Resume - Senior process engineer upstream oil and gas design consultancy. Ammonia plant o...

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ACADEMIC QUALIFICATION: B.E. (Chemical Engineering), Annamalai University
First class with Distinction
Overall percentage of marks: 87.3 % out of 100 %
University Gold Medalist

Master of Science (M.S.) from The Birla Institute of Technology & Science
Overall CGPA: 10 upon 10

Overall percentile score in GATE: 94.92
(GATE = Graduate Aptitude Test in Engineering conducted by Ministry of Human Resource Development, Govt. of India)

P.G.Diploma in Operations Management
Indira Gandhi National Open University
Overall CGPA: 4.18 out of 5

LABOUR CARD: Currently holding resident card in Muscat –Oman valid for next 2 years upto Mar-2008

MEMBERSHIP /CERTIFICATION:
* Passed in Tamil Nadu Boiler Operation Engineers' examination during 1994 (conducted by the Inspector of Boilers – Government of Tamil Nadu).
* Member of Indian Institute of Chemical Engineers.

COMPUTER SKILLS:
* Fluent in writing programs in Quick Basic, FORTRAN, Excel (able to write programs in Visual Basic to certain extent).
* Versatile user of Windows XP / MS Office 2000/XP/2003 / Graphic page design softwares.
* Having excellent presentation skills using MS PowerPoint.
* Versatile user of Internet and its resources – collected wealth of literatures and softwares
* Hands on experience in using Chemshare Design-II and Aspen Plus simulation packages. For the upstream oil and gas industry jobs, I am currently using Hysis, Pipesim, TLNET, TGNET and SHELL-FRED softwares.

SUMMARY OF EXPERIENCE:
B.E., MS, with 16 years total experience in Design consultancy, Process engineering Group and Naphtha based Ammonia plant operations.

* Versatile in three fields: Design Consultancy, Process Engineering & Design as well as Plant Operations.
* Preparation of Process Flow Diagrams, Piping Instrumentation Diagrams, mass and energy balances, equipments sizing and rating, sizing and specifying pipelines, pumps, heat exchangers, separators, demisters, relief valves and rupture discs, compressors and turbines, packed beds, HAZOP studies etc.
* Able to write computer programs for rating and problem solving;
* Total in-charge for Plant operation and managing experience in Naphtha based Ammonia plant having sections like Naphtha and fuel oil tank farm, Hydro-de-sulphurisation, Reforming, Shift reactors, CO2 removal section, Methanation, gas compression, Ammonia synthesis converter, Ammonia storage and refrigeration, PGHRU, Auxiliary boilers and Captive power plant, all utilities plants.
* Plant optimization, process troubleshooting, production planning, plant emergency control, implementing safety systems.
* Designing and implementing energy conservation steps and Modification proposals, process design, reliability improvement, modernization and retrofit/revamping studies, conducting field performance tests, conducting performance guarantee test runs for revamped plant.

DETAILS OF EXPERIENCE
Mar. 2006 – Till date: Senior Process Engineer in Upstream oil and gas field – reputed design consultancy firm Worley Parsons Oman Engg LLC in Muscat

Working as Senior Process Engineer (Lead Engineer) in many upstream oil and gas projects involving Basis For Design, Front End Engg Design and Detailed Engg Design stages.

* Performing process simulation using HYSYS.
* Performing Hydraulics using PIPESIM and transient surge analysis using TLNET/TGNET.
* Dispersion calculations and radiation calculations using SHELL-FRED software
* Process design and rating of shell and tube heat exchangers.
* Preparation of PFS / P&IDs / PSFS.
* Implementation of process licensor's front-end design engineering.
* Design of pipeline blow-down and relief systems.
* Process design of oil-gas separators and knockout drums.
* Design of manifolds, surge relief systems, scrapper launcher and receiver.
* Performing calculations and preparing process data sheets for control valves, centrifugal pumps and multiple screw pumps, ESD valves, etc.
* Co-ordination with other disciplines, process licensers, clients and national and international suppliers.
* Preparation of material requisition, technical specification and bid evaluation and vendor documents.
* Familiar with the relevant API, NFPA codes and standards as well as SHELL DEPs/SPs/Gus/ERDs. Also familiar with DOW-LPPs and Union Carbide's TMS standards.
* Familiar with working in an ISO 9001 environment.

