Resume - Refinery operation, technical service to hydrocracker/hydrogen/sulphur recovery ...

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Resume #88478

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Objective
To aspire for a responsible, challenging and rewarding position

Date Of Birth ? 1sth June, 1969
Gender ? Male
Nationality ? Indian
Marital Status ? Married
Present Job Title ? In-Charge, Hydro processing Unit, Technical Support to Operation
Present Employer ? Bahrain Petroleum Company

Professional Profile

* Fully Skilled Professional with 12+ years of industrial experience in the field of Process Design, Technical Service, Petroleum Refinery Operation, Emergency Handling, Up-gradation/Preparation of Operating/Turndown/Process Safety Procedures, Quality Control Management, Analysis by Hysis, HAZOP and Risk Assessment, Plant Troubleshooting, Energy Survey and Modifications for Performance Enhancement, etc. Presently working with BAPCO, Bahrain as a technical and operation assistance for hydro processing plant

Accomplishments

BAPCO, Bahrain
* Service from 21st Sept'2007 to till-to-date
* Operational and Technical assistance to improve plant performance & conservation of energy
* Review, update and maintain procedures & schedules for safe & trouble-free operation
* Analysis of Plant performance using PI Process Book and HYSIS
* Plant Troubleshooting and remedial actions to achieve on-specification products
* Assistance in day to day operations, i.e., chemical consumption, PPE, technical survey, etc.

Numaligarh Refinery Ltd
* Service from 7th Jan'1999 to 20th Sept'2007
* Full involvement in Project, Commissioning and Operation of Hydrogen and Hydrocracker Plant
* Review, update of Process Manual, PFD, P&ID, Emergency Procedure, Fire & Safety Regulations
* Preparation of punch list, expedite for early job execution
* Did many troubleshooting and modification jobs during plant start-up
* Gave many energy conservation ideas and helped in implementation thru MOC
* Helped in HAZOP study, Risk Evaluation and Remedial Action
* Trained field and panel operators about Plant Operation, Technical Know-how & Industrial safety
* Member of NRL Engineers technical forum
* Efficiency calculation of reactor, pump, compressor, heat exchanger, fractionators, heaters, etc.
* Preparation of daily reports, process capability, specific energy consumption, fuel loss, etc.
* Involved in commissioning activities of Utilities like ETP, Water Treatment, etc.
* Worked with Technical Service Department for around three years
* Full involvement in Revamp Project pre Evaluation and process calculation
Bureau of Energy Efficiency (Productivity Council, Chennai, India)
* Awarded with Certified Energy Manager in year 2005

BPCL (Bharat Petroleum Corporation Limited, Mumbai, India)
* Service from 4th Apr'2005 to 30th Sept'2005 in deputation
* Successfully commissioned of Hydrogen, Hydrocracker and Sulfur Recovery Plant
* Trained Operators, prepared operating manuals, reviewed P&ID & corrected ESD Logics
* Involved in activities like equipment commission, Heater dry-up, Catalyst Loading, Sulfiding, etc.
* Assisted in Equipment performance evaluation, guarantee test run etc.
* Handled many emergency situation

PDIL (Projects & Development India Limited, Noida, Delhi, India)
* Service from 7th Nov'1997 to 6th Jan'1999
* Development of PFD and P&ID, Cost Estimation, Uses of Codes & Standards, process design
* Technology Evaluation and Selection
* Familiarity with API, ASTM, ASME, NACE, BS Codes & Standards.

Expertise

Process Design
* Line Sizing * Control & Relief valve Sizing
* Distillation Column * Pump Hydraulics
* Heat Exchanger Calculations * Use of simulation software
* Review of PFD & P&ID * Technology Evaluation & Selection

Technical Service
* Plant Troubleshooting * Analysis of Plant Performance
* Corrective & Remedial Course of Action * Daily Operational Activities
* Reactor conversion Calculation * Unit Material Balance
* Co-ordination with Vendor * Data Collection & System Survey for Energy
* MOC Evaluation and Implementation * Assistance for Operational Excellence
* HAZOP Study * Energy Conservation Drives & Schemes
* Revamp Study * Safely related survey and audits

Plant Operation
* Plant Commissioning * Preparation of Operating Procedures and Schedules
* Start-up/shut-down activities * Emergency Handling
* Permit System * Knowledge of DCS
* Quality Control Actions * Daily Operational Activities
* ESD & PLC knowledge * Familiar to Plant Safety Regulation & Standards
* Training to operator * Job notification and maintenance follow-up

Experiences
Process, Commissioning and Operational Experiences are highlighted here:

* During the project stage of Hydrocracker units the following problems faced which can provide lots of experience so that the mistakes are not to repeat in future projects, like
* Reactor internals, bubble caps developed cracks. Metallurgy problem
* Reactor feed pumps spillback control valves (Y-type) fixed in wrong directions.
* CHPS sour water line faced back pressure. Design problem.
* Underground CBD system crosslink with FCBD system.
* Hydrocracker GTR failed. Wrong feed analyzed in pilot plant study
* Low pressure nuts & studs were replaced due to inferior quality, project mistake
* Plenty of Leaks in high pressure line flow orifice flange spare plugs
* Frequent rod packing failure of Kobelco make make-up H2 compressor
* Failure of feed filter (German make) 3-way valves
* Sea water cooler (surface condenser) frequent fouling problem

