Commissioning Process Engineer
Chevron
Total years of experience :19 years, 11 Months
-Act as technical focal point for Proces -Commissioning Engineering on the
project
-Ensure work is carried out in accordance with relevant codes, standards and
procedures
-Suport the implementation of safety in design in the execution of construction
-Pre-commissioning and Commissioning activities .
-Produce references sketches for Commissioning Procedures using Adobe
Acrobat
-Participante in the preparation and review of specific procedures( Flushing,
Leak Test, Basic Cleaning, Site Acceptance Test, Boil Out, Refractory Dry-Out
Steam Blowing, Catalist Loading, Functional Test Procedures etc .)
-Walk down job site to confirm commissiong procedures match installed
Equipment .
To aid the Project achieve its objectives by:
- Ensuring necessary HSE reviews are undertaken and identified actions completed.
- Attending reviews for commissioning and preparation for start-up requirements.
- Performing walkdown and following the punch list clearance for Gas & Sulphur Plant Systems.
- Carrying out commissioning activities such as chemical degreasing of amine plant, dry-out of refractory furnaces, boil-out of waste heat boiler & effluent cooler, Gas & LPG driers initial regeneration, LPG demercaptanization, dynamic tests of rotating equipments (blowers, pumps & compressors).
- Attending N2He Leak Testing of all Critical Systems Prior to Introduction of Hydrocarbons.
- Supervising with Production departament import of dry gas to perform gas plant dry-out for commissioning activities completion and preparation for start-up (Introduction of sour HC during first oil production).
- Overseeing all necessary commissioning preparation work (monitoring preservation, monitoring of mechanical completion and pre-commissioning activities, commissioning temporaries, etc).
- Assist System Engineer to review commissioning procedures, commissioning dossiers, functional test and all other tasks related to commissioning works.
- Overseeing specialist sub-contractors carrying specific commissioning tasks.
- Ensure acceptable Formal Handovers to Operator are prepared.
- Participate in and assist with the co-ordination of the Project’s performance test.
- Contribute to the Commissioning Group’s improvement process and close-out report
- Ensure all process related works for the facilities are in accordance with project specifications and making sure they are maintained in order to safeguard technical integrity
- Provide commissioning team with technology requirements for engineering applications
- Provide technical support to the project on commissioning, operating procedures and troubleshooting.
- Contributing to Commissioning support for Start-up within the ICAT.
- Reviewing commissioning deliverables issued by Contractors and Suppliers
Supervise local crew in commissioning/start-up and operation of 3 trains Gas Oil Separations and Gas injection . Performing pre- commissioning, commissioning, start-up and operations activities include of a 3 similar train which consist in Gas Oil Separation Unit (two separation stages ), Desalter, Oil Stabilization Column, Flash Gas Compressor, Gas Dehydation Column (using TEG), Glycol Regeneration Unit, Gas injection Compressor ( Nuovo Pignione ) .
Duties and responsibilities include :
-Monitoring the consumption and stock of materials available at field site, and request personnel, materials in order to avoid any delay in operations
-Carrying out regular inspection of assigned area during shift to identify or detect any faults, and take appropriate action within established guidelines to ensure the continuous, safe and efficient operation
-Monitoring through the Work Permit System all work performed in my area of responsibility
-Monitoring plant by studying laboratory test reports, standard log sheets and other daily operating activity reports, and highlights abnormalities and inform the superintendent
-Complying with all company Health, Safety and Environment as well as Work Permit, policies and procedures.
-Coordinate production start up, shutdowns, and changeovers
-Making adjustments as necessary during shift to produce product within specifications.
Monitoring and controlling the onshore Gas Plant consist in Gas Treatment Unit (three process trains) and Sulphur Recovery Unit (three sulphur trains). Involved in Gas Treatment unit: Gas Sweetening with amine (MDEA), Gas Dehydration (molecular sieves), Gas Hydrocarbons Dew Point control (Toromont refrigeration package), Condensate Stabilization Unit (Dresser Rand compressor for off-gas recovery), NGL Fractionation Unit.
Monitoring the operational activities, and co-ordinates the process activities according to instructions and production requirements. Carrying out start-up preparation, normal operations, shutdown of process/utilities lines as per Standard Operation Procedures. Developing trends in operating conditions, reporting significant changes and initiating action .
Actively participating in the plant revision when coordinating commissioning activities after overhauling such as:
- Shut -down the plant in safe conditions
- draining the hydrocarbons
- purging the pipe and the columns by steam or by nitrogen
- discharging the molecular sieves from the reactors and fill up with new molecular sieves
- Blinding the plant following the blinding plan
- Preparing the reactors, filters, columns, reactors and vessels for inspection.
- Purging with nitrogen after revision and start up the plant
Also participating in leak tests, flushing, blowing, pressure tests, hydro tests, tightness tests, in accordance with operation manual and start-up diagrams,
Performing regular operation maneuvers for ensure a safe and efficacious performance of the plant and its equipments .
The Attahaddy gas plant has been designed for treating raw sour natural gas from the Attahaddy gas field by reducing CO2 content and ensuring the compliance with the water and hydrocarbon dew point temperature specifications. Involved in all the plant activities, in all the areas, controlling the plant using the DCS system manufactured by ABB, during the plant normal operations, start-ups, normal and emergency shutdowns also during the maintenance activities. Complying with all company Health, Safety and Environment policies and procedures.
