Engineer Project

Ken Singh

**** ******* *****

Baton Rouge, LA ***10

Tel : 225-***-**** / 225-***-****

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

Objective: Sr. Process Engineer

Summary of Experience : More than 20 years of Refinery, Petrochemical, & Fine chemical manufacturing, including Polymer industry & operating experience with Project Management in EIL(Bechtel Company affiliate), KBR, Shaw Stone & Webster, ExxonMobil, & Honeywell for basic design, front end loading (FEL), FEED package and detailed engineering design package including process studies of grass root as well as revamp units with feasibility studies, optimization studies and technology evaluation including PHA co-ordination, arranging meetings of consultant, plant personnel, PHA initiator or OSHA. Presented findings of PHA analysis using PHA WORKS PRO 5. Worked on relief valves load calculations for all scenarios, sizing, installation, troubleshooting using BERWANGER Program for more than 1,000 relief valves for refinery and chemical plants. Strong knowledge of reaction, distillation, and solids handling. Developed expertise for safety & environmental practices with process safety management in plant environment in career as worked for LDEQ for 5 years as Environmental Chemical Specialist. Lead & supported the activities for new product development including scale up, design, safety analysis and troubleshooting and start-up support. Worked on developing pilot plant facility from PFD and material balance leading to scale up of the model to actual plant. Also estimated man hours, man-power planning and scheduling tools from $50,000-$70million projects for US refineries and petrochemical plants.

Had a lead role in sizing and specifying equipment design using codes of ASME, API, NFPA, NEMA and chemical industry for the last 20 years, the specific process design standards for rotating equipments like pump, compressors (natural gas compressors),hydrocarbon liquid transfer by pipelines including vessel, tank, reactor, heat exchanger, filters, columns and single and two phase flow line sizing including design standards for connected instrumentation. Prepared design packages including FEL packages for detail design with equipment specification, installation and start up for multiple process units. Worked on simulation, heat & material balances, PFD, P&ID’s for process units with detailed equipment sizing and design including instrumentation & line sizing from concept to commissioning.

Worked on Front end loading and Process design package for Onsite, Offsites and the Utility system design including hydraulics, data sheets, PFD, P&ID’s, LDT for cooling water system, fire water system, instrument air system, plant air system, steam(LP, MP, & HP) system, nitrogen system, flare system and stack design including overall steam and cooling water balances for number of refinery projects.

Well versed in process design of variety of refinery units including simulation by PRO II, HTRI, BJAC for rating heat exchangers, PFR-FRNC-5 for rating fired heaters, BERWENGAR for relief valves, PHA WORKS PRO5 program for process hazards analysis for process units including preparation of PFD’s, P&ID’s, equipment and instrument specifications for Crude & Vacuum distillation, Hydrotreater, H-Oil, Reformer, Asphalt blowing, Propylene recovery and FCCU of petroleum refineries. Worked as technical services lead in an operating refinery. Strong knowledge of heavies including hydrocracking, FCCU and H-oil. Worked on several projects for $100,000 to $10 million on schedule, in budget and to the client satisfaction.

The experience in polymer includes the feasibility and technology selection for LDPE/HDPE, EO/EG and Ethylene plants. Worked on the process design part for PFD/P&ID’s, equipment sizing including columns, tanks & vessels, pump, compressors, & filters selection, MOC selection and detailed engineering for 200-600 ktpa ETHYLENE plants. Also did instrumentation, line sizing, plot plans, equipment layout during detailed engineering. Got involved in pre-commissioning and commissioning leading to gurantee runs for 600 ktpa Ethylene plant in China.

The project engineering and management experience initial project screening, project development (FEL), execution of detailed design and construction, HSSE, cost, schedule and quality. This includes execution of procedures and 100% compliance with MOC and PSSR. In addition assisted in mechanical start-up plans and procedures, provide technical support during star-ups, support training and assurance documents and knowledge transfer for successful completion of projects from $50,000- $10 million in petrochemical and refineries industry in the past 10 years. The engineering support to facility were executed safely, timely and cost effectively. It included scope definition, conceptual and detailed design and cost estimate. Working knowledge of project life cycle, have integrity & values, work well other team members and handles sensitive issues very tactfully. The projects in 1-10 million dollar range were completed in budget, on schedule and with defined man power from concept to commissioning and gurantee runs for 3 refinery units, e.g crude unit capacity expansion, propylene recovery unit from LPG, and asphalt blowing unit. The project responsibility included multiple projects assignment upto $30-40 million in a year.

