Process Engineer
Resume:
RESUME
Name - IB Singh
A) Professional Experience : 30 years and 5 months
01. a) Period : January, 2001 to till date
b) Company : Qatar Petroleum, Doha, State of Qatar
c) Position : Operations Engineer d) Total experience : > 11 years
e) Responsibility : Process Engineering and Plant Operation ( RFCC complex and Sulphur complex )
Assignment :
- Interacted with Process licensor UOP and Lurgi for finalisation of Engineering activities
- Reviewed PFD’s and P&ID’s of Resid Fluidized Catalytic Cracking unit and other basic engineering documents along with Process Licensors, i.e. M/s UOP and Lurgi etc
- Checked / finalized Utilities, catalyst and chemical requirements for unit start up
- Reviewed and finalized DCS graphics, group trends, inter locks and logics etc
- Checked inter connectivity of RFCC unit with upstream and down stream units
- Finalised pre commissioning and start up plan and executed the same with Lurgi / UOP
- Reviewed Operating manuals and Procedures which were followed during start up
- Checked Training simulator details / performance and suggested improvements
- Did final Inspection of all static equipments with UOP and LURGI before start up
- Did Refractory dry out activities and subsequent inspection with UOP and Lurgi
- Was involved in the commissioning and start up of units ( RFCC, Condensate refinery, Sulphur recovery units, Amine treating and Power Generation Package of refinery )
- Coordinated for training of Engineers and Operators for above units with Lurgi / LG
- Developed inventory control charts for catalyst hoppers and caustic tanks etc
- Suggested / Prepared many process / trouble shooting schemes for above units of Qatar Petroleum refinery
- Coordinated for ISO 9001 certification of refinery, RFCC section. Developed procedures and documents for the same. Also did IMS audits of other sections of the refinery.
02. a) Period : Feb, 1998 to Dec, 2000
b) Company : Essar Oil Limited, Jamnagar, India
c) Position : Joint General Manager d) Total experience : ~ 3 years
e) Responsibility : Process Engineering and Plant Operation ( RFCC, SRU, ARU, SWS, DHDS, CRU and Utilities )
Assignment :
- Interacted with Process licensors like Stone and Webster Engineering corporation, USA, Comprimo, Holland, IFP, France and ABB Lummas, Holland for finalisation ‘of Process and Engineering ‘ related issues of RFCC, SRU, ARU, SWS, DHDS & CRU etc
- Reviewed PFD’s and P&ID’s of Resid Fluidized Catalytic Cracking unit & other basic engineering documents along with Licensors and ABB Lummas
- Reviewed ‘ Process and Equipment data sheets ‘ including ‘ Isometrics ‘ drawings
- Did ‘ Hazop and Operability study ‘ of RFCC Unit with SWEC and ABB Lummas
- Checked / finalized Utilities, catalyst and chemical requirements for unit start up
- Reviewed and finalized DCS graphics, group trends, inter locks and logics etc
- Checked inter connectivity of RFCC unit with upstream and down stream units
- Finalised pre commissioning and start up plan for all these units
- Reviewed Operating manuals and various procedures and finalized the same
- Trained Operators and fresh engineers for safe and smooth operation of above process
units and also prepared training material and documents for future training
- Closely supervised and followed ‘ Engineering, Procurement, Construction and other operation related activities
03. a) Period : May, 1996 to Jan, 1998
b) Company : Reliance Petroleum Ltd, Jamnagar, India
c) Position : Deputy General Manager d) Total experience : ~ 2 years
e) Responsibility : Project and Process Engineering and Plant Operation
( SRU’s, ARU’s, SWS’s and Sulphur Granulation units )
Assignment :
- Interacted with M/s Bechtel, London & Houston, M/s UOP and M/s Pritchard corporation, USA for ‘ Process and Engineering related issues ‘ of Sulphur recovery units ( 3 trains ), Amine regeneration units ( 3 trains ), Sour water stripping units ( 3 trains ) and Sulphur granulation units ( 2 trains, 1000 tons / day capacity each )
- Was involved in ‘ Process licensor selection ‘ for Sulphur recovery units of refinery
- Reviewed and finalized plot Plans, PFD’s and P&ID’s of Sulphur recovery units with M/s Pritchard corporation, USA and of Amine regeneration and Sour stripping units with M/s UOP, USA and M/s Bechtel, London and Houston
- Reviewed 3-D models of SRU’s, ARU’s and SWS’s with M/s Bechtel, London / Houston
- Did ‘ Hazop study ‘ of Sulphur recovery units with M/s Pritchard corporation, USA, Bechtel, London and Houston including Amine regeneration & Sour water stripping units
