Senior Process Engineer
Amec Foster Wheeler
Total years of experience :13 years, 3 Months
Worked as part of two major projects team on FEED design for Unconventional Gas Project (360 MMSCFD) and Fadhili Gas Program Project (2, 500 MMSCFD) located in KSA.
• Led process team for gas separation, compression, Hydrotreating (HDO) stabilization and storage areas;
• Responsible for producing and checking a series process deliverables e.g. PFD, P&ID, Cause and Effect charts, equipment list, Line List, calculations and datasheets for pressure vessels, pumps, HX, tower, and gas compression;
• Established concept study in FEED changes;
• Developed P&ID in terms of safety issues such as isolation, ROV, PSV, BDV, and ESDV;
• Liaison with flow assurance engineer to identify the worst case in maximum slug volume to be dumped in inlet separators and ensure no hydrate forms in the pipeline and inlet process plant;
• Represented FEED process engineering function in HAZOP and prepared close-out report;
• Liaison with other disciplines to provide necessary engineering inputs;
• Reviewed vendor’s documents, drawings, datasheets, specifications and calculations;
• Supported project team to respond bidders’ technical queries for the process units;
• Supported process team in other areas such as TEG units and acid gas removal units.
Worked as part of offshore start-up team in Giant Offshore Greenfield Kashagan (450 Mbopd) located in Caspian Sea, Kazakhstan.
• Reviewed start-up and operation principles for minimizing gas flaring;
• Developed Commissioning, start-up and Operations procedures;
• Ensured all process safeguards such as PSV, BDV, ESDV and non-return valves installed as per P&ID;
• Carried-out start-up Hysys process simulation in deferent throughputs of units;
• Represented process engineering function in HAZOP meetings prior start-up;
• Developed 'what if' scenarios and train operations within them;
• Supported Management of Change process from process point of view and reviewed other MOC;
• Developed Process and F&G alarm prioritization in DCS to assist operators to take action correctly;
• Corrected alarm / trip schedules and control valve set points in DCS;
• Ensured that process units operated within design envelop and Shell practice guidance;
• Supported Operations team in the delivery of production targets;
• Process debottlenecking in start-up e.g. TEG foaming and tuning the process controller set points;
• Monitored process plant operating conditions and products laboratory results;
• Developed Shell Process Data Books for monitoring facilities operation on-line through Shell IT server.
Worked as part of a major project team on feasibility study, concept design, FEED, detailed design, commissioning, start-up and testing of process plant in Yadavaran oilfield Project located in Iran executed by Sinopec E&P.
• Supervised PMC process team for process plant units i.e. oil separation, desalting, stabilization, gas compression and dehydration to produce 85 Mbopd, 25 MMSCFD gas lift and 80 MMSCFD gas export;
• Responsible to check process deliverables e.g. PFD, UFD, P&ID, hydraulics, line sizing, Hysys process simulation, process calculations and datasheets, PSV sizing, cause & effect chart and control narratives;
• Reviewed assessment of safety protection layers (LOPA);
• Optimized Process plant by choosing proper technologies and tuning process parameters using Hysys;
• Checked and optimized TEG unit using Hysys;
• Represented FEED process engineering function in HAZID and HAZOP;
• Negotiated with Sinopec to develop Early Production scope of work;
• Assigned as technical adviser for Early Production in feasibility study, concept, FEED, EPC, testing and start-up;
• Supported the project team to respond bidders’ technical queries;
• Liaison with flow assurance team to identify possibility of wax, asphalten and hydrate formation;
• Represented detailed design process engineering function in HAZID, HAZOP and SIL;
• Managed interface issues between EPC contractors as well as LLI manufacturers;
• Reviewed vendor’s documents, drawings, datasheets, specifications and calculations;
• Developed start-up manuals for Early Production according to vendor data books and P&ID;
• Ensured that process unit operated within design envelop and NIOC practice guidance;
• Supported Operations team in the delivery of production targets;
• Supported process engineering inputs to Management of Change;
• Monitored process plant operating conditions and products laboratory results;
• Participated in investigation of incidents within process plant, wellhead areas and manifolds;
• Managed interface issues between surface process facilities and sub-surface team to identify oil producer wells optimum choke size in terms of pressure and flowrate;
• Process unit debottlenecking in start-up such as level fluctuation in separators and RVP specification;
• Liaison with Sinopec, EPC contractor, Vendors and Operator to ensure smooth operatorship hand-over;
• Minimised gas flaring though using the associated gas from Early Production as fuel for existing gas turbine generators to generate electricity and sale it to the local authority;
• Reduced 25% CAPEX of Early Production through improving scope of work by revamping of existing facilities and minimizing required new equipment;
• Received appreciation letter from Managing Director for distinguished performance in over 12 years working for NIOC.