The AIR Permit environmental regulatory experience includes writing Air Permits using TEMPO processor program for Refineries, Petrochemical and Major Industrial plants for their initial installation and modifications including Title V Initial, Renewal and Modifications permitted by the State of Louisiana (LDEQ)

Responsible for determination of limitation and capabilities of process units and their pressure relief systems using BERWANGER program. Performed the engineering calculations for pressure relief systems for various scenarios including fire case, blocked outlet, control valve failure, reflux failure and other related contingencies. Developed PSV documentation packages. Documented the global relief scenarios. Performance evaluated for flare system including header and flare stack. This includes the knowledge and usage of ASME Section VIII, API 520, 521, & 2000.Worked on design, installation and performance for more than 1,000 PSV for various clients in refinery and petrochemical plants. Working knowledge of process safety management (PSM) including management of change (MOC), process hazard analysis (PHA), and pre start-up safety reviews (PSSR).

Worked on Process Hazard Analysis (PHA) co-ordination, Presentation, Scribing, arranging meetings of consultant, plant personnel, PHA initiator or OSHA. Presented findings of PHA analysis for severity, likelihood including credits, hazards, consequences, and safeguarding using PHA WORKS 5.0 for EXXON,HONEYWELL & MOTIVA. I had several trainings for Quality, Plant safety, Berwanger work for pressure relief valves and PHA WORKS 5.0 for process hazards analysis for chemical plants in Baton Rouge & Houston.

Consultant (ExxonMobil ) 2013-Present

Consultant-Process Engineering

Worked on FEL-2/3 estimate for downstream facility in Lake Charles for Frac Plant and OSBL including meter runs for Ethane, i-C4, n-C4, gasoline and tankages.

Worked on FEL-3 estimate for Client in Texas for their OSBL facility for Natural gasoline storage and monitoring for their 3 operating well.

Expert in processing facility process design as Lead Engineer for sizing meters, vessels, tanks, columns, pumps and big compressors for natural gas.

Technipower Inc. 2012-2013

Consultant(ExxonMobil/FCS-Process Design)/Project Manager

Highly specialized in Refinery, Petrochemical, Polymers and Environmental air permit projects for ExxonMobil plants in U.S and overseas.Responsible for planning, organizing, and execution of major facility projects at the corporate level with strong focus on safety and environment considerations including cost estimates, FEL packages leadership, project execution, project reconcillation and co-ordination with other disciplines to ensure the success of the project.

Worked on Ethylene glycol cooling project for Joilet Refinery for ExxonMobil in Illinois as a consultant for process design and FEL process.

Honeywell International Inc. 2011-2012

Senior Chemical Process Design Engineer

Consultant & Responsible for process technical expertise for plant operation, ensuring plant is operating within applicable standards and focusing on process improvements. Worked on PSM (includes Emoc, PSSR, PHA and action items, HAZOPS etc operating procedures, Key process indicators and safe operating limits and EHS compliance. Provided technical support for engineering, design, construction, maintenance and process issues during start-up and shut-down of plants including process control techniques used for support.

Lead the team of process engineers during meetings, process issues in start-up/shut-down and KPI’s. Also worked from home during weekends and holidays for plant support using Honeywell VPN.

Completed training for Green belt, had SIX SIGMA green belt certification. It would save plant $125K per year, if implemented as designed. Worked closely for HS&E and plant safety by implementing latest techniques according to OSHA regulations. Very familiar the use of UNIFORMANCE and ASPEN plus 7.0 simulation for reactor modeling and overall plant simulation. Worked on process improvements and equipment optimization to save Honeywell more than $0.5 MM. Also worked on capital projects for the plant within limit of $10-$100 MM.

