Training on Polymerization and Solid State Polycondensation

Zimmer gave us training about Polymerization and Solid State Polycondensation

Dolphin Energy Ltd

Got Safety training to work on Oil and Gas Plant of Dolphin Energy Ltd Qatar

Shut Down Project Manager

• Established organization consisting of Planning, Execution, HSE, QA / QC, Admin, Equipment & Plant, Tool Store, Warehouse, Finance, mess facility, purchasing for the contractual agreement, and Sub-Contractors.
• Managed for preparation of schedule, Organogram, submission of method statements, JSA, HSE safety plan, PQP, ITP, WPS, for all above mentioned shutdowns.
• Pre shutdown activities managed and performed successfully like, scope study, site verification, scope clarification with Management, established TSF and fabrication workshop, Pre-shutdown fabrication (fit-up, inspection, welding), weld mapping, preparation of work packs, flange management sheet, work control sheet, material control sheet, pressure test procedure, crane location plan, scaffolding erection, insulation removal, tagging for blinds, valves & equipment, TPC for rigging tools, inspection of electrical items, coloring of blinds, flange management tagging.
• Managed and organized sub-contractors.
• Estimation for the cost of project and ensure that all the resources (including HR, tools, equipment and plant) necessary for execution are within stipulated budget allocated to the project in order to control the cost of the project.
• Cold Eye review for each department to observe the level of readiness and any other requirement.
• Daily coordination & job progress meeting with client’s management and also to discuss & resolve the issues.
• All activities are performed successfully maintaining safety and quality work.
• Targets for HSE a) Zero fatalities b) LTI free work site c) TRIR less than 0.5 (OSHA) d) No environment incidents.
• Rigging studies for heavy weight lifting of critical jobs.
• Fabrication and welding of field piping, managed PWHT.
• Execution of all additional and emergency jobs raised during shutdown period.
• Controlled mobilization and demobilization of man power and equipment.
• Prepared lesson learned and completed the close out report for shutdown activities.
• Reviewed and approved invoices for further submission.

Senior Manager

I have worked as Maintenance Shift Superintendent and managed multidiscipline maintenance activities (Mechanical, Electrical, Instrument & Control) Condition Monitoring, & Workshop for whole plant consisting of Process (Stream 1, Stream 2), Utility, Offsite, & Export Gas Compression (EGC).
Responsibilities:
• Daily meeting with Senior Manager Field Maintenance to generate work progress reports, discuss, receive work instructions, and resolve issues.
• To ensure various maintenance disciplines works are performed in a safe and efficient manner, planned, and executed properly.
• To contribute for an efficient and cost effective performance of field maintenance of all plants.
• To monitor and coordinate for implementation of preventive, corrective maintenance programs and planned shutdowns / Turn-around.
• Liaison with relevant departments, exchange information, clarify issues, and coordinate with other Superintendents and Senior Engineers.
• Liaison with operation and technical services to plan and coordinate major shut downs and Turn-around activities.
• To coordinate for material and procurement requirements. Participate in preparation and monitoring of capital and operating budgets.
• To participate regularly for all disciplines in maintenance tasks, machinery condition monitoring, and troubleshooting to ensure necessary technical resources are allocated by respective discipline for effective resolution.
• To review and discuss maintenance work progress and related issues with Superintendents, Engineers, and Supervisors, on daily basis.
• To evaluate work techniques and procedures used to carry out the maintenance activities.
• To monitor the quality and performance of maintenance programs against the KPIs and ensure continuous improvement of services.
• For annual Turn-around in house scope of work to confirm for all resources, spare parts availability, special tools, required erection of scaffolding, removal of insulation, method statements, TRA, preparation of PTWs and Vendor arrangements.
• To identify and recommend the requirement of specialized contractor work.
• To monitor contractor’s performance and quality of service to ensure compliance with their contractual obligations.
• To coordinate and supervise the Mechanical Workshop activities for progress on daily basis to meet the requirements for keeping plants in continuous and smooth working condition.
• To ensure that “safe systems of work” and “safe conditions” are in place while performing the maintenance activities.
• To take part regularly in weekly HSE Management Walk Down, task risk assessments, HSE meetings, emergency drills, implementation of policies and procedures.
• Monitor and manage maintenance staff performance, and annual performance appraisal.

