Rajivan Panicker

The company is BOO contract with KOC. It includes Slug Catchers, Low Pressure Separator, Convection Heaters, Electrostatic Dehydrators, Electrostatic De-Salters and auxiliary water treatment and injection systems. The plant process medium to light crude from the nearby wells. This is unique plant as there are no settling tanks. Till the dehydrator, the facility processing sweet crude at low GOR, runs on the well head pressure

* Involved in Transfer of the facility from contractor to KOC. Includes various activities such as assisting in NDT activities, process design evaluation for two S&T Heat Exchanger’s, technical and commercial negotiations for facility transfer at middle management level, cost control and preparation of related documentation. Lead a multidisciplinary team with operators, electrical, mechanical and instrument engineers. Facility Transferred on April, 2019.

* Currently working as shift lead, under operation & maintenance manpower supply contract for KOC.
Troubleshooted operational issues for smooth running of plant.

 Involved in preparation of SAFER (SABIC Assurance For EHSS Risks) on a daily basis.
 Involved in trouble shooting and reporting on a daily basis
 Worked with both floating roof and fixed roof tanks.
 Trouble shooted Ammonia tank annular space level occurrence
 Involved in Ammonia tank decommissioning. Was recognized for the same and given appreciation award and was in the plant roll-of-honor list.

MOES operates in upstream oil and gas segments and designs and supplies test separators and other related equipments such as mud system, well head completion jewellery etc.

* Involved in FEED cum detail engineering for Fuel Gas Scrubber for Dragon Oil Dubai, for site at Turmiskestan. Further also involved in bid support and engineering. Includes test separator design and validation as per API. Involved in mud system design at well head. Involved in capital cost estimation for a green field NGL plant for Africa using HYSYS Economic Evaluation after HYSYS steady state simulation.

KEAS is involved in design and engineering for upstream Oil & Gas, from concept to commissioning.

* Working on FPSO’s, and Early Production facilities in the Middle East, Far East and America.
Associated with project from ITB to commissioning. The process involved IDC and SDC checking of documents and strict adherence to standards (Shell, API and internal standards). Further, the process had regular meetings (video/telephone conferencing) with client at various milestones and involved minimal comments from clients on the deliverables.
* Involved in concept study for Atasyil Tekkel, Mexico FPSO handling sour crude for separation of gas, water and oil and disposal

The company is BOO contract with KOC. It includes Slug Catchers, Low Pressure Separator, Convection Heaters, Electrostatic Dehydrators, Electrostatic De-Salters and auxiliary water treatment and injection systems. The plant process medium to light crude from the nearby wells. This is unique plant as there are no settling tanks. Till the dehydrator, the facility processing sweet crude at low GOR, runs on the well head pressure.

* Involved in Sonic and Smoke less flare study using Aspen Flarenet. Had discussions with the vendor
Flare Industries, USA on the same. Involved in maintenance of the same during s/d.
* Simulated using HYSYS the EPF facility for evaluation of various options like hot water recirculation and export oil heat recovery
* For the installation of the third heater, simulated the hydraulics using PIPEPHASE
* Troubleshooting the issue of line vibration due to oversized control valve in the De-Salter Water outlet.
* PSV sizing for water injection pumps
* Co-ordinated with KOC personnel regarding issues and requirements
* Participated in Sep/Oct 2013 shutdown. My role was
o installing and analyzing corrosion coupons
o Inspection of vessels and tanks before final boxup
o Getting baseline thickness for pipelines, heaters and vessels
o Suggestions of internally coating the vessels for protection, which was accepted and done.
o Suggestions for improving water clarifier by accurately determining the oil bucket level.
* Was member of a team involved in design capacity validation of the plant. In the process identified and
overcome debottlenecks and advised plant operators for optimum performance of the plant.
* Participated with similar role as in Sep shutdown during the April 2014 shutdown.
* In the process became familiar with KOC standards
* Involved in design of coated pipes for salty water handling
* Trouble shooted the issue of quality achievement of less than 30 PTB in export crude with the help of the mixer vendor (ProSalt, USA). This involved judicious pressure drop estimation across the mixer and the right ratio of wash water. This was an issue from the inception of the plant.
* Was involved in the Procurement process for projects and shutdown activities
* Was involved in the HAZOP and SIL study conducted by KOC
* Involved in Corrosion Control and monitoring activities