- Checked / finalized Utilities, catalyst and chemical requirements for unit start up
- Reviewed and finalized DCS graphics, group trends, inter locks and logics etc
- Checked interconnectivity of Sulphur block units with upstream and down stream units
- Finalised pre commissioning and start up plan for Sulphur block units
- Reviewed / prepared Operating manuals and various procedures for above units which were followed during start up
- Trained Operators and fresh engineers for safe and smooth operation of above process
units and also prepared training materials and documents for future training
- Closely followed Engineering, Procurement, Construction and Operation related jobs
- Interacted with other disciplines like mechanical, Electrical and Instruments etc for jobs
04. a) Period : April, 1988 to April, 1996
b) Company : Indian Oil Corporation Limited, Mathura Refinery, India
c) Position : Senior / Deputy Process Engineer d) Total experience : 8 years
e) Responsibility : Process Engineering / Technical services
( All process units in the refinery and Utilities block units )
Assignment :
- Did Independently process monitoring daily of Crude and Vacuum distillation unit ( CDU
and VDU ), Fluidized catalytic cracking unit ( FCCU ), Visbreaker unit, Meroxes, Amine
treating, Sour water stripping, Sulphur recovery and Bitumen units
- Did Process modifications for product quality, yields and energy improvements and also for improving on stream days of all above units
- Did Trouble shooting and De bottlenecking jobs / studies for above process units
- Interacted with process licensors like UOP, Comprimo, IFP, and other engineering companies like Engineers India Limited and Triune engineering for detailed engg jobs
- Developed ‘ Dynamic training simulator ‘ for FCC Unit for training of operators and engineers which is being used extensively in the refinery
- Prepared, finalized and implemented ‘ Power and steam load shedding scheme ‘ for total refinery in order to avoid un wanted interruptions of critical units like FCC unit
- Did Hazop study of CDU, VDU, FCC, Visbreaker, Meroxes, Amine treating, Sour water stripping and Sulphur recovery units and made no of recommendations for safe and smooth operation of these process units
- Trained fresh engineers for ‘Process engineering ‘ jobs and developed various operating procedures for plant operation etc
- Did ‘Process Simulation ‘ studies for improvements in these units
- Refer Annexure-1 for details of ‘ Process simulation modifications & other jobs’ done
05. a) Period : Mar, 1982 to Mar, 1988
b) Company : Indian Oil Corporation Limited, Mathura Refinery, India
c) Position : Production Engineer d) Total experience : 6 years
e) Responsibility : Plant Operation of all process units of refinery
( CDU, VDU, Visbreaker, Meroxes, FCC, Amine treating, Sour water stripping, Sulphur recovery units )
Assignment :
- Worked as Shift in charge / Shift engineer for refinery process units ( like Crude and Vacuum distillation unit, FCC unit, Vis breaker unit, Amine treating and Sour water stripping unit, Sulphur recovery unit etc )
- Handled various emergencies like power and steam failures including equipments etc
- Was Shutdown in charge / co ordinator for CDU, VDU, FCCU, Visbreaker, Meroxes, Amine treating, Sour water stripping, Sulphur recovery and Bitumen blowing units
during annual turnarounds. Prepared total shutdown plan and timely executed the same
- Operated process units on Pneumatic as well as DCS ( Toshiba, Honeywell etc )
- Supervised 5 engineers and 30 operators during shift operation
- Prepared Training documents and conducted regular training sessions for Operators and Engineers for units like CDU, VDU, FCC, VBU, ARU, SWS and SRU etc
B) Personal details :
a) Postal address : Post Box 50252, Umm Saieed, Doha, State of Qatar
e_mail : **********@*****.*** and **********@*******.***
b) Date of birth : 05.05.1959 c) Nationality : Indian
d) Passport details : No Z1029399, Validity : 15th Jan, 2016, Issued from : Qatar
e) Educational qualifications : - Bachelor in Chemical Engineering
- Masters in Chemical Engineering - Master in Business Administration ( Finance ) - Specialisation in ‘ Process Engineering and Plant Design ‘
- Did Graduation and Post graduation in Chemical Engineering from
Indian Institute of Technology, Roorkee, India ( earlier known as University of Roorkee )
And MBA ( Finance ) from Indira Gandhi National Open University, New Delhi, India
Annexure – 1
Details of ‘ Process Simulation, Modifications and other jobs ‘ done :