* Some of the commissioning and operation bottlenecks & emergencies of hydrocracker, hydrogen plant (NRL, BPCL & BAPCO) experienced and learned are, like
* Fire in fractionators fin fan due to no reflux as the line choked with congealed VGO
* No reaction in 2nd stage reactor at SOR condition, design problem
* Rising temperature pattern in reactors from SOR
* Limitation in 2nd stage reactor furnace from the first start-up, design problem
* No flow in one of 2nd stage reactor feed pumps spillback Control Valve, unknown reason
* Frequent seal failure of Ebara make reactor feed pumps
* 2nd stage reactor bed DP high (2 times in 6 years)
* Fouling of naphtha vaporizer, difficulty in cleaning due to fixed tube sheet
* Frequent loader valves failure of wet off-gas compressor, condensate carry over
* Fouling of HP exchangers, HPNA build up due to full conversion, no bleed
* REAC fin fan fouling, external air side, rectified by chemical cleaning (detergent foam)
* Frequent failure of injection water pump, packing failure, loader valve/dampner damage
* No flow in one of reactor quench lines, Reverse welded, arrow marked wrongly
* RGC turbine low performance, hydrogen plant steam drum internal damage
* Too much hammering and leakage in LG condensate system, no insulation as per P&ID
*
* Technical support service to Hydrocracker unit in preparing material balance, fuel consumption, specific hydrogen consumption, evaluation of reaction conversion percentage parameters, like
* Process data collection for licenser
* Calculation of reactor conversion like, X (T*), X(RCP), PPC, Hydrogen partial pressure
* Determination of reactor ageing (fouling) and time to replace catalyst
* Calculation of specific energy consumption of process unit, production cost
* Calculation of fuel consumption & oil loss
* Material balance calculation of process units

* Some useful process modifications as per MOC which led to considerable energy saving, like
* Step-less loading system (Hydrocom) of make-up compressor
* Replace warm-up (UCO) of 1st stg feed pump by filtered feed to improve capacity utilization
* Install 3rd injection water pump to avoid NH3 by running two pumps on continuous basis
* Diversion of UCO to diesel product
* Interconnection of Dedicated HSD oil to normal HSD route in unit limit to have CV facility
* Full utilization of HPRT(High Pressure Recovery Turbine)
* CLPS gas KOD (knock out drum) to facilitate condensate separation
* Off-gas comp and CLPS line drain to flare as a safety measure, eliminates H2S hazard
* Waste heat recovery of heaters, generation & superheating of 110 psig steam
* Insulation & tracing of Khuff gas (Fuel Gas) line to heaters to improve efficiency
* Insulation & tracing of HVGO line from tankage to HCU unit limit to conserve heat
* One spare naphtha vaporizer (HE) kept to avoid down time
* Recovery of H2 from refinery fuel gas which is around 30% rich in H2
* Flare gas treatment and recovery of fuel gas

* Some Troubleshooting activities needs to be highlighted for future reference and knowledge, like
* 2nd stage reactor conversion problem, high NH3 in recycle gas
* Low kerosene smoke point, high aromatic feed to 2nd stage, high CAT
* Condensate carry over with sour gas to SRU, no individual flaring provision during upset
* Condensate carry over with CLPS off gas to PSA, no KOD, no dedicated PSA

* Some of process analysis done using simulation software are following,
* CLPS section study for determining scope for maximizing production of LPG
* Fluid properties and its depressurization study.
* Crosschecking equipment and process parameters with respect to design calculations.

* Some workouts relevant to process design
* Familiar with codes & standards required start process design
* Line sizing, pressure drop & velocity limitation
* Pump hydraulic Power, NPSH, head, shutoff head and BEP calculation.
* Heat Exchanger Pressure drop and heat duty calculation
* Control valve and Relief Valve design.
* HPRT – Head, Horsepower
* Compressor- Polytrophic and Adiabatic head, Horsepower, Efficiency

* Assistance to technical service for gathering data to study the viability of modifications or revamps
* Use of exaquantum & log books for DCS data and laboratory test results
* Bottlenecks to be faced to implement a new system, some trial run methods
* Calculations and analysis relevant for production of Euro-diesel
* Hydrocracker revamp for capacity augmentation to treat straight-run diesel
* Study for Reactor catalyst replacement and sulfiding

Computer skill

* Process simulation software: Hysys
* Engineering application user end: SAP, DCS Data acquisition software exaquantum, PI Process
* Application: Microsoft office, Internet Access and WEB Browsing,
* Platforms: Windows 98/2000/XP/Windows Vista
* Programming Language: FORTRAN, Dbase, C++, Visual Basic etc.

Education

* University of Calcutta
M. Tech., Chemical Engineering, Specialization-Petrochemicals & Petroleum refinery Engineering, 1997, First Class, 75%, University College of Science & Technology, Calcutta
* University of Sambalpur
B. E. in Chemical Engineering, 1993, First Class, 60%, Regional Engineering College, Rourkela
Total 61 days vocational training Refinery and Steel Company (Fertilizer Section)
GATE qualified for getting sponsorship for Master of Technology Course
* Assam Higher Secondary Education Council
Higher secondary, 1988, Second Class, 58%, Cotton College, Guwahati, Assam
* Board of Secondary Education, Assam
High School Leaving Certificate, 1986, First division, 76%, Higher secondary School, sarupathar

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