Sustainability and Energy Engineer
SABIC
Total years of experience :17 years, 11 Months
ISO 50001:2011 (Energy Management System) certified as a 1st affiliate in Sabic with no findings in DNV audit
Lead internal and external audit to ensure the energy utilization across the site is well monitored and controlled as per requirement of ISO 50001:2018.
Energy (EnPI - Energy Performance Indicator, EE - Energy Efficiency, SEEC EI - Energy Intensity)
SEEC & Benchmark Reporting based on specified boundary.
Sabic Certified Energy Expert.
Sustainability (GHG emissions, Energy consumptions, Water consumptions and Material Effectiveness) reporting.
Performance monitoring on Significant Energy Users (SEU) and optimizing based on KEV (Key Energy Variables) control
SABIC 2025 target to achieve reduction of 25% of Energy Intensity, Green House Gas emissions (CO2 eq.), Water Intensity and 50% reduction of Material Effectiveness from the base year 2010.
Operating Management System (OMS) prepared for Sustainability (OMS-424) & Energy (OMS-423) procedure to provide the guidelines and structure to report sustainability and energy footprint of affiliate and facilitate improvements in order to drive the system for efficient use of natural resources and reduce the emissions to protect the environment.
Carbon Neutrality Program studies to re-think the total facilities according to Saudi 2030 Vision.
Circular Economy awareness to plant focal points to identify the wastes with innovative recycling.
Adhering to Sustainable Development Goals (SDG’s) 10 out of 17 goals adopt by Sabic to support the United Nations Department of Economic and Social Affairs Mission.
Lead the Brainstorming sessions & Energy opportunity assessment studies, Site Energy walkthrough with Operation & Process Team to identify and troubleshoot the energy-impacting asset.
ASPEN Utility Optimizer developed for the entire complex to improve the overall fuel gas utilization efficiencies.
Balancing Fuel Gas, Steam and water for the entire complex to identify the loss and opportunities for integration.
Analyze business-planning production for the year and develop performance targets for monitoring plant utilization, energy performance, chemicals and utilities consumptions.
Coordinates with departments and management in translating the international benchmarking (Solomon) analysis results into roadmaps for performance improvement.
MOC review in the 1st stage of project regards to sustainability and energy management to approve or reject the projects
Calculate the emissions, flaring, energy savings, energy consumptions…etc. for all operations and projects to ensure proper tracking of energy efficiency.
Analyze the energy efficiency data to ensure proper performance in line with the company directions.
Recommend and report the energy-related updates and calculations to ensure timely sharing of the updates with the management and related teams.
Advise on any improper or deviation of energy efficiency for equipment, operation conditions, projects or activities to ensure the needful support.
Develop the energy limits and standards for all assets, operations, materials handling.
Design and recommend the energy reports, forms and templates to ensure proper record.
Maintain and update the energy record to ensure availability of information.
Conduct energy-related audits to ensure the desired compliance by the respective energy team.
Participate in deploying or developing the Energy Management Systems and Certification in line with company directions, Code of Practice, and International Certificates; ISO50001.
Communicate and train the operations focal points and process trainers understand with respect to energy consumption how their activities and behaviour contributes to the achievement of energy objectives and targets.
Draft and propose different types of communications, on timely basis, for energy related targets and objectives to all relevant personnel.
Professional Freelance - Online Process Engineering Solutions
PROJECTS:
• Conceptual design for small scale projects, bottlenecks and retrofit studies.
• De-bottlenecking project for Methanol plant and Purge gas to Ammonia Plant studies with Haldor Topsoe - Denmark
• Distillation online performance test project for with DPT - London
• Developing KNOW-HOW design of R&D new products to pilot plant scale projects.
• CO2 recovery from flue gas project.
• Front End Engineering Design (FEED), Basic and Detail Engineering review and approval.
• Economic feasibility analysis by NPV, IRR & PB.
• Project Coordinator & QA/QC for catalyst change out.
PROCESS:
• Prepare monthly reports about full plant evaluation of all rotary and static equipment with detail analysis.
• All (Reformer, Synthesis and Converter) catalyst performance evaluation, life prediction, EOR SOR optimization, troubleshooting and recommendations to operations.
• TA shutdown job pack preparations (JHSA, JMS, SOW etc.) change out project leader and QA/QC.
• Energy Loss Management System key player to identify and save the energy loss in all units and to optimize the energy utilization.
• Implemented Air to Fuel ratio (in Boiler), Steam to Carbon ratio (in Primary Reformer) and Oxygen to Gas ratio (in Auto thermal Reformer) calculation block in DCS based on Carbon number change in feed gas.
• Perform rigorous engineering calculations for sizing equipment and mass and energy balances.
• Capacity Utilization, Product Optimization, Utility/Chemical consumption Energy Conservation etc.
• Search and evaluate new technologies available in the market for potential deployment to enhance the process.
• Rich experience in troubleshooting Ammonia and Methanol Plant process operation issues, investigation and diagnosis of major operational upsets, incidents and failures, identify root causes and recommend mitigation measures.
