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Career Episodes Saudi Arabia

Career Episodes Saudi Arabia

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Published by asb121314
Career Episodes Saudi Arabia
Career Episodes Saudi Arabia

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Published by: asb121314 on Jan 16, 2011
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05/22/2014

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Career Episode 1
In my first career episode I describe my last projects with Uhde ThyssenKrupp. I havebeen working with Uhde since November 18, 2006 until March 12, 2008. There are two distinctperiods: one in Saudi Arabia where I've worked as Process Engineer - CommissioningSupervisor for Safco 4 Project (period of November 18, 2006 - June 15, 2007) and the secondperiod as Process Engineer - Consultant in Head Quarter office, Dortmund - Germany (period of August 7, 2007 - March 12, 2008).
Saudi Arabia SAFCO 4 Project (SABIC Company) Jubail City.
As Commissioning Supervisor for Ammonia Plant in SAFCO 4 I was responsible forplant preparation for "Sustaining Load Test" and "Performance Test" of 3300 mtpd of theworld's largest ammonia plant. I coordinated the Client Company - SAFCO operation personneland I collaborated with other Uhde engineering departments such as Mechanical,Instrumentation, Rotary and Electrical ones.As a daily routine I checked the plant parameters, collected the data from the field andControl Room, lab analysis, and took decisions regarding the operations and maneuvers that hadto be done in order to achieve the plant design specifications.During the plant test and inevitable trips and shut-downs I was directly involved ininvestigations regarding the cause and effect, route cause analysis and field inspections. After allthe data had been collected, all the investigations had been done and after a conclusion had beentaken, I was a member of engineering team who made the final reports, taking the appropriatemeasures in order to prevent future hazards.I analyzed the design mistakes and the effect during the plan normal operations. In closecontact with Engineering Design department I proposed solutions in order to improve the processand to achieve the design parameters of the plant. Also after the construction stage, duringcommissioning and normal operation, a series of erection and construction errors appeared.Together with the Mechanical and Civil engineering department I prepared the action plan forcorrections. All the major design mistakes, constructions errors, and other technical problems(catalyst poisoning, heat exchangers internal by-pass, or broken tubes, internal columnsdisturbing, etc) were corrected during the Turn Around shut-down of the plant (period of January20, 2008 - February 20, 2008). As former Commissioning Supervisor, I coordinated the shut
 
down plan and I was responsible for the site progress of all the engineering departments: Civil,Mechanical, Instrumentation. Electrical, and Rotary.The organization chart for Safco 4 Project was:
Germany - Dortmund: Uhde ThyssenKrupp office head-quarters
As Process Engineer Consultant for Uhde I did preparations for HAZOP study,checked and correcting the PID, PFD. data sheets, Trip Schedule, emissions and consumptionlists for EAgrium Fertilizer Project from Egypt.For future Ca Mau Fertilizer Project (Vietnam) I was responsible for technicalbackground support for Uhde sales team. During the bidding process, together with the salesdepartment I prepared the engineering documentation (material balance sheet, emission andconsumption lists, PFD's) for client company PVFCC - Petrovietnam.Another task was field inspecting for Duslo Sala revamping project in Slovak Republic. There, as Uhde licensor representative, I investigated the final construction stage tocompare with the original PID, analyzing the effects and impacts of potential erection andconstruction errors to commissioning and start up of the plant.
 
Personal Engineering Activity
Saudi Arabia SAFCO 4 Project (SABIC Company) Jubail City.
During Saudi Arabian SAFCO 4 Project, I did the preparations of ammonia plant forFinal Performance Test. When I started the project, the commissioning had already been ongoing for 6 months, and the maximum design capacity had not been reached yet. The "bottleneck" of this project was the
CO2
removal system. The efficiency of the main absorber columndid not fit with design specifications.One of the tasks was to improve the absorption system. In this respect during the plantrunning I was conducting a series of tests and experiments, changing the MDEA solutioncomposition, flow and temperatures and collecting data for future simulation. Then after, I usedprocess simulation softwares like Aspen and Pro II in order to find a solution for increasing theefficiency of the
CO2
removal system.I prepared a complete report with all my conclusions sustained by collected data, trends,simulations and observations, and then I sent it to the design department in Dortmund and toBASF licensor of the
CO2
removal system. After a series of meetings between the Client -SAFCO - Sabic, Uhde, and BASF a decision regarding future modification was made.During the final Turn Around shut-down, my task was supervising of the final works andmodifications inside the
CO2
removal system. I inspected the main absorber, flash drums, andstripper, checked signs of corrosion, preferential flow circulation, internal packing rings layerdistribution. I supervised and controlled the final works regarding the installation of a new gasdistributor inside the absorber in order to improve
CO2
absorption. The new design for the gasdistributor was a result of my conclusions regarding the efficiency of the absorber column. It wasdone by Uhde design department together with BASF, based on the field data sent by me. Today,due to this modification the world largest ammonia plant is running at 105% capacity.Another job which I completed in the Saudi Arabia was to increase the efficiency of thesyngas drying unit. The syngas drying unit's central piece was the two dryers filled up withmolecular sieves working in parallel. Most probably during precommissioning, commissioningperiod, the molecular sieve from one dryer was contaminated. Due to this fact, when thecontaminated dryer was in service, traces of water escaped, and affected the reaction in thesynthesis column. My idea was to increase the regeneration time sequence for defect dryerworking only on the logic sequence. Together with the software DCS engineer I completed this

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