Plant Chemical Engineering

SIBUSISO BLESSING SIBIYA

Surname Sibiya

First Names Sibusiso Blessing

Gender Male

Date of birth 17 November 1982

Nationality South African

Marital Status Married

Driver’s License Code 10 (C-1)

Contact Details +27 (0-722****** / +27 (0-792******

************@*****.*** / **************@****.***

SCHOOLING

Highest Grade Passed Grade 12

Institution Zinikeleni Secondary School

Year Passed December 1999

TERTIARY EDUCATION

Institution Vaal University of Technology

Qualification(s) Baccalaureus Technologiae: Chemical Engineering - 19 April 2011

National Diploma: Chemical Engineering - 08 April 2008

WORK EXPERIENCE

Name of Company Sasol Synfuels Operation

Department Utilities

Unit Combined Circle Gas Turbines (CCGT)

Designation Production Foreman / Shift Supervisor

Duration 01 July 2009 – Present

Day to day duties

Take shift handover to understand all changes from the previous shift.

Complete plant inspection at the start of the shift and on regular basis in order to ensure plant integrity, identify deviations and safety compliance.

Give plant status to Shift Supervisor Coordinator at the main central control room.

Check if everyone on shift has reported for duty and call for coverage if there are shortages to ensure that overtime limit stay within legal limits.

Take over as a DCS panel operator if there is an emergency or shortages on the plant.

Check for email communication from management and understand plans for the day.

Hold a shift meeting to find out of any issues to be reported to maintenance colleagues and give feedback to shift personnel of the current day’s plan. Discuss toolbox talks, encourage everyone to work safe by sharing safety themes. Enforcing discipline to achieve adherence to rules and regulations to ensure effective working environment.

Issue all work permits for the day and ensure safe execution of the work.

Attends/leads daily meetings with Instrumentation, mechanical, electrical, vibrating monitoring, Honeywell, safety department to coordinate/prioritise maintenance and production activities, in order to ensure equipment availability/integrity of plant.

Verifies and approves clock times on SAP, to ensure correct remuneration for hours worked for all personnel on shift.

Ensures that equipment monitoring is completed, and results and deviations recorded, to improve equipment reliability.

Conduct regular internal audits (IMS, ISO 9001, and ISO 14000/1) to ensure compliance.

Emergencies.

Leads plant team in managing abnormal situations, and emergencies, in order to ensure the safety of plant and personnel. Give feedback to the Shift Supervisor Coordinator and senior standbys.

Follow all emergency procedures to ensure safe making of plant and affected equipment.

Compile a report on incidents and accidents to management and report to SAP to initiate an investigation of how to improve plant and personnel safety.

Initiate and lead firefighting or other safe emergency actions in my area until it is taken over by higher authority.

Start- up and Shutdown

Manages start-up and shutdown of equipment or plant in order to ensure safe and efficient plant operation.

Assist the DCS operator in safe start-up and shutdown of the plant.

Assist the Field operators in ensuring the blanks are removed and blank lists are signed by all relevant parties.

Plant preparations for Turnaround and clean outs

Before starting up of equipment’s or plant I ensure that all work has been completed, permits signed off and clearance of operation has been issued from the maintenance department.

Ensure safe making of the equipment before start-up or shut down by purging or steaming up as per equipment requirement.

Hand over the equipment to maintenance department on shutdown and receive if after maintenance.

Background of the plant

Attended 2 weeks of training at South and North Cairo Power Stations in Egypt 2009.

The plant consist of two GE9E Gas turbines machines that produces 104MW per machine (208MW in total).

The Gas turbines uses Natural gas or Methane Rich gas as fuel.

The plant consists of Heat Recovery Steam Generator (HRSG) that produces superheated steam at 163t/hr per boiler (326t/hr) that is sent to steam turbines.

The plant also consists of a Lurgi Boilers that uses Pulverized Fuel from fine coal and produces steam at 540t/hr per boiler. A total of 4860t/hr of superheated steam. There are a total of 9 boilers.

The plant consist of 4 steam turbines that drives a generator and produces 60MW per turbine (240MW total)

Name of Company Sasol Synfuels Operation

Department Refining

Unit Catalytic Polymerisation and LPG recovery Unit

Designation Senior Process Controller /Panel Operator

Duration 01 July 2003 – 30 June 2009

Day to day duties

Take shift handover and check the plant in the control room Distributed Control Systems (DCS) machine.

Look for any deviations and check all groups on TDC 3000 and Honeywell Control Response Optimiser (CRO) machines.

Operate DCS control console to coordinate and regulate process variables and to direct flow rates of various process and utility streams according to prescribed schedules.

Maintain records of key production variables such as production volume, yield, and input consumption.

Reports plant conditions, deviation from specifications, and plant availability to the shift team members and to Shift supervisor.

Check for sample results from previous shift and do changes on the plant and request for Outside operators to take samples to ensure plant is running on specification.

Enters defect and incident notifications into SAP to assist the Shift Supervisor.

Rotate with other colleagues and work outside for a month, to be Senior operator outside to ensure plant is operating safe outside and attend to any deviation and perform plant start-up and shutdown outside.

Undertakes regular full plant inspections to ensure housekeeping is maintained, and to check safety equipment, and complete IMS (Integrated Management System) requirements

Emergencies.

Follow emergency procedures by communicating to Shift Supervisor Coordinator to send emergency team.

Request Outside operator to meet the emergency team at the assembly point.

Ensure safe shutdown, isolation, initiate and coordinate response instruction during emergency situation.

Start- up and Shutdown

Start –up and shutdown of equipment’s and whole plant from DCS during schedule work or in emergencies.

Activate emergency shutoff valve after communicating to the Outside operator.

Plant preparations for Turnaround and clean outs

Receive instructions from Shift supervisor and execute as instructed to safely prepare equipment’s for turnarounds.

Communicate to the outside operators to safely prepare equipment or plant for turnaround.

ADDITIONAL SHORT COURSES

Short course on Fluid Flow Catalytic Reactors – University Of Pretoria

Root Cause Analysis (RCA)

Environmental Awareness and Hazard Identification

Behavior Based Safety Observation (BBS)

SAP SYSTEM - PSM1, PSM2, PSM3, MOC, EDMS, EDMS 01, EDMS04, EDMS 05, EBP

Easy DMS and Business Warehouse, SAP Navigation, MORPM01 and MORPM04

Business Understanding, Invocom Skills 1 and Invocom Skills 2

Premium Combustion Service (PCS) training

Incident Investigation and Prevention

Emergency Management – Communicator Awareness and Area Emergency Controller

Legal Responsibility and Accountability

Construction Regulations

Machinery Supervision (GMR 2 (1) Appointee)

Complainant’s role in disciplinary enquiry and disciplinary handling skills

Basic Root Cause Failure analysis (RCFA)

Explosion protection for plant maintenance

Asset management

Workplace Coaching training

Emotional Intelligence self-awareness

Crucial conversations

REFERENCES

Mr. Simon Baloyi (Vice President) – +27 (0-82-336-****

Mr. Dennis Mthombeni (Process Technologist) – +27 (0-73-121-****

Mr. Charles Tshabalala (Process Safety Specialist) – +27 (0-82-402-****

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