Plant Engineer

Curriculum Vitae

** *** ****** ******, *** District

Nasr City, Postal Code 11471

Cairo, Egypt.

Name : Khaled Wefqi Mohamed A. Azim Osman

Tel No. +202-********

Mobile: +201**-*******

E-mail: *******@****.***

In : https://eg.linkedin.com/pub/khaled-w-osman/102/22a/956

Present Employer : Shell Exploration and Production, Egypt(SENV)

Operations Division.

Academic Education:

B.Sc. Chemical Engineering 1985 - Distinction with Class Honors Faculty of Engineering and Petroleum, Kuwait University.

Professional Profile (Summary) :-

Chemical engineer with 30 years of diversified experience in the oil and gas industry related to oil & gas production, gas processing, and oil refining and petroleum production encompassing the following:

• Plant design, commission and startup of new facilities

• Operations of oil refineries and gas processing facilities and LNG plants.

• Process engineering support including feasibility and performance improvement studies, troubleshooting, debottlenecking, performance evaluation/testing of process units.

• Operations readiness for new facilities. Application of startup Readiness programs including Construction& Mechanical, Technical, Organizational and Operational

• 20 years in leading positions managing plant Operations with different engineering disciplines to achieve Company’s objectives

Experience gained through numerous assignments across employment with operating companies in Kuwait, UAE and Egypt.

Experience in gas processing covers various aspects of processing technologies including Gas Compression, Acid gas Removal and Sulfur recovery, Gas Dehydration, Cryogenic processes (LNG).

Experience in refining covers Crude & Vacuum units, hydroprocessing technologies ( including fixed ( Cat Cracking RFCC) and Expanded bed (H-Oil) and distillates hydrotreating), Catalytic Reformer, steam reformer based hydrogen generation and all associated utility systems.

Major Achievements:-

Owner representative through leading an Operation team during the FEED, detailed engineering, commissioning and start-up phases for several projects including the following :

A 28 tons per day Superclaus process based Sulfur Recovery plant for ADNOC/ADGAS on Das Island, Abu Dhabi, 1990

An additional LNG train ( 420 T/hr) on Das Island, Abu Dhabi,1994.

A 1500 gpm MDEA based Acid Gas (CO2) removal facility for Shell/Bapetco in Western Desert, Egypt, Nov’2014. Additionally developed and applied Shell standard start-up Readiness and handover of the facility.

Operations representative for the pre-commissioning/commissioning and start up for a 150 MMSCFD grass root new offshore gas plant for processing associated gas on Das Island, Abu Dhabi, 2011.

Led a troubleshooting task force that managed to resolve a major foaming problem encountered in one the LNG trains at ADGAS resulting in 20% production increase.

Led a task force that managed to resolve a major 46000HP propane compressor rotor problem that resulted in increasing plant reliability by 10%.

Applied root cause analysis tools on various plant operational problems to identify the real root cause of the problems namely but not limited to ; LNG plant total power failure, Bed migration in Mole sieves dehydration facility, DEA regenerator top inlet pipe distortion…etc.

Identified and resolved a design malfunction in the major Cryogenic tower which resulted in recommendation to replace the tower in kind due to major problematic leaks. Supervised Vendor new design engineering activity. Flaring due to the leak problems stopped leading to 2-3% production increase.

Skill Profile: -

Rapid adaptability to new work settings.

Proven ability to work and develop relationships with a variety of actors in various settings.

Good analytical and problem solving abilities.

Good communication and interpersonal skills. Fluent comprehension of Arabic, and English.

Tested ability to work well under pressure, individually, and within a team.

Demonstrated leadership, organization, and time-management expertise.

Refer attached for Employment History with detailed Professional and Skill Profiles.

Employment History: -

2012- Present:

QC/SU Manager (AK Project Bapetco/Shell Egypt JV): Seconded to Bapetco( Shell JV) to manage all the Operations Readiness Team activities ( including Production and Maintenance) in the FEED/ detailed engineering/ execute phase and commissioning / start-up and handover for the expansion project of the new CO2 removal plant through construction as QC to pre-commission/ commission, start-up, and hand-over, planned for Q3,2014. The Operations Readiness activities follow Shell Operations Excellence standards with regard, but not limited to:

- Prepare to assume the designated role of AK Plant Operations Manager managing a team of 47 staff and lead the team to be involved in all of the OR activities and the future operations of the new plant.

- Ensure that the Operations Readiness activities identified for the AK Project are carried-out by the EPF /EPC Companies as per contracts and within the time frame.