Sonia International Company, LLC (ExxonMobil / FCS) 2008-2011

Consultant(Process Design)/Project manager

Highly specialized in Refinery, Petrochemical, Polymers and Environmental air permit projects for plants in and around Baton Rouge. Responsible for planning, organizing, and execution of major facility projects at the corporate level with strong focus on safety and environment considerations including cost estimates, FEL packages leadership, project execution, project reconcillation and co-ordination with other disciplines to ensure the success of the project.

Prepared proposals for the Process Design packages for Crude revamp, Propylene recovery from LPG, Asphalt blowing and Hydrotreater technologies. The polymer technology includes Ethylene, EO/EG, PP-Unipol for Chinese and overseas clients.

Also worked on various PSV scenarios including fire case, blocked outlet, CV failure, reflux failure and global relief scenarios using ASME section VIII, API 520, 521 & 2000. There were total of 52 PSV packages done in last few months. Also worked on deficiencies, gaps, required information and package completion to client’s satisfaction.

Worked on PHAST(10 models), FLARENET (2 models) and EFFLUENT SCREENING(30 PSV’s) for 6 units in Company.

Also had formal Trainings in PHAST and FLARENET modeling during the contract period in the company.

Shaw Stone & Webster Inc. 2005 - 2008

Baton Rouge, LA

Sr.Lead Process engineer/Project Manager. Responsible for the conceptual and process design of units of a chemical plant. Also did the relief valve sizing of the major chemical plant in Baton Rouge. It also included heat exchangers sizing, design and rating using heat exchanger program, HTRI & BJAC.

NALCO Chemicals

Geismer, LA

Conceptual design and process studies for Flame Arrestor project, SO2 Scrubber project and ACN Header project. Also did the man-hour estimate for the SO2 scrubber project. The work included preliminary line and headers sizing, pump specifications, instrument and other piping specifications and pressure drop calculations.

Honeywell

Geismer, LA

Did the preliminary sizing of 210 safety relief devices for the MPP and 125 unit of Honeywell at Geismer. Checked, identified and sized the new PSV required for the expansion of their MPP and 125 units.

Pequiven Offsites

San Jose, Venezuela

Lead the process engineering including hydraulics, data sheets, PFD, P&ID’s, LDT, for cooling water, steam, instrument air, plant air and flare systems for utilities and offsites for Propane dehydrogenation (PDH) plant.

Petrochina, Fushun

China

Lead the process engineering including hydraulics, PFD, P&ID’s, plot plan, FE/CV, PSV and LDT, for the quench section of 600kta ethylene plant. Witnessed and was involved in pre-commissioning and commissioning including gurantee runs in china.

State of Louisiana (DEQ) 2001-2005

Baton Rouge, LA

Environmental Chemical Specialist III. Lead and responsible for the Air permits for Refineries, Petrochemical and Major Industrial plants which includes Title V, initial, renewal and modifications. Also responsible for small source, minor modifications, variance, exemptions and name/ownership change multiple air permits.

Bristol- Myers Squibb Company 2000-2001

Syracuse, NY

Senior Project/Process engineer. Responsible for the conceptual, technical and feasibility reports & Protocols including CAR for the Pharmaceutical formulation of the batch process for the pilot and commercial plants in Puerto Rico and Syracuse. Lead and supported pilot plant facilities from PFD and heat and material balance to actual full scale plant for noxxyl medication. Performed process evaluations, scale-up designs, safety analysis including pilot plant start-up. Also developed several models for each medication for cost analysis, safety analysis and scale up to full size plant. Worked and co-ordinated with several departments like process, project, mechanical, electrical, instrumentation and civil which were internal customers including external customers. During the process from concept to commissioning wrote process manuals, safety instructions and environmental and safety manuals for atleast two formulations.

1997 to 1999

Petrocon Engineering, Inc

Baton Rouge, LA

Senior Process Design Engineer. Responsible for the FEL and Process design package for the revamp of TDA/TDI complex for the capacity expansion for the plant in Lake Charles. It included heat exchangers sizing, design and rating using heat exchanger program, HTRI.

ExxonMobil, 1994 to 1997

Baton Rouge, LA

Senior Process / Project Engineer. Worked in the plant operation for crude unit and related units for more than 2 years. Also Responsible for the DBM and PDS’S relating to OXO-ALCOHOL’S plant in Baton Rouge. Also worked on SRR’S using EXXON’S standard SAFE-1 program during my tenure at Chemical plant. This program integrates all plant relief valves for header sizing and eventually for flare header sizing calculations.