Key Accomplishments in Design consultancy:

* Lead Engineer for the BFD/FED/DD stages of two oil field expansion projects in South Oman for Petroleum Development Oman.
* Iso-Pentane handling and storage facilities for Equate Petrochemicals – Kuwait, including fire protection system facilities specifying.
* Fire water network and other facilities for the huge construction camp facilities for Bechtel
* Co-ordinating Environmental Impact Assessment studies for Oman Gas Company in one of the pipeline project
* Process Design Checker for many other jobs within the department including the Daleel Petroleum's gas pipeline project
* Hazop studies and Design reviews for the above projects.

Oct. 2002 – Feb-2006: Ammonia Plant Production Manager in Southern Petrochemical Industries Corpn - India

* Responsible for the complete operation and maintenance of ammonia plant, process optimisation and troubleshooting, production planning and budget control, quality systems and safety & environmental management systems implementation, developing subordinates and trainees, annual maintenance shutdowns planning and execution, modernisation and retrofit of ammonia plant, energy reduction programs designing and implementation.
* Responsible for the complete Operation and Maintenance of entire Ammonia plant, Auxiliary Boilers, Captive power plant, Ammonia storage and tanker loading system, Inert gas generation units, Cooling water treatment, Naphtha and Furnace oil storage tankfarm, handling and unloading of imported Naphtha and furnace oil shipments.
* Responsible for the plant production, process and equipments troubleshooting and process optimization - where Hydro-desulfurisation, Reforming of Naphtha, steam-Methane Reforming, CO Shift conversion, Gas purification, Methanation and high pressure Ammonia synthesis are part of the plant processes.
* Responsible for designing and implementing energy/cost saving proposals, conducting Hazop studies for the modification proposals, taking lead role in revamping and retrofit of Ammonia plant and feedstock conversion project, co-ordination with technology suppliers like Haldor Topsoe.
* Responsible for the compliance towards ISO 9002, ISO 14001, TQM, HSE related activities of Ammonia plant and applicable Statutory requirements.
* Responsible for the production planning, budget preparation and control for raw materials, utilities and chemicals, budget preparation and control for maintenance spares and consumables, capital proposals initiation and implementation, inventory control, fixed assets management.
* Responsible for the motivation and work culture in the multi discipline team of around 20 Engineers and 100 Technicians for the Ammonia plant.
* Responsible for devising training modules and imparting training to the Engineering graduate trainees and Technician trainees, performance assessment, conducting emergency trip drills and evaluating the technicians performance.
* Experience in restructuring and re-engineering of the plant operation for higher production, cost control and more profitability.
* Scrutinizing and approving the financial commitment for the spares and consumables procurement, contractors work bills certification, scrutinizing and approving the off-loading of works to contractors.
* Co-ordination with major raw materials supplier Indian Oil Corporation, production and service function heads of other associated plants and nearby industries.
* Co-ordination with Catalyst suppliers regarding the performance assessment of current charges of catalysts and deciding for the procurement of future charges.
* Pre-planning of jobs to be taken up during annual maintenance turnarounds, co-ordination and follow up of materials procurement for the turnaround requirements, implementing all the turnaround activities within the time schedule + budget in a safe manner, conducting post-turnaround reviews / preparing reports / recommending improvements for next turnaround. (Dedicated execution of Turnaround during the year 2004).

Apr. 1999 – Oct. 2002: Head of the Department of Process Engineering Group in Southern Petrochemical Industries Corpn - INDIA

Responsible for the process engineering activities of the entire Site consisting of Ammonia, Urea, utilities, boilers, captive power plant, ammonia importation terminal etc.
As Head of the Dept. of Process Engineering Group,
* Responsible for the following Process Engineering activities: -
- To carry out technical studies for maximizing the production and minimizing the energy consumption
- Monitoring and trouble shooting of the plant processes and equipments
- Proposing & devising energy conservation schemes - Prepara-tion of PFDs and P&IDs
- Identifying & suggesting pollution control measures
- Identifying and eliminating the bottlenecks in the plant processes and in the equipments' design
- Rendering engineering assistance to the procurement of equip-ments and technical evaluation of the offers
- Developing software programs for our monitoring and design purposes
- Suggesting ways to optimize the specific consumption of raw materials and utilities
- Working out the cost - benefit analysis of various modification proposal schemes
- Carrying out inspection activities during plant shutdowns
- Analyzing the plant trips and process upsets and suggesting re-medial measures
- Training the subordinates, etc.