- Prepare the future Operations of the AK Gas Development Project during the ”Execute Phase” and the “Operate Phase” such that at Hand-Over (year 2014) all Operations Excellence requirements, as per Shell standards, are in place. Examples are as per below.

- Mange the Operations Readiness team with the tasks of being the focal point/coordinator for the following specific OR activities:

- Operations input to HAZOP/SIL /HFE (Human Factor Engineering) & Model reviews, and Operations Requirements into documents/drawings/technical specifications ….etc.

- All Project to Asset Handover Documents .

- Spare parts coordination between the contractors and the field, utilization of the E-SPIR system, and ensure that spare parts information (BOM) is ready and complete to be loaded into the SAP system. This in addition to Asset Register hierarchy (also to be loaded to SAP system).

- Operating Manuals (Production, Maintenance & Laboratory) coordination between the contractors and the field, steering standard lay-out and content, and ensure completion prior to Commissioning and Start-up.

- Completion of Risk Based Inspection (RBI) activities for the A K Project.

- Quality assurance of the Project Flawless Delivery (FDP)program is applied. This includes SIMPOS during construction, and tie-ins.

- Update HSE Case, including PTW, Isolation Procedures and Emergency procedures/ Response plans for the above.

- Reliability and Availability Model.

- Completion of Alarm Management activities prior to loading data onto the DCS system.

- Completion of the Operating Envelopes.

- Coordination of training, development and recruiting activities for the Operations Readiness Team by making use of third party facilities and/or on-site training and importing expertise, and recruiting and re-allocation of field staff. Review of Competency Plan for the future “Operate “staff/ employees and contractors.

- Providing support for the attendance of the team to FAT/ SAT testing, as required and ensure that all future A K staff is competent before start-up.

- Assigning the disciplines of the Operations Readiness Team with regard to all of the above and provide the required support for them in order to produce a quality input/ deliverables of all the required OR activities.

- Advise & steer, on a continuous basis, Operations Readiness activities by joining the regular projects and contractor progress meetings and follow-up by tel. conversations, meetings, reports and field visits.

- Act as a reference point/liaison between the field management and the project team with regard to day-to-day activities, tie-ins, and brown field modifications, especially during construction, pre-commissioning and commissioning, all the way to start-up and handover followed by performance test runs and normal Operations. Attend the daily plant meeting on site to ensure smooth communication and trouble shooting of interface issues.

- Prepare Operating budget (Production and Maintenance) for post hand-over ( Operate phase).

- Pre-Start Up audit & Operational Excellence review prior to acceptance.

- Purchase of New Lab equipment/ arrange training and Chemicals Requirement Reports, including MSDS.

2003- 2012:

Operations Manager / Head of Operations Support ( ADGAS)

Key member of ADGAS Management team applying breadth of diverse management and technical knowledge and experience.

Plans, directs, coordinates and manages all the Operations and production activities of the entire Das LNG complex, comprising Process, Utilities and Storage & Export facilities, capable of producing and shipping 8.5 million tones of liquefied natural petroleum gases products and sulphur annually. This sums up to a total sale of 200 ships per year.

Agrees and sets corporate objectives and Operations Division performance targets and manages appropriate strategies in order to translate company missions into measurable Divisional activities and KPI’s.

Ensures that all production targets are met, the Plant is operated safely and efficiently in accordance with company policies, objectives and customer quality standards.

Nominates and follow-up Operations personnel seconded to projects and modifications in order to develop the work force to prepare for smooth commissioning and start-up, with all documents/procedures readiness.

Involved in high level of technical knowledge, highly organized and business focused, especially with long-term interaction and company long term strategies. Highly focused in developing the national young teams/ Engineers for quality and prompt integration and accountability within the Operations division ( and other divisions) teams/ work forces.

Main Duties:

-Plans, directs, coordinates and manages the activities of assigned personnel in the Operations Division. Performs management functions and exercise financial authority at the levels established.

-Participates in the planning, coordination and recommendation of long and short term production programmes carried out in conjunction with the Marketing Division and ADMA oil production plan. Includes the preparation of annual production budget, attending managerial meetings, discussing existing capacities, capabilities, conditions of plant and equipment, time constraints, to decide in conjunction with other Divisional Managers concerned on an appropriate programme.

-Develops and approves the Operations Division Policies and future strategies including Divisional objectives. Conduct and lead meetings and discussions to arrive at mutual consensus with all parties.