Projects involved in are

 FEED for Desalination Plant for Clarity Aqua Systems Ltd, Kochi, Kerala
Involved in
 Conducted Simulation using Aspen HYSIS of Multi Effect Distillation (MED)
 BFD, PFD & P&ID generation
 Process Description formulation
 Installed ASPEN HYSYS 8.5 standalone version on one computer

 3-Phase Vertical Test Separators for Chenkuttavan for sizing of vessel including plate pack.
 FEED for Cold Heavy oil production with Sand for LFTP, for KOC, North Kuwait
Involvein
 PFD & PID generation
 Sizing of Heat exchangers using HTRI, Vessels as per SHELL DEP and Air Coolers using HTRI
 Sur IPP Gas Supply Station - Inlet Separator sizing using SHELL DEP
 Gas Sweetening Facility (GSF) for KOC, West Kuwait
o Debottlenecking & Detailed Engineering
 Conducted simulation of the TEG dehydration and Gas conditioning unit using Aspen HYSYS
o The units involved were TEG contactor, lean/rich plate exchanger, Stripper and stall column
 Conducted hydraulic studies based on simulation for Amine absorber, Amine stripper.
 Involved in PFD & P&ID modifications based on the simulation results.
 Was involved in Long Term Modification (concept study) analysis for Al-Rashed, EPF KOC North
Kuwait
 Was resident at Kuwait for a month and half for the project
 Completed simulation of the facility using HYSYS
 Completed Fire water study for the facility
 Was involved in preparation of shutdown.
 Involved in sizing of Restriction Orifice for PSV adequacy estimation
 Involved in HYSYS simulation for Gas pipeline depressurization study
 Was involved in building Smart P&ID’s for Takreer Refinery Al-Ruwais, AbuDhabi, UAE. The work included line tracing for on-site verification/addition/deletion of existing old P&ID’s and data collection for making the P&ID SMART. The units covered were VDU, REFORMER and SULPHUR RECOVERY UNITS. Was stationed in Abu Dhabi Takreer Refinery for two months.
 Involved in complete simulation for LTTF project KOC, including Gas separation, Crude




Stabilization, Amine and Glycol sections.
 Using HTRI designed Shell and Tube and Air Coolers for LTTF project, KOC Kuwait
 Simulated using HYSYS the crude treatment facility for EPF project in Sudan. The activity involved formulation of the Feed for different API (High 35 and Low 18 API)and EPF simulation.
 Gained familiarity with international standards such as SHELL DEP and API.

involved in beneficiation of China Clay
 Was involved in making a comprehensive simulation in C programming language for the Rotary Kiln, which has been hosted on our company intranet
 Involved in conceptual study for clay production/handling unit in Gujarat.
 Succesfully installed Rockwell SCADA system in control room machine.

Is involved in production of Urea from natural gas, designed by technology licensor’s
HaldorTopse (for Ammonia plant) and Snamprogatti (for Urea plant).


 Debottlenecked the Process Air Compressor (PAC) using inlet suction chilling.
 Also involved in monitoring process data by calculation and personal computers ie. Monitoring the energy consumption of the complex.
 To port the MIS reporting which was Excel based to ORACLE platform
 Was involved in making of TOP (Total Operating Parameters) for the entire complex for the year
Was a team member for Aspen HYSYS simulation of the primary Reformer.

Application Engineer, promoted to Senior Application Engineer
TATA HONEYWELL LTD., INDIA (Engineering Software Division, Hi-Spec Solutions - Process)
Application Engineer in Tata Honeywell, an alliance partner of Honeywell, Inc. USA. Was initially recruited as Engineer and later on was promoted to the position of Sr. Engineer. A brief description of various positions at Tata Honeywell follows:

 Process Engineer, Dynamic Simulation Group
Executed Dynamic Simulation projects. Projects included oil and gas platform and refinery simulations. The units simulated were Chilling and Refrigeration section for an Off-shore platform and CO burner for a FCC plant. Control strategies for the same were also implemented.

 Process Engineer, Oil Movement and Storage
Responsibilities included editing tank farm graphics and debugging issues with Task Control Module, Task Monitoring Module, Blend Ratio Control and Blend Property Control Honeywell product suites. Four blenders (MS, HSD, SKO and FO) with on-line analyzers (NIR and conventional) were commissioned. The same was based on NT platform with Honeywell TDC 3000 (TPS series) DCS. Was given an award of appreciation after completion of the project.