Process Safety & Relief Systems Engineer
Resume:
JOJO JOHN PERIAPURAM, PE, MBA, CCPSC®
League City, Texas 77573
832-***-**** *********@*****.***
Texas Licensed Professional Engineer (Chemical) CCPSC U.S. Citizen Active TWIC Card
PROFESSIONAL SUMMARY
Process Safety and Chemical Engineering professional with 26+ years of experience in petrochemical, refining, specialty chemicals, energy, and carbon black manufacturing environments. Texas Licensed Professional Engineer (Chemical) and Certified Chemical Process Safety Professional (CCPSC) with extensive experience leading and supporting Process Safety Management (PSM), Process Hazard Analysis (PHA), Layer of Protection Analysis (LOPA), Process Safety Information (PSI), Management of Change (MOC), pressure relief systems, operating procedures, incident investigation, process risk assessment, and process safety improvement initiatives.
Experienced PHA facilitator/coordinator with responsibility for six full-plant five-year PHA revalidations and numerous small- and medium-sized project PHAs. Strong technical background in relief system evaluation, PSV sizing and selection, Cause & Effect development, PFD/P&ID development, process control, process simulation, equipment design, and process troubleshooting.
Proven ability to work with Operations, Maintenance, Engineering, Instrumentation & Controls, Reliability, contractors, and management to identify process hazards, evaluate safeguards, implement risk reduction measures, and maintain safe and reliable operations. Experienced managing internal and external process safety resources and providing technical leadership, mentoring, and training.
CORE PROCESS SAFETY COMPETENCIES
Process Safety Management (PSM)
Process Hazard Analysis (PHA)
PHA Revalidation
Layer of Protection Analysis (LOPA)
Independent Protection Layer (IPL) Evaluation
Process Safety Information (PSI)
Management of Change (MOC)
Relief System Engineering
PSV Sizing & Selection
Fire Case Relief Analysis
Thermal Relief Analysis
Cause & Effect Diagrams
PFD & P&ID Development
Process Risk Assessment
Safeguard Evaluation
Incident Investigation
Root Cause Analysis
Operating Procedures / SOPs
Alarm Management
Process Safety Auditing Support
Mechanical Integrity Support
Process Control Safety
Safety Instrumented Systems Support
Emergency / Startup / Shutdown Risk Assessment
Process Safety Training
Contractor & Engineering Resource Management
Process Safety Metrics & Continuous Improvement
PROCESS SAFETY LEADERSHIP
PHA / LOPA / Risk Assessment
Coordinated and managed six complete plant-wide PHA five-year revalidations.
Facilitated numerous PHA studies for small- and medium-sized capital projects.
Facilitated PHA/LOPA revalidation for the ONEOK Mont Belvieu facility.
Participated in LOPA and IPL evaluations to determine adequacy of existing safeguards.
Reviewed process hazards, initiating events, consequences, safeguards, and recommendations.
Worked with Operations, Engineering, Maintenance, Instrumentation, and management to develop practical risk reduction measures.
Process Safety Information
Managed PSI documentation and engineering information.
Prepared, reviewed, and maintained PFDs, P&IDs, Cause & Effect diagrams, process descriptions, and engineering documentation.
Supported engineering document management and migration from ProjectWise to SharePoint.
Reviewed process design information for consistency with operating and process safety requirements.
Management of Change
Initiated and executed MOC activities associated with process modifications, control changes, equipment modifications, operating changes, and process improvements.
Evaluated technical and process safety impacts associated with proposed changes.
Coordinated engineering, Operations, Maintenance, and Instrumentation input during MOC implementation.
Supported safe commissioning and startup of modified systems.
Relief Systems / Pressure Protection
Extensive experience evaluating plant-wide pressure relief systems.
Performed PSV evaluation, sizing, and selection.
Evaluated fire-case and thermal relief scenarios.
Used iPRSM for relief system engineering and evaluation.
Identified relief system deficiencies and developed mitigation plans.
Supported P&ID reviews and relief device documentation.
Process Safety / Operations
Developed and validated Standard Operating Procedures (SOPs).
Supported alarm management and process control improvement.
Conducted process troubleshooting and root cause analysis.
Supported commissioning and startup risk management.
Provided process safety training and mentoring to engineers and operations personnel.