• Process simulation and modeling HYSYS, ICON & Heat Exchanger rating - HTRI
• Engineering document review (P&ID, PFD, datasheet, etc.)
• APC Control DCS support for process operations
• Process Optimization experience in Methanol, Ammonia, MMA, DMA, DMF, Formaldehyde, Sulphonated Naphthalene Formaldehyde, Polypropylene and Penta Plants.
PROCESS SAFETY MANAGEMENT:
• Certified PHA Leader on HAZOP, WHAT-IF & FMEA by Dr. William Bill - USA
• Experience in PHA (HAZOP & WHAT IF methodology) studies for more than 10 plants.
• Developed PSM Element PSSR (Pre Startup Safety Review) procedure and implemented with training.
• MOC (Management of Change) technical reviewer.
• Lead Risk Assessment studies, JHSA, JMS before start of Plant shut down activities.
• Perform risk assessments (RA), root cause analysis (RCA) and provide process documentation and operating instructions.
• Work Permit Management System, Alarm Management systems review.
• Assessment studies for plants with multi-disciplinary team to enhance plant reliability & product quality
PRODUCTION SUPPORT:
• Production full support to resolve day to day and chronic issues and major difficulties in plants.
• Inter department assistance with Inspection, Process Safety, Mechanical, Instruments, Electrical for plant threats.
• Sharing production optimization measures every day in meeting.
• Ensure the environmental impact of the plant is minimized and within the limit.
• Develop procedures (commissioning & De-commissioning) and operating procedures.
• Implement calculation blocks in DCS for Panel men ease operations to optimize the plant 24/7
• Ammonia Tank Commissioning (Atmospheric tank 10, 000 MT capacity) for cryogenic service.
TRAINING & DEVELOPMENT:
• Lead and supervise the team of Process Engineers (8nos) to plan and control work assignments in order to achieve monthly target.
• OJT (On Job Training) for fresh Process engineers with prepared schedule in target time to understand the process and functions of all unit operations.
• Short term training for Chemical Engineers to develop their academic project in-plant facility.
• Front End Engineering Design (FEED), Basic and Detail Engineering review and approval.
• Conceptual studies for new projects, modifications and innovative ideas.
• Purge Gas from Methanol plant to produce Ammonia - Conceptual studies with Topsoe Denmark.
• De-bottlenecking studies for Methanol plant with Haldor Topsoe - Denmark
• Distillation online performance test MHC & MRR check with DPT - London
• Process Licensors Evaluation.
• Process Optimization and trouble shooting.
• Monitor and improve the efficiency of rotating equipment
• Process simulation studies using HYSYS & CHEMCAD for Natural Gas Plants.
• Control valve selection and sizing in spreadsheets
• Pipeline sizing and pressure drop calculations in spreadsheets.
• PSV’s TSV’s sizing as per API Standard
• Selection and sizing of steam traps for different conditions
• Orifice sizing and design
• Developing Engineering Calculation tools in Excel sheets
• Shell and tube heat exchanger design manual calculations
• MOC (Management of Change) technical reviewer.
• PSSR (Pre Startup SHE Review) specialist in developing the procedure.
• PHA Leader certified (HAZOP, WHAT-IF, FMEA & Check list) by Dr. William Bill - USA
• P&ID Review & site verification
• Developing SOP’s (Standard Operating Procedure)
• Assessment studies for plants with multi-disciplinary team to enhance plant reliability & product quality
• APC Control DCS support for process operations
• Handled Plant Simulators, Process Engineering Software CHEMCAD.
P&ID Review/site verification
Operations support
Adopt HSE rules and regulations to maintain the company assets and properties
Developing commissioning and operating procedures
Optimizing the usage of raw materials and energy consumption and evaluating the effectiveness of used catalyst to meet out process requirements
Designed and executed Stripper column in ASPEN PLUS simulation software
Designing, installing and commissioning new production units, modifications, upgrades and troubleshooting existing processes
Preparing reports, flow diagrams and charts
Supporting the conversion of small-scale processes into commercially viable Large-scale operations
Ammonia Tank Commissioning (Atmospheric tank 10, 000 MT capacity) for cryogenic operations
Trouble shooting process related and equipment related problems, to achieve optimal running conditions with minimum down time.
Carrying out efficiency calculation for rotary equipment and static equipment
Project handled in CO2 recovering from Flue gas.
Persuasive usage of management techniques like 5S, and TPM to increase productivity, reduce wastage and ensure safety of plant and personnel.
Coordinating with PHA team for giving recommendations to reduce operation risk
Steam to Carbon ratio maintaining for optimal production with less energy consumption.
Handled catalyst loading and unloading in Reformer and HTS catalyst
Following up shut down activities and reporting the daily status
Trained in field operations of Ammonia plant to monitor the performance of rotary and static equipment.
10, 000 MT capacity of Ammonia storage tank commissioned for atmospheric (cryogenic) storage.
Heat Transfer, Mass Transfer, Transport Phenomena, Chemical Process Industries, Chemical Process Design etc.
