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SUMMARY
Twenty-two years experience in detailed FEED - mechanical, thermal and process design of pressure vessels, direct fired process heaters, hot oil heaters, boilers, pressure pipework, heat exchangers, reactors, incinerators, furnaces and associated ancillary equipment for petrochemical plants. Very strong E&I, DCS / PLC skills and ability to integrate process equipment to control systems.
Extensive field experience in site erection, installation, commissioning and client handover of the aforementioned equipment. Solid commercial background in contracting, tender preparation, tender evaluation, contract negotiations and project management. Seasoned design team leader, field supervisor and troubleshooter.
SALIENT PROFESSIONAL SKILLS
Pressure Vessels / Heat Exchangers / Air Coolers
* ASME VIII, TEMA, API 660.
* Detailed design, vessel wall and tube plate thickness, supports, nozzle loadings.
* Tube layouts, surface area sizing, preparation of data sheets and calculations.
* Thermal and hydraulic design, fluid thermodynamics.
Direct Fired Process Heaters & Boilers
* API 560, API 530, ASME 1, AS1228, DIN 4754.
* Detailed thermal design of radiant, shield and convective sections.
* Detailed mechanical design, foundation loadings, lifting lugs, coil supports, tube plates, refractory and insulation selection.
* Burners, fuel trains, BMS & controls.
Combustion Equipment
* Detailed burner, combustion air and fuel train design, NFPA, UL, FM, AGA.
* Detailed design of incinerators, afterburners, combustors
* Air pollution control equipment.
* BMS, control and safety interlocks.
* Extensive commissioning, troubleshooting and tuning experience of combustion and process equipment.
Pressure Piping
* Selection, sizing, layout, pressure drop calculations.
* Stress analysis, support and restraint systems, thermal expansion, allowable movements and loads, ASME B31.1, ASME B31.3
Instrumentation & Process Control
* Formulation of P&ID, process flow diagrams, selection of instruments and controls.
* Integration with plant DCS, ESD, PLC or hardwired control panels.
* Cause & Effect Diagrams, Functional Logic Diagrams, EDS function, PLC programming (Allan Bradley).
Software
* Use of various specialist engineering software packages.
* Word, Excel, PowerPoint, MS Project, AutoCAD 2002.
* Various Pipe Stress Analysis, Pressure Vessel, Shell & Tube & Fired Heater software packages (HTRI / TEMA FTS/FSE/FIV / ESCOA / SIMFLEX / Advanced Pressure Vessel / WINHEAT)
* Computer simulations of normal, abnormal and emergency operating scenarios.
Commissioning
* Planning schedule and start up sequencing
* Blowing, flushing, boil outs, filling, pressurising
* Pre-commission, dry run, functional testing
* Commissioning
* Performance testing, operator training
* Client hand over
Contract Management
* Cost control, cost and time to complete.
* Bid preparation, estimate and tender evaluation.
* Project management.
* HAZOP.
EDUCATION
University of Canterbury, Christchurch, New Zealand, 1979 - 1982
I completed a Bachelor of Engineering degree in Mechanical Engineering.
REFEREES
Available on request.
CAREER SUMMARY
1996 - 2005 Engineering Manager, Process Heat & Combustion Ltd, Auckland
1995 - 1995 Lead Engineer, Davy John Brown, Brisbane Australia
1993 - 1995 Facility Manager, Waste Management Ltd, Auckland
1989 - 1993 Process Engineer, Waste Heat Engineering Pty Ltd, Adelaide, Australia
1988 - 1989 Mechanical Engineer, Lurgi, Bunbry Australia
1984 - 1988 Design Engineer, T O'Connor & Sons Adelaide, Australia
1983 - 1984 Graduate Engineer, NZSFC, New Plymouth, New Zealand
WORK EXPERIENCE:
Process Heat & Combustion Ltd
Engineering Manager
Specialist heat transfer equipment design and installation company working in the Oil & Gas, Petrochemical and Mining industries. Responsible for the activities of various engineering disciplines for the detailed design of fired heaters, heat exchangers, boilers, reactors, separators, glycol dehydrators, water bath heaters, thermal oxidizers, pressure vessels and associated ancillary equipment. Involved in all aspects of the work from feasibility study, conceptual and detailed design, procurement, field construction and startup supervision.