In addition to routine maintenance work other major and critical jobs:
• 103- 2 K600 Off Gas Compressors: Replacement of liner of 1st stage cylinder and complete overhaul.
• 103-1K600 Off Gas Compressor: Complete overhauling and replacement of piston rods of 2nd stage 3rd cylinder due to scratches on rods.
• 123-0k1010B Main Plant Air Compressor, replaced bearing with modified hole 2.4mm and did complete overhauling of compressor.
• 109-1E0240 Sour Water stripper Re-boiler: Shell and bundle cleaning was carried out.
• Replacement of EGC Rolls Royce Engines.
• Overhauling and inspection of stream turbines.
• Overhauling of high pressure fuel gas compressors and gear box.

Deputy General Manager Engineering

I had been Managing, planning, scheduling, executing, preparing budgets for preventive, predictive, corrective, breakdown maintenance, and shut down maintenance activities of all plants, utilities and for centralized Work Shop.
In addition to other maintenance jobs especially to rectify recurring problems; managed along with maintenance procedures for replacement of bearings like 24064BMBC3 & gears like M8 x 79 NT x 120 W along with other parts for gear box of 22 gears train, for replacement of shafts 4.5 Ton, 6 Meter long of baler hydraulic system working at 250 bar pressure, maintenance of solenoid valves of SMC, YUKEN, KONAN for hydraulic and pneumatic systems.
ACHIEVEMENTS:

1- Repairing of Shaft of Polymerization Hitachi Reactor: The damaged surface of the shaft got repaired on site without removal from the reactor vessel. Complete procedure regarding pre weld heat treatment, post weld heat treatment, welding and machining complying with the required tolerances were managed. Thus Plant was saved from a longer shut down.
2-Repairing of Vessel of Esterification Hitachi Reactor: Due to crack in the catalyst dosing nozzle; the HTO was leaking from jacket to the vessel. The reactor vessel was cut for root cause analysis. Repaired the lining, jacket, nozzle, and shell without any abnormality and plant was in service.
3-Repairing of shaft of Calender M/C (Train of 22 Gears): Shafts repaired with special technique and are in service without any problem.
4-Manufacturing of Bearing Puller: A special bearing puller is designed, manufactured, and used to remove successfully11 bearings (24064BMBC3) from the shafts.

Senior Engineer

Ø 4 Years in Maintenance & Engineering Departments
• In addition to preventive, corrective, shutdown & TA maintenance jobs of 120 T / D Petrochemical & 180 T / D Solid State Polycondensation plants carried out liaison with operation department for proper and in time solutions of the problems for the sake of high quality continuous and optimum production.
• Managing and planning for execution of annual turn around considering maintenance activities, spare parts, man power, & job allocation of petrochemical, solid state polycondensation plants, and effluent treatment plant.
• Being experienced of petrochemical plants; worked as Group Leader for trouble shooting of other three petrochemical plants.
AS MECHANICAL ENGINEER IN PTA/AROMATICS PROJECT, AND [ARAMCO FEED STOCK FROM NGL PLANT TO IBN RUSHD SURGE SPHERE (INSTALLATION OF PROPANE & BUTANE PIPE LINE)]:
(August 1997 – March 2001)

Aromatics plant’s capacity is to produce 349,000 MT per annum of Benzene and 374,000 MT per annum of Para-Xylene.
Carried out the activities as Mechanical Inspection Engineer for PTA/AROMATIC Project

Deputy Manager Maintenance

• In addition to preventive, corrective maintenance of Rotary and stationary, have experience of many shut downs of petrochemical plants, 5 shutdowns of petrochemical plant of Rupali Polyester Ltd. Fifth shutdown (annual turn around) conducted in May 1994 and this was a big shutdown of both lines including the replacement of mechanical seals of three reactors, PC1-1, RA12 and PC3-2.