-Ensures the LNG plant and equipment performance are regularly monitored and analysed to maintain and improve availability & reliability. Ensures that the Division’s staff keeps up-to-date with Operational /Engineering techniques and developments to achieve the desired performance level.

-Develops contract strategies and assists Contracts Department in the preparation of conditions of Contract and pre-qualification invitations and ensures the Division follows ADGAS contract development/selection progress.

-Directs the planning and coordination of work performed by manufacturers’ representatives, vendors, specialists and external consultants related to Operations.

-Controls the preparation of the annual budget for the Division, monitors and control / manages expenditure and justifies the variances.

-Approves specialized contractors activities to ensure quality of workmanship and compliance with HSE & Engineering standards.

-Initiates the Plant Standing Instructions and ensures revision and updating of the existing Plant and Operations Standing Instructions. Custodian of Permit to Work system and Operating Manuals in the Process, Utilities, Storage and Exports areas. Approves changes to these manuals, when deemed necessary, such as those due to changing conditions, new equipment, modifications, breakdown in efficiency and accidents/incident investigations and RCA recommendations.

-Directs and participates in the planning and coordination of overhaul programmes in conjunction with the Maintenance / Engineering and Integrity & Quality Divisions. Includes considering the supply of feed gas, levels in storage tanks, overhaul scheduled elsewhere, etc. synchronizing timetables with the Maintenance / Engineering and Integrity & Quality Divisions and ensuring equipment is prepared for maintenance or overhaul according to the agreed programme.

-Initiates plant and equipment modifications and approves proposed modifications presented by Department Heads / Team Leaders to improve Plant efficiency / safety and environment where necessary. Coordinates priorities for investigation with Maintenance / Engineering and Integrity & Quality Managers, reviews and approves findings and proposals.

-Liaises with upstream Site Managers for the planning and coordinating of feed gas supplies necessary to meeting production targets/programmes. Liaises with other offshore companies on resolving complex technical issues relating to gas supplies.

-Daily contact with other divisions including engineering and projects consisting of staff from a very diverse multicultural environment.

-Plans and controls the manpower requirements for the Division ensuring effective implementations of the Emiratisation policy. Manages the identification of training needs and the establishment of job targets for all the jobs by managerial responsibility. Ensures the proper implementation of approved training and development programmes within the Division with emphasis on UAE Nationals and through continuous follow up and effective succession planning.

-Controls impact of operations on environment by monitoring units, effluents, flaring, emissions and coordinates efforts for plant-wide compliances with ADNOC and International standards for Health, Safety and Environment protection programmes. Initiates, implements and promotes HSE improvement changes and drives better awareness across the workforce. Liaises with upstream Das and offshore for minimization of overhaul flaring of unutilized gases.

-Undertakes senior role of Plant Management as and when required.

-Prepares and presents necessary reports on plant performance and production achievements to Shareholders and General Management, on daily or weekly basis.

-Performs and assist in other related or similar tasks such as attending the regular Plant Manager’s meetings, Leading Plant Team in case of emergencies, participating in the updating of safety procedures, chairing HSE committee meeting etc. is responsible for the safety of all personnel and protecting equipment in the LNG industrial complex. Is accountable for jetties security as per IMO regulations and ISPS codes. Guide and direct improvements in the plant by leading and approving initiatives to enhance environment, reliability, availability and production effectiveness. Liaise with Project Division from the early stages and provide experienced manpower with some exposure to design review, statement of requirement and operability issues and Hazop, safety and cost control, risk assessment and scheduling etc. And with regard to preparations of new procedures and integration before and during handover. Follow-up on outstanding issues/ anomalies after start-up.

-Supervises the creation of deliverables through the everyday coordination with the respective personnel and documenting areas where improvement is necessary under modifications or projects. This includes lessons learnt and tracking tools to ensure timely closure.

-Careful attention to the multi cultural team especially at construction and pre commissioning / commissioning stages with high focus on developing the national and young teams.

-Review and ensure that all new projects processes and milestones are meeting the target deadlines and make the required amendments to readiness findings including audit and lessons learned during all stages. This includes commissioning and start up of integrated new plants. This is done by nominating the suitable Operations team and supervising them through schedules and correct reporting mechanisms. Later integrations of the project operations team into the existing organization.

-Ensure company safety policies are enforced to all duties and procedures at all levels, and that all near misses and lessons learned are documented and communicated to all employees of all departments.