Carrying out similar or related duties such as maintaining shift log, initiating emergency procedures as required while complying with Company safety rules and regulations.
Involved in all the plant activities, in all the areas, controlling the plant using the DCS system, during the plant normal operations, start-ups, normal and emergency shutdowns also during the maintenance activities. Complying with all company Health, Safety and Environment policies and procedures. Monitoring the operational activities of my assigned area, via the DCS, and co-ordinates the process activities according to instructions and production requirements. Maintaining continuous radio contact with duty personnel, informing them of current operating conditions, laboratory results and co-ordinates the action necessary to maintain within the agreed operating parameters. . I participated active in Plant revision when I performed activities like :
-shut -down the plant in safe conditions.
-draining the hydrocarbons
- purging the pipe and the columns by steam or by nitrogen
- discharging the catalyst from the mercury removal reactor and fill up new one .
-Blinding the plant following the blinding plan
- Preparing the reactors, filters, columns, reactors and vessels for inspection .
- Purging with nitrogen after revision and start up the plant
Monitoring the operating parameters and modifying them using Distributed Control System: DELTA V-EMERSON according to process requirements. The plant has the goal to remove sulphur components from C3-C4 fraction coming from the top of debutanization column. Controlling the entire process and equipment as:
-an absorption column with DEA, provided with 10 orifice plates, where the hydrogen sulphide is removed.
-a pre - washing column (with caustic soda) where the hydrogen sulphide tracks are further removed
-an extraction column (8 orifice plates) with caustic soda for mercaptan absorption
-a caustic soda separator vessel and a sand filter used for separation and removing of the caustic soda tracks from C3-C4 fraction before being routed to Gas fractionation unit.
-caustic soda regeneration unit composed of a steam pre heater, an oxidation column with graphite rings filling and a caustic soda- residual gases separator.
Ensuring the continuous and safety functioning of the plant in accordance with designed parameters, realizing the established production schedules lowering the processing expanses. Planning the demand of material and financial resources in order to fulfill the plant production schedule, performing the process operations and organizing the revision activities. Performing start up operations and intervention activities in case of shutdown, organizing the activity of supplying with feed stock, catalysts, chemical products and storage of final products. Coordinating the training activity of the subordinated personnel regarding safety and fire fighting regulations to be observed during the shift. Checking the quality of the feed stocks and of the final products, adjusting the process parameters to meet the designed specifications.
Coordinating pre-commissioning, commissioning activities after revisions and overhauling activities including the following operations and tests: leak tests, flushing, blowing, pressure tests, hydro tests, tightness tests, solo motor run for pumps
Familiar with handover flow chart and issuing all kind of documents and forms pre-commissioning and commissioning related contained in the Handover Procedure (piping - cleaning, inspection & box-up certificates, discipline acceptance certificate DAC, punch list, mechanical completion for system etc) as a result of pre-commissioning activities.
Coordinating the following processes: IPB (isopropyl benzene) obtaining by alkylation of benzene with propylene, Phenol and Acetophenone synthesis. Controlling the mercaptan absorption process from C3 fraction, using DEA (diethanol amine) and the dehydration unit using molecular sieves as well. Ensuring the observance of technical documentation, monitoring the production achievement and products quality, supervising supervisors’ activities. Elaborating (alongside with supervisors) the operating manuals of the plants after revamping works, attending to process improvement. Taking the corrective adjustments of the process for a better quantity and quality of the final products: Phenol, Acetone, Acetophenone, IPB. Monitoring the evolution of the pollutants analyzing each of them, adjusting process parameters for lowering the environment impact.
Starting up the plant after revisions works or overhauls, keeping the production at the designed specifications; preparing the plant for revisions or maintenance operations, shutting down the plant in safe conditions if necessary. Coordinating process activities, verifying products and raw material quality, lowering the raw material consumption and energy as well. Training the subordinated personnel regarding the plant equipment and process stream, elaborating the overhauls and revisions schedules. Elaborating the work procedures in compliance with safety regulations and fire fighting rules.
Involved in activities regarding pre-commissioning, commissioning, handover and start-up for systems but also for designated units.
Preparing cold/hot/confined space Permits to work; ensuring safety at workplace (by Tag Out/Lock Out, Start card, tool box talk) during the project phases and regular operations.
Collaborating with all departments involved such as electrical, instrument, piping and vendors.
Performing piping and pre-commissioning work as:
- caring out test packages, issuing construction / commissioning punch lists for utilities and hydrocarbon systems;
- checking the engineering documentation including the pressure test packages, supervising and supporting the pressure test activities.
Issuing DAC (Discipline Acceptance Certificates) dully signed by Contractor and Client; System walk-downs together with the client, QC and safety officer before feeding utilities and hydrocarbons or starting certain equipment; Piping related field activities (flushing, chemical cleaning, air/steam blowing, System Reinstatement after hydro test and then after pre-commissioning activities); Punch lists clearing; Performing commissioning activities as:
-System leak test, drying and inertizing systems, mechanical completion for a system;
Bringing utilities systems in service (charging the pipelines and the users with cooling water, plant air, N2, service water, instrument air, demi water, steam condensate and HP/MP/LP/LLP steam);
Participating in troubleshooting emergency shutdowns and preparing and coordinating the repairing activities.