUS instead of J&M, based on this evaluation the company recovered 400000/- Euros.
Stats : 1st Division
Stats : 1st Division
Stats : 1st Division Participation in Debating Competition