Sulphonation Plant Production & Planning Section Head
Galaxy Chemicals
Total years of experience :17 years, 6 Months
• Control, operation process and production facilities of Sodium Lauryl Ether Sulfate (2 Lines) and Linear Alkyl Benzene Sulfonic Acid LABSA (2 Lines), Formulation 1 Plant, Packing Section with Sulfonation Plant capacity 250, 000 MT/ year through Emerson Delta V control system (DCS).
• Oversee the Production and Plant operations on daily basis.
• Provide process documentation, Manuals, Operating Instructions and review the routine files as DPR, OEE, OTIF, NDR%, Dispatch VS Rolling Plan, slow moving Materials, Monthly report, Monthly Usage variance report, Budget, ERP Navision System Booking CaPex Studies, ...etc.
• Daily checking field log book, and DCS process log book, DCS process parameters, DCS trends, and provide supervision and troubleshooting for any process offset.
• Commissioning and startup for new production lines or units.
• Technical training and evaluation for team members through KPIs aspects.
• Involved in RCA, Complains, internal Auditing, PSSR, Annual Maintenance planning & execution, Spare parts reviewing, Catalysts replacement.
• Review plant production & packing plans, R.M purchase orders, MRP.
• Involved in safety incident reporting, investigations, NCR reports.
1. Operate of the Framchem facilities within the defined operating windows and according to procedures to meet the desired operating deliverables.
2. Design, implement, use and maintain a fit-for-purpose asset management program for the site.
3. Develop relevant manufacturing cost budgets for the site (including capital expenditure plan) and report progress against these budgets.
4. Develop raw materials and utility consumption plans and report progress against these plans.
5. Organize site management and staff development.
6. Execution of site personnel strategy: recruitment, training, development, dismissal.
7. Execute relevant HSE/Q policies in line with Nufarm HSE global guidelines and in compliance with local legislation, site operation management systems and global and internal procedures.
Supervise two continuous Sulphation production lines, Formulation Plant of oleo oils, sulfur furnace, SO3 conversion unit, sour gas absorption unit, Tank farm of Ethylene oxide, alcohols, Oleo oils, Organic feed materials and utilities, maintain proper operating conditions, and additionally lead numerous capital projects. Develop best practices, routines and innovative solutions to improve the production rates and quality of output. Take a lead in new units from feasibility study to preparation and planning, mechanical completion and integrity check, pre commissioning & operational testing, commissioning & initial startup, performance &acceptance tests, and post commissioning. Supervise the utilities of the plant . Oversee more than 160 personals in traffic, quality control, SH&E, and production, and Manage inventories. Ensure all Documentation as per standard ISOs systems. Provide process documentation, operating instructions and update routine files as DPR, OEE, NDR%, Dispatch VS Rolling Plan, slow moving report, Monthly report, and Monthly Usage variance report.
Handling of Simulation Package and Process Modeling for modifications. Preparation of detailed process design feed and Basic Engineering Package, preparation of PFD, UFD, P&ID for modifications. Line, and equipment's sizing (Gas, Liquid and Two Phase Flow). Carrying out tests like cleaning, passivation, hydro test, flushing, purging, pressure testing, and mechanical integrity testing of vessels, columns, and pipe works, system checkout, operational testing, dry run, and hot testing, dynamic testing, simulation trails, start up, and initial operation. Conduct PHA, HAZOP, PTW, LOPA, SLA, QRA, Task Based Risk Assessment, accident Analysis, investigations, etc. Write operation, procedures and commissioning/start-up manuals. Preparation of Cause & Effect (C&E) chart, PSD & ESD logic diagram. Contribute in commissioning & start-up of PVC, VCM, Incinerator, EDC, and Zero Liquid Discharge units ( Ineos Technology). Working closely with automation team, ABB, Ineos, Honeywell, Emerson Delta V for developing process control system. Review field log sheet book, check the trends, alarm responses, etc.
Oversee the day-to-day operation of the processing plant. Operate chemical processes or systems of machines, from DCS control room, using panel boards, control boards, or semi-automatic equipment. Monitor, measure, and report on production related process performance, general issues, and Operate within standard operating procedures (SOPs), GMPs, and Job Safety Analysis (JSAs). Troubleshooting solving & supervise start up and shutdown for the plant efficiently and safely. Manage the team in accordance with H.B. Fuller policies, practices, procedures, and programs during the shift.
1- Handling budget and expenditure
2- Achieve production targets of Deflocculates (STPP& Sodium silicate) production plant, and preparation of Production monthly report..
3- Analyzing operational issues like RCA.
4- Accessing new processes, and Installing new equipment.
5- Doing quality checks.
6- Providing technical support and training
7- Drafting manufacturing documentation
8- Analyzing data, Downtime, charts and graphs.
1-Manage process units, Installing new equipment, operations like RO units, softeners, bio reactors, filtrations.
2- Control the quality of the water produced and distributed, and waste water collected and purified.
3- Organize and coordinate the work carried out by our teams.
4- Implement contractual clauses, Meeting project deadlines.
5- Build and develop relationships with customers and partners.
7-Contribute to internal and external reporting.
8- Adapt and apply Quality, Environment & Safety systems.
Higher diploma studying transport Phenomena, Heat Transfer, Mass Transfer, Unit operations, Plant design, Oil & gas industries, Environmental engineering, statistics, control & Optimization, my project was Bio Diesel.
Grade of the Project: Excellent.
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