Santos Ltd, Ballera Phase 3 Queensland, Australia
Senior Mechanical Engineer
Natural Gas Plant – CO2 Removal
Overall responsibility for the design, fabrication, FAT, delivery, site erection and commissioning of a direct fired process heater (API 560), pumping station, unfired steam generator, pressure vessels and interconnecting pipework. Located in a very remote desert area in Australia. Duties entailed: -
Leading the FEED team for –
* Detailed design of the heater structure, refractory, support legs, walkways and ladders, stack and heating coils (Radiant, Shield and Convective).
* Prepare heater data sheets, calculations (mechanical, heat transfer, pressure drop, tube wall, combustion, fluid properties, pressure vessel), and ITP's.
* Pipework layout, isometrics and stress analysis.
* Detailed design of the unfired steam generator and pressure vessel and controls. Prepare vessel data sheets, ITP's etc.
* Formulate P&ID, burner management system and ESD functions.
* Prepare Cause & Effect diagram and Functional Logic Description to enable integration and control of the heater and boiler from plant DCS and ESD.
* Size and select combustion equipment, fuel trains and combustion air fan.
* Check workshop drawings, oversee fabrication, check QA hold points.
Mobilise to site and lead the field crew:
* Develop installation and hookup work packs.
* Oversee field erection of equipment and mechanical installation.
Commissioning Engineer
* Develop pre-commissioning and commissioning programme for the plant startup
* Commission equipment, conduct performance acceptance test, operator training and client handover.
* Conduct HAZOP, write operation and maintenance manuals.
UCB Chemicals Sdn Bhd – Seremaban, Malaysia
Senior Mechanical Engineer
Crylcoat Plant Expansion
Overall responsibility for the process and mechanical design, installation, commissioning and handover of all equipment necessary to double the facilities heating capacity encompassing:
* Managing a local team of engineers, CAD drafters, project and support personnel.
* Engineer, design and install a new direct-fired process heater. Integrate into an existing system and develop a common control regime.
* Review existing hydrocarbon pipework, stress analysis, reselect new API 610 pumps, install new pipework and tie in to existing pipes.
* Review chemical reactor heating system and devise new heating and control system.
* Resize new degass vessels and nitrogen-pressurized vessels. Design and install vessels and controls and integrate into existing plant.
* Engineer and design new shell and tube heat exchangers, oversee fabrication and testing. Obtain statuary approvals.
* Devise and implement field PLC and modus communications with existing plant DCS.
* Liaise with statuatory authorities for pressure equipment and third party inspection agency.
* Oversee equipment fabrication, witness QA hold points, hydrotesting and NDT.
* Oversee local sub-contractors, review operating procedures and OH&S issues.
* Plan, coordinate and implement plant shutdown and tie-ins
Commissioning Engineer
* Develop detailed commissioning plan and activity durations.
* Implement commissioning plan and manage specialist vendor commissioning personnel.
* Witness and certify operation of vendor equipment
* Provide specialist commissioning support.
* Arrange and implement performance testing and client hand over.
Petrochemicals Sdn Bhd – Pasir Gudang, Johore, Malaysia
Project Manager
Petrochemical Plant Upgrade
* Manage engineering design team for an upgrade project within an operating facility.
* Conduct progress and design meetings with client, staff and contractors. Resolve issues. Report on project status and budget.
* Develop P&ID, specification and performance sheets, equipment layout, piping layout.
* Prepare tie-in plan, manpower allocation, scheduling and site safety plan.
* Check design calculations, drawings and documentation.
* Procure equipment, oversee fabrication, and attend FAT.
* Supervise installation, resolve site issues as required.
* Manage commissioning and performance testing.
