Production Engineer
THE DOW CHEMICAL COMPANY
مجموع سنوات الخبرة :2 years, 5 أشهر
THE DOW CHEMICAL COMPANY, DUBAI SITE (April 2012 - To Date)
Position held: Production Engineer
Designed by DOW Engineering Team, capable of producing 125MTPD of LATEX, plant is equipped with distributed control system (DCS DELTA-V 10.3.1 by EMERSON)
Job Responsibilities: • As a technical resource for Operations personnel, applying technical skills within Manage Production, to optimize plant operations, resolves plant problems and enables safe and efficient production of low cost, quality products.
• Applies, Deference to Expertise, Sensitivity to Operations, Reluctance to Simplify, Preoccupation with Failure and Resilience to promote the development of a Highly Reliable Organization.
• Understands all applicable process technology, equipment and control technology. Works with Technical Advising and plant personnel to optimize operations to meet Business and plant goals. (EH&S, Production, cost, quality, energy, reliability)
• Participates when required in advanced trouble shooting and coaches others to learn these skills. Ensures findings are documented in Plant OD for future usage.
• Provide leadership and direction in the day to day decision making for the operating area of responsibility.
• Networks with other engineers on site and within the business to leverage knowledge on plant operations. Example: Maximize Production, Improvement, Site Optimization, etc.
• Ensures MET is understood and utilized.
• Ensures Operating Discipline / ODMS requirements are met and include appropriate MET (Most Effective Technology)
✓ Coaches plant employees on effective implementation and utilization of MET. Implements best practices in order to optimize operations.
✓ Applies skills and knowledge in Statistical Process Control (SPC) technology to projects.
✓ Provides Six Sigma Methodology and technical support to projects.
• Works with Plant Process Control Coordination Role to ensure process control is optimized in the facility.
PAK-AMERICAN FERTILIZERS LIMITED (Sep2010-March2012)
Position held: Shift Engineer/Production Engineer
Pak-American Fertilizers Ltd. (ISO 9001-2, 14000 and OSHA 18000 certified) is an M.W Kellogg Designed Ammonia plant, capable of producing 600MTPD of Anhydrous NH3 and 1050 MTPD of Urea. Plant is equipped with Totally Distributed Control System (TDCS 3000X by Honeywell-Yamatake)
Job Responsibilities: • Prepare and supervise critical operational activities: start-up, shutdown, and provide technical support to the Shift Supervisors throughout these activities.
• Enhance, implement and update operational procedures and planning associated with maintaining and improving plant efficiency.
• Participate in scheduling, preparation and execution of the maintenance plan and Annual turnaround of Ammonia plant. Propose changes and modifications to improve the safety and reliability of plant operation.
• Coordinate / liaise with Urea and Utilities Shift Engineers as well as with other disciplines for load management of complex.
• To Prepare Production Report & Daily Shift Logging report for onward submission to Higher Management.
• To propose modifications for better integrity, maximum production and to achieve best product quality.
• DCS & PLC handling and Emergency responses.
• To apply and maintain Safety standards in production facility and also make necessary steps to prepare the plant for OSHA audit.
• Ensure uninterrupted, safe and efficient operation of the unit & responsibility for emergency handling, startup and shutdown of Ammonia Plant.
• Assessing Daily troubleshooting and maintenance activities by coordinating with services departments by ensuring safety measures.
PROJECTS
Commissioning and Startup of 125 MTPD LATEX Plant at DOW Chemical Company, Dubai Site
I actively took part in plant commissioning and startup with DOW Engineering team i.e. commissioning of reactor, cooling water system, waste water treatment plant, MET, LEV, DT, Bulk storage tank, Pigging system and CATOX.
PROFESSIONAL TRAININGS:
• "Situational Team Leadership Training" by Dow HRD.
• "Delta V Software & Hardware Training" by Emerson Middle East (Dubai)
• "Apollo Root Cause Analysis Training" by Dow E&HS RCI, Dubai.
• "Basic Emulsion Training" by TECH CENTRE Dow Coating Material Shanghai China Team in Middle East Head Office (Dubai)
• "Production Operations Management" from My Learning Program, organized by Dow USA.
• DCS Delta V 10.3.1 VERSION, 1 week training on a simulated software
• Many more basic trainings according to DOW E&HS Standards i.e. isolation of energy ( tagging, knocking, SWP issuer etc.
• Digital log book training.
• Extensive Safety training carried out with fire drills and HAZOP STUDIES.
• I developed SOP for entering in confined spaces of ammonia plant and also delivered presentations on my work.
• Attended a 5 days training session to improve Communication and Technical Skills relevant to plant operation safely.
• Process and system studies: Coating Emulsion Polymerization and recovery, LEV System, Mixing, Coagulation, supporting utility, Process and Product Quality Control, De mineralized Water Unit, Steam Boiler, Cooling System, CATOX Unit, Waste Water Treatment, Ammonia Refrigerant, Compressors and pumps, tank storage etc.
• Management of Change (MoC) Standard System Coordinator.
• Production Operation Management (PP-POM) Work Process.
• ODMS (Operating Discipline Management System)
• Root Cause Analysis (Apollo RCA Certified)
• New Product Scale Up Projects.
• DOW EH&S Standard.
• Delta V System
• DCS Control System: Yamatake Honeywell TDC 3000 LCN
• Operating and maintenance of main and auxiliary equipments in the plant (pump, compressor, Heat exchanger, etc)
• Competent with Microsoft Windows Operation System and Microsoft Office programs.
• Excellent knowledge with Chemical Engineering Simulation software, DELTA V.
• Good knowledge of process units in a Fertilizer sector.
• Ability to continuously drive for process improvement.
• Ability to work in a dynamic environment.
• Good interpersonal, communication and management skills.
• Capable of giving strong attention to details.
• Strong analytical ability.
• Conversant with Microsoft Office applications.
Bachelor of Science in Chemical Engineering COMSATS Institute of Information Technology Lahore Pakistan Pakistan Engineering Councel Registration Number CHEM/9581. NEBOSH International General Certificate in occupational health and safety. IOSH Managing safely.