Promoted continuous improvement and process safety culture.
PROFESSIONAL EXPERIENCE
INEOS ACETYLS – Texas City, TX
Principal Process Engineer / Site Process Safety Lead
August 2022 – June 2026
Provided process engineering and process safety leadership for a petrochemical manufacturing facility while supporting capital projects, turnaround activities, operations, and process safety programs.
Key Process Safety Accomplishments
Served as site-wide Process Safety Engineering Lead, providing technical support to Operations, Engineering, and management.
Led process safety engineering activities associated with the site's major five-year Turnaround (TAR).
Performed comprehensive plant-wide pressure relief system evaluations using iPRSM.
Identified relief system deficiencies and developed mitigation plans for each affected system.
Eliminated reliance on external relief engineering services by performing the work internally, saving approximately $25,000 annually.
Supported PHA, LOPA, MOC, PSI, and process safety improvement activities.
Reviewed and evaluated PFDs, P&IDs, Cause & Effect diagrams, relief systems, and process design documentation.
Mentored junior engineers in process safety engineering and process engineering practices.
Managed internal and external engineering resources supporting process safety activities.
Engineering / Data Systems
Managed engineering documentation migration from ProjectWise to the INEOS SharePoint environment.
Configured PI Event Frames and Notifications.
Trained engineers on PI System Explorer, PI DataLink, and PI applications.
Reviewed environmental emissions calculation spreadsheets and redesigned them to improve accuracy and eliminate calculation errors.
ONEOK – Mont Belvieu, TX
Senior Process Engineering Consultant
September 2018 – February 2020
Provided process engineering, process safety, process control, and optimization support for the Mont Belvieu facilities.
Process Safety Accomplishments
Led the complete five-year PHA/LOPA revalidation for the MBS facility.
Participated in safeguard and IPL evaluations.
Developed and updated P&IDs used for PHA and process safety reviews.
Developed complete Cause & Effect diagrams for the facility.
Worked with Operations and Engineering to identify and resolve process hazards and operating risks.
Process Optimization & Controls
Optimized hot oil heater operation, reducing fuel consumption by 12% and generating approximately $8 million in annual value.
Implemented APC control for SCR operation.
Implemented APC control for heater oxygen control.
Debottlenecked Degas Drum capacity.
Developed PI Vision dashboards for MB1, MB2, MB3, and MBS fractionation units.
Developed a PI-based Manual Valve Tracking system.
US SILICA – Texas
Process Engineering Consultant
March 2018 – July 2018
Re-engineered chemical water treatment systems.
Developed Allen-Bradley PLC programming.
Commissioned and validated modified chemical treatment systems.
Developed SOPs and operator training materials.
Supported safe startup and transition to normal operations.
Participated in engineering reviews associated with system modifications.
SNF FLOQUIP – Plaquemine, LA
Senior Process Engineering Consultant
January 2016 – March 2018
Facilitated PHAs for Powder Plant capital projects.
Supported process safety reviews for process modifications and equipment changes.
Commissioned a $1.2 million blending project.
Optimized LP1/LP2/LP3 process conditions, increasing production capacity to 120–160%.
Completed the third revision of P&IDs for a $35 million Powder Plant Unit 4 project.
Redesigned LP3 post-hydro piping, improving reliability by more than 15%.
Redesigned fluidized-bed dryer screen, improving drying performance and reliability.
Modified granulator fan capacity to improve conveying and reliability.
Modified screw design to reduce equipment failures.
PRAXAIR – Houston, TX
Process Engineering Consultant
August 2013 – December 2015
Facilitated PHAs for small- and medium-sized capital projects.
Evaluated process hazards and safeguards associated with process modifications.
Implemented a process gas boiler outlet quench project valued at approximately $200,000.
Re-rated hot air system at PA2, improving efficiency with approximately $900,000 annual value.
Modified auxiliary boiler steam superheater piping, generating approximately $400,000 annual energy value.
Installed process gas steam superheater at Sulphur, LA, improving efficiency by approximately $300,000 annually.
Redesigned turbine discharge steam flowmeter arrangement, reducing pressure drop and increasing power generation by approximately 400 kW.
Designed and implemented PSA bypass systems supporting safe-zone transition and reducing losses associated with plant trips.