A) Process modifications :
Sr No Description Status
01 Made process scheme for maximum hydrocarbon stripping in reactor of FCC Unit of UOP design. Scheme implemented and CRC level in spent catalyst dropped from 0.80% to 0.25% wt. This resulted in drop in regenerator temperature from 680 to 650 deg C, increase in LPG and gasoline yield by 1.0% and 2.0% wt respectively. Also unit capacity could be increased from 140 m3/hr to 185~190 m3/hr on average basis Implemented
02 Resized primary absorber trays of FCC unit to avoid liquid carry over problem in the down stream column ( sponge absorber ). Scheme implemented & problem solved Implemented
03 Prepared process scheme for monitoring of slurry line temperature to avoid chokage due to catalyst / coke. Now it is possible to monitor temperature and avoid plugging Implemented
04 Designed and installed trim cooler for heavy naphtha circuit in FCC unit in order to avoid cooling limitation and also to get more distillate recovery and increase unit capacity. Scheme implemented successfully and is in operation Implemented
05 Proposed and implemented scheme for FCC unit bottoms streams rerouting for cooling in order to control main column bottom temperature and avoid coking. This has resulted in reducing unit interruptions and increase on stream days of unit Implemented
06 Modified slurry settler circuit top liquid routing which has drastically reduced fouling / coking in FCC unit bottom circuit and has increased on stream days of unit Implemented
07 Resized catalyst loading system of FCC unit which resulted in catalyst loss reduction at the time of fresh catalyst loading in hopper at least by 15~20% on average basis Implemented -
08 Did / conducted various test runs in FCC unit for yield and energy improvements ---
09 Did / conducted various test runs in CDU / VDU for yield and energy improvements ---
10 Did / conducted various test runs in Vis breaker unit for yield & energy improvements ---
11 Did / conducted various test runs in SRU for recovery and energy improvements ---
12 Designed and implemented charcoal & sand filter scheme for best amine quality Implemented
13 Redesigned lean amine trim cooler to avoid fast fouling & frequent maintenance. This resulted in elimination of frequent fouling of existing exchanger, better H2S absorption in amine absorbers, less H2S in final fuel gas and also better LPG quality Implemented
14 Redesigned Vacuum column bottom vortex breaker to avoid bottom pump piping vibrations, choking and pump damage etc. Scheme implemented successfully ---
15 Developed and implemented ‘ Total power and steam load shedding scheme for the refinery. This has resulted in avoiding un necessary interruptions of FCC unit during power failure and increased on stream days of unit followed by less maint problems Implemented
16 Prepared process scheme for avoiding running of third compressor of 600 KW at the time of catalyst loading in FCC unit by routing excess air from Bitumen unit compressor to plant air header. Now it is possible to manage refinery operation with two compressors only which has been put in practice. Implemented
17 Designed water wash system for water washing of bitumen unit over head gases. This scheme was expected to bring down oil level and recovery of the same ---
18 Did test run of refinery cooling water system. Based on the study, air cooler fans were changed by FRP blades which has resulted in energy saving of 30~40 KWH Implemented
19 Suggested change in over head air coolers metallurgy of CDU in order to use spare tubes available in the refinery ( other metallurgy ) with out affecting cooling capacity. Implemented
20 Coordinated with Comprimo, Holland for installing of Super claus process in existing Sulphur unit of refinery in order to get more sulphur recovery & less SO2 emission Done
21 Resized Bitumen unit knock out drums to avoid liquid carry over to over head gases and plugging of over head lines. Scheme was implemented & problem got minimized Done
22 Developed and implemented full fledged process scheme for isolation and also commissioning of Bitumen reactors during operation. This has increased on stream days of the unit Implemented
23 Made process scheme for heat integration of hot streams in FC unit to Propylene recovery unit. This as resulted in fuel oil saving ( equivalent to 4~5 MMCAL/hr ) Implemented
24 Studied air blower requirement for burning / oxidation of Bitumen unit flue gases. It was found that existing blower is not required & same was stopped. Saving: 50 KWH Implemented
