Process Engineer Project Management

Job Title

SENIOR PROCESS ENGINEER

Summary of Experience

** +Years

Industries: Oil & Gas, Petrochemicals and Fertilizers (Technical Services).

Acquired PMP certification (Project Management Professional) from Project Management Institute (PMI), USA.

31 + Years of Process Engineering experience comprising of Concept, FEED, Detail engineering and Technical Services (Natural gas and Naphtha based Ammonia, Urea and Utilities plants) department-Trouble shooting, Performance evaluation and process monitoring. Considerable experience with PFDs, P&IDs, Line Sizing, DBM, Hydraulic calculations, HMB, Pumps, Exchangers, Flare, Flare Radiation study, Vent stack, Flare header, Line-list, Tie-in List, Process & instrument data sheets, Development of Cause & Effect Matrix, Alarm & Trip List, HAZOP, Operating Control and Safeguarding Philosophy (OCSP), Fire water, Foam & Deluge system calculations, Hydraulics and related deliverables, Flow assurance studies, Relief load estimation, Sizing and selection of Relief Valves, and Debottlenecking studies. Ensures that process designs are optimal, safe, cost effective and in compliance with the latest International Codes, Corporate requirements and procedures.

Proficiency in API and other international standards. Man hour estimation, Project deliverables -Technical Document Register (TDR) and equipment list preparation. Review of bids for engineering services, and equipment & analysis. Preparation of Scope of Work (SOW), ITB and procurement support. Pre-commissioning, commissioning, Start-up of Ammonia, Urea, NPK and Utilities plants. Interfacing experience with other engineering disciplines and Clients.

Working experience in the Middle East & Africa since May 2005.

Software Experience: HYSYS & PIPESIM

Jun.2024 – Oct 2024.

Jun.2022 – Nov.2022

:

PUSB Engineering Private Limited, Chennai, India

HOD - Process

Fichtner Consulting Engineers (India) Private Limited, Chennai, India

Process Consultant

May.2017 – Mar. 2022

:

Arabian Gulf Oil Company (AGOCO), Libya

Senior Process Engineer

Dec.2012 – April 2015

:

Petromasila, Yemen

Process Technical Authority

Sep.2009 –Nov 2012

:

Greater Nile Petroleum Operating Company, Sudan

Lead Process Engineer (PMC)

May.2008 – Jun 2009

:

Ramboll Oil & Gas, Qatar

Lead Process Engineer

Jun.2005 – Apr.2008

:

Saudi Arabian Fertilizer Company, Saudi Arabia

Process Engineer

Feb.1991-June.2005

:

Madras Fertilizers Ltd, Chennai, India

Jan.1990-Feb.1991

:

M/S. Specsim Engg. Pvt. Ltd, Mumbai, India

Assistant Process Engineer

May.1989-Nov.1989

M/S. ONGC. Ltd., Mumbai, India

Safety Engineer

Feb.1989-May.1989

:

M/S. ESSEL PACKAGING LTD, Mumbai, India

Production Engineer

Detail Work History

:

PUSB Engineering Private Limited, Chennai, India

HOD - Process

Development of all the Process Discipline deliverables and approval from the client, Petronas. Guiding five Process Engineers for the same.

Fichtner Consulting Engineers (India) Private Limited, Chennai, India

Process Consultant

Present assignment involves development of Safeguarding Memorandum (SGM) document for Off-shore platforms for Shell owned facilities in Brunei. This comprises of development of Relief, Flare & Vent system reports and adequacy check of PRVs, PRV/BDV/MDP line sizing, Relief Headers as per DEP and API.

AGOCO, Libya

Senior Process Engineer

Assignment involved development and analyses of project specifications, tender and proposals requirements.

Managed and monitored contractor Process Engineering progress. Developed scope of work (SOW) in order to define all the required deliverables. Review, comment and approve Process Engineering deliverables from the engineering consultants & EPCC contractors including Design Basis, PFD, P&ID, simulation report, process calculations and equipment & instrument data sheets based on relevant international design standards and guidelines for projects- Gas Utilization & condensate recovery, LPG recovery from associated gas and Produced water treatment & injection. Provided necessary engineering inputs to the other disciplines. Communicated for required data from the project end users and get SOW approval. Managed Technical Queries during bidding, execution process, and coordinated responses. Prepared Technical Bid Evaluation Reports. Provided recommendation and endorsed vendors.

PETROMASILA, Yemen

Process Technical Authority

Provided process engineering support to various projects as required.

Prepared conceptual design for modification and new process facilities.

Provided the necessary technical decision in case of unresolved conflicts between disciplines and act as focal point between non technical disciplines such as procurement, contracting, construction and the engineering team.