1999 – 2003:

Senior Process Engineer in Operations Division.

In charge of Process Engineering Dept. and reporting to Operations Manager.

Main Duties:

-Lead the group of Process engineers towards providing technical support and trouble shooting techniques to all Operations disciplines (Process, Storex, Utilities and Production) for a 720 T/hr LNG plant with LNG and LPG products.

-The above would include liaison with other divisions and external parties (ADNOC group of companies) for achieving optimum plant conditions with regard to safety, environment protection, high efficiency and maximum on-stream availability. Auditing process units and final products specification to ensure customer satisfaction.

-Refer to and understand Engineering drawings, PFD’s, P&ID’s and vendor data sheet.

-Direct contact with Process Licensors in order to discuss and address immediate plant problems and /or recommend long-term solutions. Liaise with engineering division and advise/ make proposals for required modification with front-end engineering.

-Hazops and Task risk assessment/ safety reviews.

-Utilization of simulation tools (e.g. Hysys) and digital control systems (DCS and plant history data base PHD by Honeywell).

-Supervision of special operating procedures like catalyst regeneration/ cryogenic column cool downs, etc.

-Support non-routine plant activities like plant overhauls, commissioning and assessment of new equipment.

-Plant mass balance and special spot cargo preparations.

-Prepare and follow-up departmental quarterly and annual objectives. Produce monthly progress reports.

-Appraise and supervise on daily, monthly and yearly basis the subordinate Process Engineers efforts in order to optimize group work and recognize and arrange for training requirement, as Process Engineers Team Leader. Discuss and set individual objectives and ensure achievement. Mentor for the development of UAE chemical engineers until final post establishment.

-Administrate and manage departmental personnel issue like leave/cycle arrangements, job assignment and resources co-ordination. This includes recruitment, assessment and interviewing new engineers. Also budgeting and financial authority.

-Member of new organization development in-house committee as division representative. New organization structured and implemented on asset-based format.

-Create and maintain special tracking systems to analyze and eventually reduce plant trips by ensuring completion of recommended action lists.

-Chairman for special task forces like total power failure investigation. This includes gathering multidisciplinary team, examining technical data and interviewing personnel. Produce report for management review.

-Create and maintain suggestions improvement system in order to enhance communication and consider all shift personnel proposals towards enhancing plant efficiency and safety.

-Prepare and deliver presentations on specific plant problems in international conferences like APCI LNG owners seminar, GPSA-Bahrain and Adipec. Member of Adipec technical committee.

-Permanent member of business development team for examining and analyzing cross- company processes towards leading the company into the future.

-Administration, technical bid evaluation and commercial awarding of certain consultancy packages like training simulators and alarm management.

1991- 1999:

Senior Process Engineer (96-99)/ Process Engineer (91-96) in ADGAS Engineering and Technical Services Div.

Main Duties: in addition to the above :

-Design; prepare data sheets, engineer, pre-commission/ commission short and long term modifications for the improvement of plant operations/ safety and conservation of the environment.

-Also participated in commissioning of new LNG train (3rd train of 384 T/hr capacities). This included liaison with the project team and EPC contractor towards solving plant teething problems and verification of all units capacities and specifications.

1985 - 1990:

Process Engineer with Kuwait National Petroleum Company, KNPC, Shuaiba Refinery, Kuwait. Shuaiba Refinery is a large Refinery with a crude capacity of 200 MBD, producing typical distillates, e.g. Naphtha, Kerosene, Diesel and Fuel Oil.

Main duties included:-

-Plant problems troubleshooting.

-Contact with licensors like H-Oil, Isocrackers, Merox units and Hydrformers.

-Refinery mass balance, products yields and blending requirement.

-Conduct routine test-runs for the Cat Reformer, Naphtha/ Diesel and Kerosene unifiners; Also, Crude and vacuum distillation unit. Sulfur plant performance.

-Design, drawing preparation and safety reviews of new plant modifications.

-Supervise catalyst change-outs and regenerations procedures and produce reports.

-Preparation (graphics and reports) for new control room with digital systems (Honeywell TDC 3000) in Phoenix, Arizona.

-Special Tasks: Conduct and coordinate Solomon’s Peers consultancy study (benchmarking).

-Prepare and deliver presentations on Refinery processes to external parties, especially educational bodies like Kuwait Institute of Scientific Advancement and Kuwait University.

-Cooling water survey in order to identify fouled heat exchangers by using rating tools.

-Plant Steam Balance to identify excess users and analyze causes.

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