25 Studied possibility of heat recovery from Bitumen unit flue gases but found un economical as only LP steam could be generated. Same was in excess in refinery Not implemented
26 Develop process scheme for recovery of heavy naphtha from Vis breaker column. The scheme was done and extra 4~5 m3/hr material could be recovered a diesel Implemented
27 Prepared detailed ‘ Process and Instrumentation diagram ‘ for power plant of refinery ---
28 Did energy audit of all refinery heaters to find out heat loss and made proposal to recover the same which was implemented in CDU / VDU later on One
29 Did Vis breaker unit decongestion study and implemented the same safely Done
30 Developed many process schemes for process units on ‘ Auto_Cad ‘ soft ware ---
B) Process Simulations ( with SIMSCI package ) :
Sr No Description Status
01 Did Process simulation study of total Vis breaker unit for yield benefits with SIMSCI package. Compressor requirement as specified by designer was eliminated as existing top pressure of column was found optimum for maximum diesel yield. The same was verified by actual test run of unit. Compressor requirement was dropped Implemented
02 Developed process scheme for conversion of flash column into tray column in Vis breaker unit by simulation. The scheme was planned to be implemented ---
03 Did simulation study of total amine absorption and regeneration system of refinery and identified optimum amine strength for absorption which was implemented. This had resulted in good LPG quality & reduction of amine consumption for the refinery Implemented
04 Did simulation study for converting Sour water stripping unit into two stage sour water stripper. Prepared process scheme : Benefit – SO2 reduction – 90 kg/hr Implemented
05 Did simulation study to find out best type of amine for H2S absorption. It was found that DEA and MDEA are the best for this purpose. So DEA use was continued ---
06 Did simulation study of FCC unit pre heat train to increase feed pre heat temperature and established that it can not be increased further with existing hard wares ---
07 Rechecked by simulation the size of new naphtha splitter system for getting 45~110 deg C and 110~ 130/140 deg C cut products and found ok ---
08 Did Mathematical modeling of total FCC unit with M/s Trident auto dynamics, USA. Base on this dynamic simulator was developed which is being used for training ---
09 Did simulation study of FCC main column and found that diesel yield can be increased by 3~4% wt. Process scheme was prepared. ---
10 Did ‘ Factory acceptance test ‘ of DCS for FCC unit which was commissioned without any problem and successfully in the refinery for the first time for this unit Done
11 Was involved in the development of ‘ FCC unit optimization model ‘ with Indian Oil R & D center for advance prediction of impact of new catalyst on unit yield etc Done
12 Did simulation study and designed ‘ SO2 scrubbing system ‘ with spent caustic for existing Sulphur recovery unit of refinery. Expected benefit : SO2 emission reduction by 90 Kg/hr. Process scheme was made Done
13 Did simulation study for Crude unit and suggested scheme for increase in pre heat and also for reducing RCO recovery. Suggested optimum operating parameters also Done
14 Did simulation study for absorption of H2S from low pressure Vis beaker unit fuel gases and developed process scheme for burning the same in heaters to save fuel. ---
C) Hazop Studies :
I have done Hazop studies of following units :
- Fluidized Catalytic Cracking unit ( FCC )
- Atmospheric and Vacuum distillation unit ( CDU / VDU )
- Vis breaker unit ( VBU )
- LPG meroxes ( UOP design )
- Sulphur recovery unit ( SRU )
- Amine regeneration unit ( ARU )
- Sour water stripping unit ( SWS )
- Meroxes ( LPG + Naphtha + Kerosene / ATF )
D) Shutdown coordinator :
I have worked as shutdown coordinator for following units of refinery during annual turnarounds :
- Fluidized Catalytic Cracking unit ( FCC )
- Crude and Vacuum distillation unit ( CDU / VDU )
- Vis breaker unit ( VBU )
- LPG meroxes ( UOP design )
- Sulphur recovery unit ( SRU )
- Amine regeneration unit ( ARU )
- Sour water stripping unit ( SWS )
E) Soft wares known :
I have knowledge of following soft wares :
- SIMSCI process package and PROII
- Audy_Sim for developing dynamic training softwares
- Hextran for heat exchanger sizing and design
- Primavera for Project management
- Auto_Cad for process scheme development
- Computer related standard soft wares like Microsoft Excel & word etc
IB Singh
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