Key Accomplishments in Process Engineering Group:

* Suggested and engineered several energy saving measures - like optimization of steam system, reducing the pressure drop in the process lines, improvements in pumping systems, improvements in heat exchangers, improvements in liquid distributors and packings in columns, improvements in cooling towers and cooling water treatment systems, etc. fetching sizeable cost savings.
* Thorough in monitoring and evaluating the performance of various catalysts in Ammonia plant, steam turbines, centrifugal and reciprocating compressors, heat exchangers, pumps, fans and blowers, boilers, captive power plants & turbo generators, cooling towers, water treatment plants, effluent treatment systems, solid handling equipments, etc.
* Experienced in preparing process flow diagrams and P&IDs for the modification proposals. Carried out numerous Hazop studies.
* Carried out Energy audit studies related to Ammonia plant.
* Worked as the Energy Manager of the Complex as approved by Tamil Nadu Government Electricity Board.
* Actively involved in the engineering phase and commissioning phase of Revamping and Modernization of Ammonia plant during the years 1996 to 1998. Had the experience to co-ordinate and discuss various technical issues related to these revamps with engineering companies like KTI-BV, Ammonia Casale and Giammarco Vetrocoke, Euro Apex, L&T and Technip.
* Carried out the shutdown inspection jobs during all the shutdowns including the SIX major maintenance Turnarounds in Ammonia plant (during 1990, 1993, 1996, 1998, 2001 and 2004). Gained thorough knowledge in the areas like charging and discharging of Catalysts and Packings, improving the performance of heat exchangers, chemical cleaning of boilers, safe working procedures adopted during such massive turnaround activities, etc.
* Played a key role in specifying, evaluating and finalizing the Reverse Osmosis treatment scheme for treating the cooling tower blow down water.
* Actively involved in the basic process design, detailed engineering and commissioning phases of Installation of a Steam turbo generator and HRSG section.
* Developed several software programmes required for the Process Engineering Group activities.
* Conducted preliminary feasibility study for using Natural gas as feedstock. Visited the ONGC's Oil and Natural gas exploration drill sites, Oil/Gas gathering stations, Oil refinery etc. in the Ramnad/Cauvery basin areas and collected first hand information.

Aug. 1995 – Mar. 1999: Sr. Process Engineer at Process Engineering Group
Looking after Ammonia plant and Ammonia Importation terminal related process engineering activities.

Feb. 1992 – Aug. 1995: Operation Engineer at Ammonia Plant
Worked as Operations Engineer in round the clock shifts in Ammonia plant.

Ammonia Plant Operation Experience

* Took lead role in the conversion of pneumatic instrumentation control system to DCS system (Yokogawa Centum XL) for the Ammonia plant and Steam generation units. I had been in the core team and involved right from conceptual design, Factory Acceptance test, commissioning and normal operation.
* Three and half years of hands on experience in the day to day operation of Ammonia plant, Boilers, Captive power plant and Ammonia/LPG importation terminal.
* Hands on experience in the Turnaround activities like catalyst charging and safe discharging, packings changing, heat exchangers performance improvements etc.
* Carried out isolation, maintenance and Re-commissioning of Naphtha and fuel oil tanks.
* Handled Ammonia ship unloading activities several times.
* Fully trained in First aid, safety procedures and fire fighting techniques and emergency preparedness plan for Process plants and chemical storages.

Aug. 1990 – Feb. 1992: Engineering Management Service Trainee
* Training as Process Engineer in Process design group of SPIC-SMO ( Project management service & Engineering Contracting division of SPIC) at Chennai, INDIA.

TRAINING / FOREIGN TOURS:
* Visited Equate Petrochemicals – Kuwait during Apr-2006 for the purpose of Design consultancy project work from Muscat.
* Visited Haldor Topsoe offices at Copen Hagen, Denmark and participated in the Ammonia plant retrofit and feedstock conversion project decision making meetings during Apr-2005.
* Participated in the Catalyst symposium organized by Sud-Chemie group at Phuket, Thailand during Nov-1996.
* Participated in several catalyst seminars organized by Sud-Chemie and Johnson Matthey in India.
* Visited the Ammonia and Urea plants of Chambal Fertilisers, IFFCO-Aonla, Tata-Babrala, GNFC-Bharuch, KRIBHCO-Hazira, Godavari Fert., MFL-Chennai and FACT-Cochin.
* Attended several energy conservation courses organized by reputed institutions like CII.
* Undergone several safety training courses.
* Attended training programmed in Corrosion controls conducted by Central Electro Chemical Research Institute -Karaikudi.
* Undergone several training programs in Management techniques for Managers.

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