COLUMBIAN CHEMICALS – Franklin, LA
Process / Project Engineer
November 2012 – August 2013
Introduced a structured project management system to improve project execution.
Commissioned classifier system for the specialty black unit, improving product quality and generating approximately $2.5 million in annual revenue.
Re-engineered ozone generation/drying system, generating approximately $435,000 annual energy savings.
Supported process safety and engineering reviews during project execution and commissioning.
CONTINENTAL CARBON COMPANY – Houston, TX / Ponca City, OK
Senior Process Engineer
July 2006 – June 2008; August 2010 – October 2012
Led process optimization initiatives focused on plant reliability and process efficiency.
Successfully commissioned Real-Time Performance Management software across three manufacturing facilities.
Developed EPA greenhouse gas reporting system.
Managed P&ID and PFD conversion projects to SmartPlant format.
Implemented continuous off-specification material reprocessing system.
Supported process troubleshooting, operating optimization, and reliability improvement.
EVONIK DEGUSSA – Borger, TX
Process Engineer
June 2008 – October 2010
Designed and implemented high-efficiency oil injection burner system, improving process yield and generating approximately $2.6 million annual value.
Investigated approximately $2 million/year raw material oil losses.
Implemented oil measurement system and connected measurement to DCS for accurate unloading and inventory control.
Optimized heat recovery system, reducing natural gas consumption by approximately $200,000 annually.
Supported process control, operating procedures, troubleshooting, and process improvement activities.
PHILLIPS CARBON BLACK LIMITED – Kochi, India
Assistant Process Manager
May 1997 – April 2005
Built and commissioned Palej #2 and #3 Carbon Black projects.
Supported plant commissioning, startup, operations, troubleshooting, and process optimization.
Participated in full-plant PHA and relief system evaluation activities.
Supported process safety and environmental improvement initiatives.
Presented technical paper on pollution control and energy conservation at the Indian Environmental Congress.
PROCESS ENGINEERING & TECHNICAL EXPERTISE
Process Safety / Risk
PHA • LOPA • IPL • MOC • PSI • Relief Systems • PSV Sizing • Fire Case • Thermal Relief • Cause & Effect • PFD/P&ID • SOP • Alarm Management • Incident Investigation • Root Cause Analysis
Process Engineering
Process Simulation • Process Optimization • Debottlenecking • Equipment Design • Process Troubleshooting • Energy Optimization • Reliability Improvement • Continuous Improvement
Equipment
Distillation Columns • Reformers • Shift Reactors • Absorption Columns • Adsorption/Dryers • Carbon Black Reactors • Boilers • Heat Exchangers • SCR Units • Bag Filters
Process Controls & Automation
DeltaV DCS • Allen-Bradley PLC • APC • OSIsoft PI • PI Vision • PI AF • PI System Explorer • PI DataLink • Control Valves • Flowmeters • Pressure/Temperature Instruments • Alarm Management
Software
Aspen HYSYS • Aspen Plus • UniSim • ProMax • DWSIM • Petro-SIM Express • iPRSM • SmartPlant • Microsoft Office 365 • Microsoft Project • Visio • Minitab • SQL Server • Wonderware SCADA • iHistorian
EDUCATION
Master of Science – Chemical Engineering
University of Houston
Master of Business Administration (MBA)
West Texas A&M University, Amarillo, TX
Bachelor of Science – Chemical Engineering
University of Kerala
PROFESSIONAL LICENSES & CERTIFICATIONS
Professional Engineer (PE), Chemical Engineering – State of Texas
Certified Process Safety Professional (CCPSC)
Six Sigma Green Belt
PMP Training Completed
DeltaV Implementation I – Configuration
DeltaV Implementation II – Advanced Configuration
DeltaV Hardware & Troubleshooting
Fisher Control Valve Sizing & Selection
Emerson Flowmeter Sizing & Selection
Emerson Pressure, Flow & Temperature Transmitter Selection
Active TWIC Card
ADDITIONAL QUALIFICATIONS
U.S. Citizen
26+ years petrochemical, refining, specialty chemical, and energy experience
Extensive PHA facilitator/coordinator experience
Six full-plant PHA five-year revalidations
Extensive relief system engineering experience
Strong Operations and Engineering interface
Experienced mentor and technical trainer
Available for plant/site-based process safety engineering roles
Contact this candidate