Head of Process Design
Shell/ Basrah Gas Company
Total years of experience :20 years, 3 Months
Currently I am working as process engineer in Asset team, giving support to operation. My duties include the following:
• Work in front line with operation to deliver safer and more reliable gas plants by providing monitoring and optimization for compression stations, NGL, LPG and AGRU plants.
• Developing and coaching Locals stuff lead 9 process engineers to deliver different activities. 3 direct reporters and 6 indirect.
• Lead a team to deliver Operating Envelopes for two NGL plants and 9 compression stations. And then to develop a training program for Engineers and Operates.
• Provide support for process safety team when needed. Such as RV calculations and HAZOP studies Conceptual design, front end engineering and detailed design for plant changes resulting from optimization studies. This includes developing excel sheets for calculations and sizing.
• Giving technical support and advice for operation, monitor and troubleshoot and optimization for the gas compression and gas processing plant, including acid gas treatment.
• Lead a team to rehab TEG units with multi discipline team.
• Reviewing Management of Changes “MOC” and give technical steering/advice.
• Standing for Process Engineering Manager when needed.
• Leading the interface between the asset and maintenance team to deliver small changes.
• Support project teams for green and brown projects
My Duties in this role included the following:
• Support Well, Reservoir, Facility management (WRFM) team and asset teams to safeguard FCP production.
• Support operation, to maintain the production via monitoring and analyzing field data by using DCS, PI and excel sheets.
• Provide technical direction, monitoring and advice on plant optimization for facilities, by implemented consistent identification of potential threats and opportunities and the translation of these into timely investigations and improvement actions.
• Provide plant assistance and technical advice on operating problems, processing constraints and all process matters.
• Support operation Integrity team to implement alarm management program. I lead a team to reduce the alarms from above 3000 to be 10 alarm in 4 months.
• Built a simulation model for the plant and calibrated it to match actual readings in the field.
• Developed Operating Envelopes for most critical equipment, maintained them and prepared a training program for Control room operators to increase their knowledge on how to use it as a monitoring and optimization tool.
• Provide support for projects that will happen in Majnoon.
During my work as process engineer supporting Engineering-Project team to deliver Majnoon First Commercial Production project. My duty includes the following:
• To assure the design is meeting the requirement of agreed standards and process safety standards.
• Prepare management of change documents for design changes to make sure that different scenarios for the first years of productions are available for operation and as back up plans.
• Participate in HAZOP’s and making sure that actions are implemented.
• Looking after preparing Work Package for Invitation for Tender documents for the post FCP activities.
• Incorporating the multi discipline action and make sure they all aligned.
• Technical deviation review to make sure that no residual risk is left and to check if deviations need to go through management of change process.
• Support other projects related to Majnoon field such as Shatt Al Arab River Water project by by participating in workshops, weekly meeting, review of CTR, and updating BfD document to control the interface between FCP-Oil and River Water project and Main Drain Outlet Project.
During my work at PDO I worked in three projects:
1- Rabab Harweel Integrated project. This project is a Sour Gas & Condensate project where the H2S is ranging from 1.7mol% to 6 mol% and CO2 is ranging from 5.3 mol% to 17.1 mol%. My main duties are:
• To model the surface facilities using Unisim simulation tool and incorporate along the project the reviews outcome. Flarenet model for the HP-flare part and sized the HP flare main and tail pipes
• Sour gas treating and processing.
• Analysis to optimize the power of compressors and to optimize and prevent temperature cross through some heat exchangers.
• To deliver Process Simulation Report
• To deliver Heat and Material Balance Report.
• To deliver Instrument Air/Breathing Air Packages, Nitrogen Package, and Drain systems. By applying Design and Engineering Practice “DEP” standards for sizing and selecting. Followed by generating datasheets.
• To do a sizing for Pipe line, RV, Control valves and vessel sizing.
• Preparing equipment list and line list.
• Delivering PEFS, PFS, PSFS and material selection diagram for the above-mentioned packages.
• Delivering revision 2 for Narrative document and,
• Delivering the first two versions of Safeguarding Narrative document for Utilities.
• HAZOP studies. Prepare the Information- Packages for HAZOP study.
2- Standardization project: The objective of this project is to standardise the design parameters for eleven test separators across the North directorates. In this project, I worked on developing excel sheet for sizing 3-phase separator with double weir based on Shell DEP. The new for this sizing was that the 3-pase separator with double weir is not commonly used in PDO. I also prepared the Process Design Basis, equipment list and Safeguarding Documents. I prepared PFS, PEFS and Material Selection Diagram Drawings. In addition, I did line sizing.