* Client handover, as builts and manuals
Wren Oil Pty Ltd – Picton Western Australia
Lead Mechanical Engineer
Oil Refinery
Detailed engineering and design of a waste liquid and waste gas incinerator complete with a thermal oil heat recovery unit. Design all associated ancillary equipment such as pumps, pipework, pressure vessels and controls. Oversee fabrication, obtain stuatory approvals.
BHP Billiton - Zamzama Pakistan
Senior Mechanical Engineer
Natural Gas Plant- CO2 Removal Plant
Lead a FEED team for the design of skid-mounted packages comprising
* Direct fired Glycol heaters.
* Pressurized expansion vessels (ASME VIII) and elevated support structure.
* Storage vessel.
* Pumping sets.
* Fuel train, combustion system and flame arrestors.
* Skid instrumentation.
* Writing operation and maintenance manuals.
* Develop P&ID's, cause and effect diagrams, DCS functional logic diagrams
* HAZOP, FAT.
Liaise with client representative, third party inspector and oversee manufacture in fabricators yard.
PT Medco Energy International - Jakarta, Indonesia
Process Engineer
LPG Plant
* Process design and equipment specification for complete LPG plant heating system comprising heaters, pipework, vessels, tanks, heat exchangers, pumps and valving.
* Produce data sheets, P&ID, PFD, equipment specification and process control philosophy.
* Devise equipment layout, main pipe rack layout and plot plan.
* Produce pressure vessel and heat exchanger preliminary designs and specification data sheets.
* Prepared enquiry documentation.
PTSSB - Prabumulih, Sumatra, Indonesia
Lead Mechanical Engineer
LPG Plant
Lead FEED team for the design of various skid packages comprising: -
* Fired glycol heater, stack, burner, fuel train, controls & instruments.
* Glycol surge vessel and pump sets.
* Fired hot oil heater, stack, pump sets, expansion vessel and elevated support structure, combustion equipment and controls.
* Interconnecting pipework, sizing, pipe layouts, layout, pipe support system, pipe stress analysis.
* Oversee equipment fabrication, QA, FAT.
* Prepare installation work packs.
Mobilise to site
Commissioning Engineer
* Supervise local work force.
* Pre-commission, line blowing, system fill and degassing.
* Prepare commissioning program and implement.
* Conduct performance test, train operators, client hand over.
Delta Corporation – Tauranga, New Zealand
Bitumen Storage & Heating Facility
Responsible for the successful and timely completion of an onshore bitumen tank farm with heated ship to shore pipeline. Project comprised
* Heated ship to shore pipeline (above and below ground).
* Heated storage tanks (API 650).
* Fired heater, pump sets, expansion vessel.
* Tank suction heat exchangers and shell & tube units (TEMA / ASME VIII)
* Interconnection pipework, controls and instruments.
* Loadout and blending pumps.
* Approvals.
Shell Todd Oil Services Ltd - New Plymouth, New Zealand
Field Engineer
Natural Gas Plant – CO2 Removal and Dehydration
Rectify a combustion problem with a new 16MW process heater. Establish testing program to determine cause, scope out repair works, supervise rectifications and recommission the heater.
Shell Todd Oil Services Ltd - New Plymouth, New Zealand
Field Engineer
FPSO - New Zealand
Rectify a burner control problem with two 30MW steam boilers onboard an operating FPSO. Ensure that the FPSO remains in operation during at all time.
* Review boiler P&ID, PLC program, operating manuals.
* Develop a fault finding plan to identify the root cause.
* Carry out plan on board.
* Modify PLC program
Test and recommission burners
Davy John Brown
Santos Ltd, Ballera Phase 1 Queensland, Australia
Lead Mechanical Engineer
Natural Gas Plant – CO2 Removal
Responsible for the process design of the thermal fluid heating system comprising waste heat recovery units (from turbine exhaust), auxiliary direct fired heater, pressure vessels, pump sets, unfired steam generator, pipework. Produce P&ID, PFD and control philosophy. Develop control functional logic diagrams for DCS programming. Produce operating and commissioning procedures. Supervise commissioning of static equipment.