Acted as a representative of company towards client in all technical matters and managed technical issues/changes presented to the client and ensure that they are resolved and ensure incorporation of the changes.

Provided technical support as necessary to all the departments.

Carried out Operational risk assessment.

Prepared process equipment specifications, data sheets and bid drawings.

Prepared data sheets for instruments and specialty items.

Coordinated procurement activities.

Provided construction and start-up assistance.

Provided Project Management and Client interface.

Coordinated with other disciplines to ensure an integrated design that meets the project requirements.

Carried out site surveys for tie-in point location and data gathering.

Focal point for HAZOP action closeout ensuring discipline engineers close out actions appropriately.

Prepared Hazardous Area Classification documents.

Prepared fire water system P&ID and fire water network layout.

Developed Deluge P&ID and Foam system P&ID.

Performed fire water hydraulics.

Prepared fire protection and safety equipment specification, datasheet and layout, escape route layout and safety sign layout.

Preparation of fire & gas detector layout and cause & effect charts

Reviewed critically contractor’s reports

Management of Change (MOC), reviewing and approving MOCs.

Trouble Shooting, Carrying out Engineering for modifications in the existing system.

Carried out Pre start up safety reviews (PSSR).

Raised commissioning issues with the package vendors and coordinated with operating department personnel.

Participated in Pre-commissioning, walk downs and raised punch list.

Support provided for preservation of packages/equipments as per vendor recommendations.

Worked closely with optimization and production teams to identify debottlenecking opportunities and constraints, initiated debottlenecking projects as necessary.

PROJECTS HANDLED:

For Flare Gas recovery system-carried out Concept, FEED, Detail Engineering, Installation & Commissioning. This project is to recover overhead Accumulator gas (rich gas) which was flared from two diesel generation plants. The flared gas is compressed in the VRU system and the separated gas/condensate is mixed with the well fluids in the existing FWKO/Oil Treater system to recover gas/condensate. This project includes vendor packages like compressor, separators, Air cooler, pumps, closed circulation water cooling system, and variable frequency drive unit.

Carried out Concept Study, FEED, Detail Engineering, Installation & Commissioning for Diesel Filtration System. This project is to remove the suspended solids of more than 5 micron size in two stages.

Performed Surge Analysis for crude oil export pipeline of 24 inch diameter & 137 km length. Evaluated the interaction of equipment, valves, and instrumentation, Observed system behavior under different upset conditions and recommended mitigation measures.

Detailed Work History

:

GNPOC, Sudan

Lead Process Engineer (PMC)

PROJECTS HANDLED:

Assignment involved to monitor, review, comment and approve vendor deliverables from the FEED/EPC Consultants for concept study/FEED/Detail engineering -Simulation reports, DBM, PFD, P&ID, Calculation reports, Process Data Sheets, HMB, Line list, Equipment list, Tie-in list, Operation, control & safeguarding philosophy(OCSP), Radiation and Dispersion calculations, Pumps, Pressure Safety Valves, Specifications, Fire fighting philosophy, Flow assurance studies etc.

Ensure the scope of the project and inter discipline activities are fully understood and covered by all discipline engineers to ensure total scope coverage without missing areas or duplication.

Manage post tender clarifications and participate in techno commercial meetings with client and close out all technical issues for EPC proposals.

PROJECTS HANDLED:

Concept & FEED - Capture free gas and install flow lines to central manifold, treatment to pipeline quality- CO2 Removal, Water & Hydrocarbon dew point control, Dehydration unit, Condensate stabilization and recovery system, Gas compression for pipeline transportation, Gas transportation & reinjection.

Concept & FEED - For 300,000 Produced Water Treatment and Injection facility to re-inject into the reservoir for pressure maintenance with the identified design criteria.

Concept & FEED - Fuel Storage Facility for hydrocarbons Diesel, Gasoline and Jet fuel as per API 2000 and API 650.

FEED - Drinking Water System -treat the well water to potable water specification.

Detail Engineering -FPF Flare and Vent stack project - Adequacy study for the revised operation conditions.

Assessment of Fire Water System.

Detail Engineering -Export Crude Oil Quality Improvement System-Crude Oil Storage tank and off-spec storage tanks.

Flow assurance study -To predict the pressure surge in the liquid lines, Establish the required pressure to enable free flow of heavy oil, Investigate propensity of hydrate formation and propose mitigation measures, Asphaltin & Wax deposition potential and recommend mitigation measures -insulation requirements, Analyse slugging potential, Maintain velocity as per API 14E to avoid erosion and sand deposition, Assess impact of turn down on hydraulic stability, liquid hold-up & back pressure requirements, and assess pressure boosting requirements.

RAMBOLL Oil & Gas, Lead Process Engineer, Qatar

Coordination of Process-engineering of the entire system in technical, scheduling and qualitative aspects.