3- Saih Rawl Depletion Compression stage 2: The objective of this project involved installation of ~ 76 MW of gas compression capacity and modification of the condensate handling system at Central Processing Plant. This will enable the Saih Rawl Main field to produce Maximum Annual Daily Load (MADL) of 30 MMSCMD gas. The planned on-stream date is end of 2015. I delivered the Process Design Basis document version R01, and PEFS for this project.
During my work in Clyde refinery in operational support role as part of production/technology team, I had the chance to get exposure and to work in liaise with operation, maintenance, plant engineers and plant controllers and appreciate their job. I am responsible of 3 boilers, demineralization plant, softening plant, cooling tower and biotreater plant.
My Duties included providing technical direction, monitoring and advice on plant optimization for the utilities plants, where I implemented consistent identification of potential threats and opportunities and the translation of these into timely investigations and improvement actions. And providing plant assistance and technical advice on operating problems, processing constraints and all process matters. Such as, on-site monitoring and operational input during shut-downs, start-ups and abnormal operating modes. Other duty was ensuring that daily focus is maintained on running the plant and that work priorities are aligned with plant operational and maintenance needs. Furthermore, I was providing technical direction and leadership in developing strategic plans for the utilities process and process control configuration. This entails the evaluation of various process unit upgrades and additions to the utilities plants. I also was providing cost effective technical solutions to constraints and emergent problems. I gave support to Operations in the delivery of performance targets. And alarm management at all utilities process units as per ESP requirement. My Duties also included, managing the interface of maintenance activities between Process, production, operation, asset engineers and maintenance. I also has exposure to acid gas treating for stripping water unit and SCOT unit.
All the above resulted in developing my troubleshooting skills.
In addition, during the start up activity in July/09 I had a chance to be a pre-start up safety review lead for Platformer, HDT, BRU and movement plants. I also developed pre-start up conditioning plan for the biotreater to prepare it for start up. I prepared a venerability report for all the units I am responsible for and followed up with maintenance to make sure they are fixed before start up.
MY duties also included working aligned with finance, supply and chain teams to develop gas and electricity contracts. I provide them with technical and operation support, and advised on fluctuations
One of my duties was to monitor the gas and electricity consumptions in the refinery and advice the supplier with next day nomination and do monthly forecasting. I also developed a philosophy to help the operators to control the gas consumption within the contract limits
I developed my HSE knowledge, particularly when I applied management of change process. Pre-Start Up-Safety Review and HAZOPs. And also by providing support for the implementation and maintenance of HSSE critical work processes - such as HEMP, IPF and TA.
My Duties also included working with Environment team to make sure that the environmental regulation and legislations are in place, by monitor the plant performance accordingly. Such as, meeting the discharge water to river spec, discharge water to trade water sewer specs. Also flue gases specs from boilers to stack.
In Shell EP Int’l, as a Development Engineer in Regional Leadership team, and reporting to Technical-Vice President of the Middle East region. To assist VP-Technical on daily basis and to accompany him in his meeting were part of my duties. I had the chance to observe and learn from very high-level managers and to improve my interpersonal, leadership, business and management skills as well as my technical skills.
I had the chance to see the business overview in Upstream Middle East and do short trainings in Egypt and Oman onshore fields.
Another duty was to be a focal point for CO2. I was part of global team that worked on increasing the understanding of CO2 opportunities, and to deliver a 5-year plan that aims to reduce CO2 emission and evaluate abatement projects. Moreover, I helped in increasing the understanding of CO2 business-related risks in EP-Middle East.
During my work in QTS as a sales engineer, my duty was to look for opportunities in Qatar market to implement water/waste water treatment technologies my company has. This also included advising the client with the best water/waste water treatment technology/process that can solve his problem. The procedure of solving included design, pricing and finally making proposal. I have gained the design, sails, proposal and technical support fields’ skills.
Further more my duty was to price the processes that have been designed for market purposes.
During this period I performed many projects for different research groups at the University of Twente. The main project was a Plant Design to study the Technical and Economic Feasibility for ethylene/ethane separation process using a gas-liquid contactor membrane. In addition I did the following projects: Developing a ChemSep Model that can perform the design and simulation of a distillation column for separation of dichloropropane from a multicomponent mixture. Vapor liquid Equilibrium for Hydrogen Ethylene Propylene system, experimental, and modeling. The conceptual design for the removal of BTX vapors from gas streams by means of a suitable solvent system. Reactive distillation.
- 03/04-03/05 Unilever research & Development
Vlaardingen, The Netherlands
Project Engineer
As a part of my project engineering work, I did work a full time-one year project for Unilever. During my work in Unilever R&D as project engineer my duty was process selection and design, and developing novel integrated laundry wash system comprising new process as well as new type of detergent. My focus was on the design of new process of water treatment consisting of a number of unit operations with deferent demands, properties and specification for systems that can take over number of detergent functions that normally represent the major part of the formulation, which leaded to promising results and clear recommendation for the way forward