Worked as part of a major offshore project team on detailed design, start-up, performance testing, operation and hand-over of process plant in Dorood Brownfield Project located in Persian Gulf executed by Total E&P.
• Supervised process team for oil processing unit (85 Mbopd), gas dehydration and injection unit (130 MMSCFD in 420 barg), seawater treatment, deaeration and injection unit (270 Mbwpd in 230 barg) and amine gas sweetening unit (40 MMSCFD);
• Responsible to check detailed design process deliverables such as process calculations and datasheets for separators, aircooler, heat exchanger, pumps, tanks, towers, and compressors, hydraulics, PFD, P&ID, equipment list, line list, Hysys simulation, OLGA model review;
• Liaison with flow assurance team to identify slug volume and possibility of asphalten & hydrate formation;
• Provided technical support in LLI tendering and responded the bidders’ technical queries;
• Promoted to Offshore Senior Process Engineer in Mar 2005;
• Established oil pre-heater rating to check suitability for different feedstock compositions;
• Represented detailed design process engineering function in HAZOP and SIL;
• Monitored commissioning activities to ensure readiness for start-up;
• Established HYSYS simulations in start-up for different feedstock compositions and flowrate;
• Assigned as site representative to lead client multidiscipline engineering team;
• Assigned as a member of Joint Management Committee to monitor process plant production and approve plant production reports;
• Monitored process plant operating conditions and products laboratory test results;
• Supported process engineering inputs to Management of Change;
• Ensured that process plant operated within design envelop and NIOC practice guidance;
• Managed interface issues between surface process facilities and sub-surface team to identify oil producer wells as well as gas & water injector wells optimum choke size in terms of pressure and flowrate;
• Supported Operations team in the delivery of production targets;
• Established root cause analysis for process related issues;
• Process debottlenecking such as equipment intervention, valve replacement, foaming, amine replacement, inefficient oil stabilization, sand filters media replacement and vacuum tower leak test and corrosion in oily water network;
• Developed process plant performance test and hand-over procedures;
• Led client engineering team to wetness process plant performance tests and generating punch list;
• Controlled punch list close out in regular meetings at site;
• Assigned as client contact point for project assets Hand-over at site;
• Liaison with Total, EPC contractor, Vendor and Operator to ensure smooth hand-over of asset to NIOC;
• Monitored oily water disposal to be in line with Kuwait Protocol requirements in terms of oil content;
• Minimised gas flaring through production enhancement in gas sweetening unit and sale additional produced treated gas;
• Negotiated with local petrochemical complex to deliver acid gas free of charge for further processing rather than flaring.
Training and Oil/Gas Plant Familiarization
Activities & Responsibilities:
Six month training including technical courses listed below and site visits.
Six month training in Iranian offshore oil and gas production platforms (Persian Gulf, Siri Island, Iran) to familiar with the common design, equipment and systems in upstream facilities.
Six month Advanced English language courses including Business English.
Worked as trainee in offshore oil and gas upstream projects and platforms
• Six month formal apprenticeship to attend oil and gas training courses;
• Six month on-job training in offshore platforms to be familiar with process units & production operations;
• Responsible in various process calculations such as hydraulic, line sizing, vessel, and tower;
• Responsible to develop PFD & P&ID.
Principal subjects: Purification and Separation Processes Dissertation: Gas Sweetening Optimization and Pilot Plant Basic Design
Principal subjects: Petroleum Industries Processes Design