KTI Corporation 1993 to 1994

Houston, TX

Process/Thermal/project Engineer. The responsibilities include rating fired heaters, burners and auxiliary items. Also did PFR-FRNC-5 simulations. Witnessed the “Burner Test” for Cosmar Chemicals, Baton Rouge at John Zink facility at Tulsa, Oklahoma for four furnaces.

1990 to 1993

The M. W. Kellogg Company

Houston, TX

Process System Design Engineer.

Global Octane’s MTBE Project, TX

Worked on development of P&ID’s, hydraulic calculations, pumps and line sizing.

Developed equipment specifications including vessels, pumps, HEAT exchangers, reactors and storage tanks.

Developed nomenclature on PDS and instrument specifications.

. It included heat exchangers sizing, design and rating using heat exchanger program, HTRI.

Marathon Hydrotreater Revamp Project, LA

Hydraulic check of all the pump circuits and line sizing.

Modifications of existing P&ID’s, equipment and instrument specifications.

Addition of new equipment and instruments.

Shell Benzene NESHAPS/PWS Project, LA

Worked on benzene NESHAPS and waste water segregation project for Norco refinery to meet NESHAPS, RCRA and NPDES compliance.

Identified benzene, oily water, clean water streams in various units of the refinery.

Developed PFD’s, P&ID’s, and equipment specifications including API’s, CPI’s, sumps, pumps for collection and treatment of waste streams.

Performed line sizing, pump hydraulics and relief valve calculations.

Education

BITS-MIT (USA)

Pilani, India

B.S. Chemical Engineering (with Honors). With Practice School in collaboration with M.I.T., Massachusetts,

U.S Citizen and have TWIC Card valid april 2016.

Commissioning Experience

Start-up of Gujarat refinery of CDU, Vacuum and FCC units.

Start-up and commissioning of propylene recovery of HOCL.

Start-up and commissioning of bitumen blowing unit of CRL.

Gurantee runs for AU-III of Gujarat refinery.

Test-run for ISOM unit at 14 MBPSD at Shell Refinery.

Professional Affiliations

Member of American Institute of Chemical Engineers.

Member of American Institute of Mechanical Engineers.

Member of American Institute of Quality Engineers

Publications

Considerations for energy conservation in Petroleum Refineries

Energy optimization in process industries

Two phase flow in horizontal pipes

Special Training

M. W. Kellogg System School

M. W. Kellogg Quality training workshops

M. W. Kellogg and EXXON Safety training workshops

Computer Skills

Well versed in PRO II & ASPEN Plus 7.0 Simulation

HTRI, B- Jac, FRI and PFR (FRNC-5,fired heater), BERWANGER simulation runs,PHA WORKS 5.0,PHAST, FLARENET,UNIFORMANCE

Worked PSM & on eMOC system for management of change system

Microsoft office including Word and Excel

CAPE Applications include HTFS, PSV-Calcs, and PIPEFLO program

Special Experience

My specific experience in Process Design of refinery units include:

Simulation of crude column calculations using CHEMSHARE DESIGN II and PRO II

Preparation of heat and material balance

Preparation of PFD’s and P&ID’s

Preparation of equipment data sheets like pumps, vessels, columns and heat exchangers. It included heat exchangers sizing, design and rating using heat exchanger program, HTRI.

Preparation of equipment specifications, line sizing and plot plan.

Preparation of operating manual and start-up procedures.

Air Permits written & approved in LDEQ:

Minor Source Modification 55

Administrative Amendment 28

Name/Ownership change 33

Rescind permits 16

State Permit -small source 45

Title V 8

Conoco Inc. Title V Modification

Shaw Shreveport Title V Renewal

Libbey glass Title V Modification

Trunkline Gas Company General Title V-Epps Compressor Station

Trunkline Gas Company General Title V-Centreville Compressor Station

Trunkline Gas Company General Title V-Longville Compressor Station

Dynamic Industries Inc-initial Title V

Lone star Company-initial Title V

All of the Air permits were TEMPO generated.

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