Waste Management Ltd
Facility Manager
Hazardous Waste Incineration Facility
Facility Manager for a new hazardous waste incineration facility. Responsible for staff, operation and financial performance but primarily to modify the incinerator to meet air discharge consent requirements. Following activities performed
* Reduced excessive fuel consumption (by 50%).
* Turned the facility into a profit maker rather than a significant loss maker.
* Implemented design modifications and improvements
* Reprogrammed DCS to improve combustion control and system response.
* Reduced HCL emissions by installing an acid gas scrubber.
* Reduced dioxin and mercury emissions by installing an activated carbon injection system.
* Produced a simulation model of the unit
* After two years of modifications re-commissioned the unit and conducted air discharge testing (passed air discharge content conditions)
* Re-wrote operating manuals and retrained plant operators
* Developed and implemented a planted maintenance program and staff professional development program.
Waste Heat Engineering Pty Ltd
Design Engineer
Design and Build Company of various heat transfer equipment throughout Australia in the Oil & Gas, Mining, Timber and Chemical industries. Extensive design and field installation and commissioning experience gained.
Shell Oil Projects
* Darwin Bitumen Plant –hot oil heater, unfired steam boiler and sour gas incinerator
* Fremantle Bitumen Plant –Sour gas incinerator, commissioning.
* Port Headland Bitumen Plant – hot oil heater, controls, commissioning
* Lyttelton - Replace hot oil heater
* Nelson Bitumen Plant - hot oil heater, pumps, storage tanks, heat exchangers
* Mt Maunganui- upgrade heater controls to PLC based system.
Mobil Oil Projects
* Adelaide – Bitumen storage tanks, transfer pumps, jacketed pipes, hot oil heater
* Adelaide – Heavy fuel oil storage tanks, ship to shore pipeline, transfer pumps, jacketed pipes, hot oil heater, heat exchangers, and heat-traced pipework.
* Adelaide – Steam boiler replacement
BP Oil Projects
* Lyttelton – Bitumen plant, hot oil heater, shell and tube heat exchanger, heated storage tanks.
* Gisborne- Heated storage tanks, hot oil heater, pumps, heat exchangers
* Bluff – Nitrogen pressurized hot oil system, vessels, pumps, suction heated and pipeline.
* Yarraville Lube Blending Plant - Heat exchangers, reactors, hot oil heater, steam generator, pipework, pumps, instruments, controls, commissioning.
Lurgi
Mechanical Engineer
Nufarm Pty Ltd
Lead Engineer for new acid plant in Western Australia. Responsible for planning and scheduling equipment supply and installation. Contract administration and preparation of monthly progress claims. Action variation requests and claims.
Develop commissioning program and procedures. Commissioning, performance testing, operating training and client handover.
T O'Connor & Sons
Mechanical Engineer
Major Australian contractor to the Oil & Gas, Power and Mining Industries. Heavy engineering, pressure vessel and boiler fabricators. Licensees to CE Natco, CE Randall, Foster Wheeler and Aquachem.
Responsible for the detailed design of pressure vessels, columns, towers, separators, fired heaters, glycol heaters, water bath heaters and natural gas skids.
Electrical and Instrumentation
Oversee fabrication and site installation.
* Pressure Vessel calculations
* Equipment and pipe layouts
* Skid layouts
* Electrical and Instrumentation
* Oversee fabrication and site installation
* Commissioning and performance testing
NZSFC (New Zealand Synthetic Fuels Ltd)
Graduate Engineer
Motunui Synthetic Fuels Plant - Methanol to Gasoline
Responsible for a broad range of general engineering associated with the fabrication and erection of six large hydrogen gas recycle heaters (8MW each) and associated ancillary equipment. Maintain and update records and document control. Cary out inspections at fabricators yard, vet progress claims, update construction schedule, prepare monthly report.
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