Coordination of internal and external interfaces. Provided input to other disciplines.

The contact partner for the customer for Process Engineering.

Managed a team of 10 process engineers. Managed day-to-day affairs of the process engineering department.

Attended meetings and discussions with clients / vendors. Building and adopting process discipline guidelines, standard formats, standard process engineering calculations and process manuals.

Preparation of process engineering CTRs (Cost-Time-Resource) sheets for prospective project bids by the company.

Provided guidance on process engineering issues to the process engineering team.

Maintained administrative records of the discipline including leave plan, attendance monitoring and job allocation.

PROJECTS HANDLED:

PRODUCED WATER TREATMENT (M/s.Total) - Halul Island

This project includes the addition of Water Flash Drum -3 Phase separator, Hydro-cyclone units, CFU, produced water injection pumps, relocation of existing pumps and modification of associated piping. The objective of this project is to achieve the specification of oil-in water content < 40 ppm (Capacity of 50,000 BPD + 10% margin).

DESALTERS (M/s. Total) - Halul Island

This project includes the addition of new facilities viz. Desalter, Fresh water Package, Export Pumps, Recycle Pumps, STHE, Chemical Injection Skids and adequacy check of flare system to meet the oil specification such as:

1) Salt content below 25 PTB.

2) BS&W below 0.5%.

CRUDE OIL IMPORT & EXPORT FACILITY (QP) at Halul Island Oil Terminal.

Carried out detail engineering for replacement of four Nos. of 4000 m3/hr crude oil pumps and associated import and export pipelines and utilities system to increase the reliability and to upgrade the system for enhanced operational flexibility.

PWI SYSTEM (QP) – Dukhan.

Performed detail engineering for addition of new Source water well pump (submersible) and associated facilities to utilize the produced water from Degassing Stations and water from the new source wells for injection, in order to ensure optimum utilization of booster pumps.

SAUDI ARABIAN FERTILIZER COMPANY (SAFCO), Saudi Arabia

Process Engineer

JOB RESPONSIBILITIES:

Provided professional engineering support and technical expertise to support development and optimization of unit operational plans.

Provided troubleshooting assistance to maintain and enhance operation and throughput of the unit.

Provided technical input for advanced process control applications to enhance operation of the units.

Finding out the root cause of process safety and operational issues in a structured manner and taking action to solve issues on permanent basis

Carried out Calculations to evaluate utility equipment efficiencies

Find out the bottleneck in the plant equipment, process by efficient data management systems and debottleneck the plant.

Monitor operating parameters to ensure unit streams are within specified limits.

Provided professional engineering advice and technical expertise for units and departments to support project development, engineering studies

Shut Down/Turn Around plans and activities, materials and contract procurement.

Ensured compliance with agreed work practices and methodology.

Evaluated process equipment performance.

Performed heat and mass balance calculations.

Prepared / reviewed PFD and P&ID for modifications/revamping of existing plants.

Equipment sizing (Exchangers, Pumps, Separators, and vessels) and data sheet preparation.

Calculated relief loads, PRV sizing and data sheet preparation.

Flare stack design, Flare header sizing and adequacy check of existing Flares.

Estimation of pipeline pressure drop and line sizing.

Participated in HAZOP meetings.

Developed basis of design for new projects and modifications.

Carried out Insulation thickness calculation and adequacy check.

Reviewed vendor documents and performed bid evaluation.

Participated in audits and incident investigations.

MADRAS FERTILIZERS LTD, Chennai, India

Assistant Manager - Process Engineering

JOB RESPONSIBILITIES:

Troubleshooting of process plant problems and suggested remedial solutions.

Tracking of process plant, equipment efficiencies like raw material consumption, Utility consumption and wastes.

Energy audit of the plant and individual equipment audit.

Foreseeing potential problems.

Diagnosis of root causes of process problems.

Evaluated process equipment performance.

Worked for Ammonia Vapor recovery system to reduce environment impact.

Performed heat and mass balance calculations.

Steam and water balance of the plant.

Prepared / reviewed PFD and P&ID for modifications/revamping of existing plants.

Equipment sizing (Exchangers, Pumps, Separators, Control valves and vessels) and prepared data sheet.

Calculated relief loads, PRV sizing and data sheet preparation.

Flare stack design, Flare header sizing and adequacy check of existing Flares.

Performed hydraulic calculations, pipeline Pressure drop and line sizing.

Developed process design basis for new projects and modification.

Reviewed vendor documents and performed bid evaluation.

Catalyst performance evaluation - Approach to equilibrium.

Monitored process parameters for optimization.

Prepared procedures and carried out Degreasing, Acid pickling, Passivation and High velocity flushing for exchangers, Condensers and piping system.

