Control operator
Total years of experience :27 years, 1 Months
Total experience : 23 year (Hydrogen production-GAS PLANT)
Present Employer
Bahrain petroleum company, BAPCO, \[267 KBPSD\], Bahrain.
(10 Years)
Experience Highlights: Commissioning / pre-commissioning/steady state Experience of Following Units in DCS/FIELD operation:
Key work Areas:
•Hydrogen Mfg. Unit(05 trains), Cap- 181 TPD (GAS PLANT)
•Hydrogen Compression Unit (4-Reciprocating Comp), 13.2 Mw each
Plant Details:
• Hydrogen Manufacturing Unit (GAS Plant)
The HMU is based on a top fired reformer (Steam reforming) with high temp. Shift converter and a PSA unit for hydrogen purification. The unit is designed to operate with Natural gas, LPG or Naphtha or combination as a feed stock.
•HMU designed by : KTI Technip : Technip @ Linde.
•Capacity : 100 MMSCFD : 100 MMSCFD.
•Main reactions :
Hydrogenolysis - The conversion of organic sulphur compounds and mercaptans to hydrogen sulphide over a bed of catalyst. Catalyst employed here is oxides of Cobalt and Molybdenum commonly known as ‘CoMoX’
Desulfurization - The removal of H2S by a bed of porous Zinc oxide where the ZnO is converted to ZnS by chemical double decomposition reaction.
Olefins saturation - This reaction is taking place simultaneously in CoMoX bed used for hydrogenolysis.
Cl2 removal - Organic chloride compounds are hydrogenolysed over CoMoX catalyst to give hydrogen chloride (HCl), which is then removed by absorption with catalyst comprising of Sodium aluminate supported on alumina.
Steam reforming - It is process by which the hydrocarbons are thermally cracked into lighter hydrocarbons essentially methane which are subsequently converted into Carbon Monoxide and Hydrogen over a nickel catalyst packed in steam reformer tubes.
CO Shift Reaction- CO in reformer outlet gas is converted in CO2. The reaction take place in catalyst bed of Copper promoted Iron Oxide in HT reactor. This is most effective and economic way of removing CO.
Main Responsibilities:
•Monitor and operate the equipment for safe and efficient operation.
• Continuous vigilant in monitoring critical parameters...
• Note down readings of DCS and cross check with Field and maintain a log of process conditions changes & upsets.
• Pump & change over / isolation for maintenance.
•Strict control of unsafe conditions and unsafe acts.
• Monitoring the smooth and safe operation of rotating equipment like pump, Turbine
• Various Field Tests for assessing plant performance like H2s check with dragger tubes,
• Maintain the record for the future/past shut down job.
• Ensuring strict compliance with safety procedure, work permit procedure.
•Strict follow-up of safety and environmental rules.
•Enforcing the safety rules in area, and ensuring housekeeping and cleanup, and assisting engineer, technical and other groups working in area, during normal plant activities as well as shutdown activities
•Hazard identification and risk assessment before doing the job.
• British Safety Council \[BSC\] checklists fill up periodically. & Safety Audit checking. Other job instructed by shift in charge and panel operator.
Project (commissioning) Experience:
I have been a part of World largest grass root Refinery commissioning at JERP, Reliance Petroleum in 2007 to 2009.
•Review of PFD, P& ID, and equipment datasheet.
•Loop punches list preparation & dilution of punch list.
•Precommissioning & commissioning activities like hydro testing, flushing (cardboard blasting, Pigging, rotamal Flushing, Air blowing), leak test, drying, final box up, purging,
•Catalyst Loading (Dense loading, Uni-dence loading, sock loading, Bucket loading).
•Alkali Boiled out @ Refractory dry out
•Silent Steam Blowing for HP steam loop.
•Compressor Suction Loop Pre cleaning & Passivation.
•Columns Internals: TSR checking, Levelness, Check list.
•Plant startup activities like hydrocarbon inventory, oil flushing, cold circulation, long circulation etc.
•Plant normalization, optimization & demo run (performance run)
Equipments:
•Steam Methane Reformer/Furnace. (384 tubes & 135 Burners, 423/951 mmBtu/hr.),
•Multistage centrifugal compressor (3.5 MW cap-22 tph),
•Four stage Reciprocating compressor (13.2MW capacity)
•Pressure swing absorber & Natural gas fired heater.
•High Temperature, High pressure CoMoX, ZNO, NiMoX Bed Reactors.
•High Pressure steam drums, BFW circulation.
•Fin fans, Coolers, Exchangers and Blower.
•Process Gas Boilers & Steam Generator \[Make : M/S Sruthers, USA\] both combine capacity to produce HP Steam to tune of 130 T/Hr @ 44.0 kg/cm2 pressure & 392 deg.cent. Temperature.
•Vacuum Distillation, Adsorption, Gas absorption, Stripping.
•Cryogenic Distillation (Linde) for CO(450Kg/ hr)from tail gas contain Hydrogen, Methane, Argon, Nitrogen And Carbon monoxide,
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