OPERATION ENGINEER
Saudi Arabian Fertilizer Company (SABIC Affiliate)
Total years of experience :13 years, 11 Months
Being an Operation Engineer of Ammonia & Utility plant, responsibilities are to monitor daily plant operational and maintenance activities, Start-Up/Shutdown, trouble shooting of plant problems and advise best optimization steps to solve issues. I am responsible to participate in plant safety reviews, problem analysis, energy conservation and environmental projects of ammonia and utility plants. Possess expertise of supervising & managing activities in following areas;
1:- Sulphur Removal (MEA process), Hydro-treating & De-sulphurization of Natural Gas units.
2:- Natural Gas Reforming, CO gas conversion to CO2 by High and Low Temperature Shift Reactors.
3:- CO2 gas absorption and stripping through Benfield Process by UOP and Methanation Section.
4:- Synthesis gas drying and Cryogenic (Cold Box) Purification by Brown and Root design Process.
5:- Purge Gas recovery by Cryogenic Cold Box process (Chart Inc.)
6:- Pre-treatment, De-mineralization of Boiler feed water and waste water treatment unit.
PROFESSIONAL SKILLS
1:- Monitor plant operating parameters through PIS, analyze trends & Lab analysis on daily basis to recommend corrective actions.
2:- Management of Change” MOC” (Permanente, Temporary & Emergency) system.
3:- Process Management Study (PSM) as well as Pre-Start-Up EHSS Review (PSER).
4:- Conduct Root Cause Analysis as a leader or Participants.
5:- Process Hazard Analysis study (HAZOP, What-If & Check list, ) JSA and Risk Assessment related to plant EHSS and operational problem.
6:- Develop and review SOP as per OEM manuals and best operational practices.
KEY ACHIEVEMENTS:-
1:- Done Joint revamp study with licensor (KBR) to save energy of 0.75gcal/MT ammonia.
2:- Performed Ammonia plant Asset Criticality Assessment study (2500 entities) to improve plant equipment's reliability.
3:- Involved in Ammonia/Utility PHA revalidation study with M/S Engineers India Ltd.
4:- Implemented "Leak Detection and Repair (LDaR)" systematic approach in synthesis gas area.
Fauji Fertilizer CO. (FFC) is the largest Fertilizer Manufacturer Company of Pakistan having 400, 000 MTPD Ammonia capacity. FFC is an Integrated Management System certified company and holds ISO-9001:2000, ISO 14001:1996 and OHSAS 18001:1999 certifications.
One of Ammonia Plant production Management team, my responsibilities are to ensure that all Manufacturing, Utility and Gas process facilities and company's assets are operated in optimum and safe conditions, support shift supervisors and shift engineers in troubleshooting and plant start-up/Shutdown;support ammonia/utility operation manager in both technical and administrative affairs related to production department and conduct training to the junior engineers.
Possess expertise and manage all operational, maintenance and administrative activities in the following areas:
- Steam reforming & CO removal section (MTSC & LTSC).
- CO2 removal system (aMDEA Process)
- Compressor section (PD and centrifugal compressors)
- Ammonia synthesis and refrigeration section
- Hydrogen recovery plants (Cryogenic Technology by Linde)
- Auxiliary boiler (130 Tons per day by Macci) and cooling tower section
- Nitrogen Plant with storage tank(LINDE, @ 600 NMC/hr capacity)
- Distributed Control System, DCS (Honeywell TDC-3000) for monitoring and controlling of Ammonia plant.
Key Achievements:
- Proposed modification of introduction BFW to process air coil in furnace convection section (E-4202A) to control its TMT and get best suggestion certificate from FFC management.
- Rationalization of Plant-II DSC alarms management system to ensure that plant process safety not jeopardizing owing to frequent less critical alarms.
- Proposed modification to lower MTSC inlet high temperature which is implemented ant MTSC inlet temperature reduced from 246 to 233 oC, hence improved its catalyst life.
- Conducted HIRADC (Hazard identification risk assessment & determining control) of ammonia plant routine activities to ensure compliance of OHSAS 18001:2007 standards.
- Worked as a Pre-commissioning & commissioning supervisor in the world largest single train Ammonia-Urea Plant in Pakistan, for SAIPEM, Italy from May-2010 to Jan 2011.
Has Worked for Engineering Division’s process engineering unit at Ammonia Plant, processing 76 MMscfd gas from Mari Gas Field to produce
1345MTPD Liquid ammonia. Leading area process engineer of the whole facility for various ongoing process improvements, energy conservation,
debottlenecking studies/projects, trouble shooting chronic process problems, plant performance monitoring and controlling.
I was also responsible for:
- Monitoring plant operating parameters as per SOP through PIS, analyze parameter trends & Lab analysis on daily basis to take corrective actions.
- Use of statistical techniques to monitor trend of process parameters / plant performance evaluation on regular basis.
- Preparation of incident reports and training circulars with the focus for system improvement.
- Preparation of process specifications & implementation of modifications to improve plant safety, reliability & productivity.
- Represent technical services in various meetings and report to the concerned managers for observed deviations and suggesting possible corrective actions.
- Designing, sizing & selection of Heat Exchangers, Control valves, Pressure safety valves and Orifice sizing.
- Catalyst performance evaluation \[deactivation rate, dead zone and activity prediction\] and develop life projection, replacement plans.
- Preparation of Monthly Sustainability Performance Report to maintain and improve energy efficiency of the plant and maintain Sustainability KPI’s.
Key Achievements:-
Technical and Economic Feasibility studies of following projects
- Acid gas removal (aMDEA Process) section capacity up-rating from 112% - 120% \[Project cost: Rs. 42 million, i.e. US $ 0.70 million\].
- Up-gradation of conventional Benfield CO2 removal system of Ammonia-I to Benfield LoHeat process. Energy saving was 0.3 Gcal/Met of Urea. Project cost was Rs. 230 million (US $ 3.84 million) with a payback of around 03 years.
- Commissioning of Natural gas booster compressors. Plant capacity factor improved from 125% - 138%. Project cost was US $ 0.38 million with a payback of 01 year.
- Installation of Charcoal filter installation for aMDEA based CO2 removal system.
- Project experience of replacement of HIMA PLC shutdown system with Triconex ESD system \[Invensys, USA\].
- Project experience replacement of ammonia convertor shell and 23-years old S-200 ammonia reactor catalyst basket with new S-300 basket.
I did Six weeks internship training at Urea Plant in Production department
- I did B.Sc. Chemical Engineering with honor by getting 3857 marks out of 4800 which becomes 80.4% and I stood third in engineering degree. - I got Punjab university merit scholarship for four years of engineering - I also won Fauji Fertilizer merit scholarship in three years of engineering after obtaining First position in first year of engineering. During my bachelor I compiled process report on “Reclamation of Used Lube Oil” after doing actual work in lab and Submitted thesis of final project on “Vacuum Distillation of Reduced Crude Oil”
I got "860" marks out of "1100" which becomes 78% of total %age
I got "728" marks from "850" which becomes 86% of total marks, and won Scholarship from Faisalabad Board of secondary education.