Well versed with ISO 9001-2000 specification and MOC.

Documentation and implementation of ISO procedures

M/S. SPECSIM ENGG. PVT. LTD, Mumbai, India.

Assistant Process Engineer

JOB RESPONSIBILITIES:

Process and detail engineering for M/S. LUBRIZOL INDIA LTD, Bombay, India.

Preparation of Energy and Mass balances.

Prepared PFDs and P&IDs.

Selection and sizing of equipments and preparation of data sheets.

Preparation of equipment layout.

Preparation of material specification.

Technical bid analysis and recommendations

M/S. ONGC. LTD, Mumbai, India

Safety Engineer

JOB RESPONSIBILITIES:

Ensured safety of the facility within all process activities.

Manage the operational integrity of the facilities through maintenance, inspection and engineering management of the process systems. Ensure appropriate process standards, procedures and specifications are in place for the assets.

Ensure stringent systems are in place with regards to Loss Prevention and Risk Management.

Participated in HAZOP/PHA activities.

Ensure strong Process Safety Culture within the plant.

Communicate safety activities, policies and procedures across the business units.

Assist with the safety compliance manual and company procedures.

M/S. ESSEL PACKAGING LTD, Mumbai, India

Production Engineer – Provided technical recommendations in order to achieve production goals in a safe and cost effective manner.

JOB RESPONSIBILITIES:

Monitoring process parameter and Corrective action.

Check raw material specifications.

Ensuring product quality and meeting production targets.

Providing technical recommendations in order to achieve production goals in a safe and cost effective manner.

Achievements

:

Developed concept and process selection criteria and selected suitable process for vapor recovery unit (VRU).

Developed concept and process selection criteria and selected suitable process for Diesel Filtration System (DFS).

Developed concept and process selection criteria and selected suitable process for natural gas treatment and field development.

Developed concept for gas compression projects and attended value assurance reviews for project approval.

Design modification proposed and implemented to get free liquid flow from intermediate separator vessel in Urea plant based on Froude No.

Recommendation given to change the number of tube passes to two from four to increase the cooling water flow based on the adequacy of Cooling Water supply and return pipe size & implemented.

Separator was proposed at the reciprocating compressor suction to knock out water droplets to avoid frequent compressor valve failures.

Operating parameter change was proposed to avoid vapor lock and to get uninterrupted and continuous liquid urea flow.

Proposed to use liquid area melt in place of solid urea to improve NPK product quality, crushing strength was increased.

Process modification was proposed and implemented to recover 4 to 5 M3/hr of 10 to 15% Urea solution to consume in the process itself and to avoid consumption of same quality of dilution condensate. Thus sending it to surge Tank, recovery and evaporator loading was avoided.

Piping modification was proposed to get more cooling water flow across the condenser to enhance heat duty.

Urea heating coil was designed and installed to obtain liquid urea from solid Urea.

Investigated and found reason for failure of one of the exchangers out of two with similar application.

Additional Information:

:

Worked as a guest faculty of Madras Fertilizers Ltd (MFL) training Center for conducting classes to the Diploma / graduate chemical engineering students. Guided University students who carried out project work in MFL.

ISO 9001: 2000

MFL was awarded ISO 9001 in 1995. Active involvement in ISO 9001 activities, good exposure to ISO procedures and systems. I was also one of the MFL’s certified ISO 9001 internal quality auditors.

As part of my MBA (IGNOU) program, submitted project work titled Effectiveness of implementation of ISO 9001 in Madras Fertilizers Ltd (MFL).

TRAINING/ SEMINOR ATTENDED :

PMP, Project Management Institute, USA

HYSYS – Training course on Advanced Process Modeling using Aspen HYSYS- conducted by M/S. Aspentech.

Workshop of efficient operation and maintenance of Boilers – conducted by Anna Institute of management, Govt. of Tamil Nadu, Chennai, India.

Supervisory Development Program - In house program at Madras Fertilizers Ltd (MFL), Chennai, India.

Productivity and Safety - In house program at Madras Fertilizers Ltd (MFL), Chennai, India.

Training program on “Windows, MS-Office, internet & Email conducted by M/S SRM Systems and Software, Chennai.

ISO-9001 Internal Quality Auditors Training- In house program (MFL).

Training of “Internal Auditors for ISO 14001- EMS Auditing”

ISO 9001: 2000 Revision and Transition Training Course.

Languages

English - RWSU, Hindi - SU, Arabic - SU & Tamil - RWSU.

Email id

******@*******.***

Mob No.

0091 805-***-****

Qualifications

B.E(Chemical), 4 years full time course, 1987

MBA (HRD-Distance education), 2001

PMP, Aug 2020

Date of Birth & Age 24-5-1966 & 58 -Years

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