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a) INTRODUCTION
P.E. 1.1 The first episode of my engineering career was about my engineering project
started on date: August 2001 when I was a final year student of chemical
engineering session (1998-2002) at University of the Punjab, Lahore and ended on
date. August 2002. The project was for one year. The geographical location of the
university campus is at canal road Lahore, Pakistan, renowned as “Quaid-e-Azam
campus, University of the Punjab Lahore. University has number of academic
programs up to advanced level, which are being offered at various Faculties and
Institutes. Among them, an institute of Chemical Engineering & Technology is a
pioneer faculty of chemical engineering in Pakistan well known and recognized
on national as well as international level.
b) BACKGROUND
P.E. 1.2 As part of my chemical engineering qualification and competency skill
requirement, I was assigned a plant design project on the “Production of 300
Tons/Day Ethylene from Naphtha cracking”.
Naphtha is a composition of hydrocarbons containing carbon atoms from C 5 to
C9. Boiling range for these fractions is 90-375 oF. Naphtha’s which are irritant,
flammable and toxic are derived from both petroleum fractions and coal tar.
Naphtha’s are used as organic solvent for dissolving or softening waxes, oils,
greases, varnishes and plastics. The less flammable fractions are used in dry
cleaning. Mineral spirits are also included under the heading of Naphtha’s.
Naphtha’s can enter into our system through inhalation of vapors, ingestion and
eye or skin contact. Petroleum Naphtha has a lower order of toxicity than coal tar
Naphtha. Overexposure to either type of Naphtha may cause central nervous
system depression with symptoms of inebriation followed by headache and
nausea. Naphtha is a major by product during crude oil refining and major part of
naphtha is exported.
Ethylene H2C=H2C is the largest volume building block for many petrochemicals.
This olefin is used to produce many end products such as plastics, resins, fibers
etc. some of the physical and chemical properties of Ethylene includes lightest
olefin wit a slightly sweet odor. It is a colorless flammable gas. Boiling point is
103.71 oC. Ethylene is a very reactive intermediate. The Ethylene double bond
reacts readily to form saturated hydrocarbons, their derivatives or polymers. The
principle reactions with commercial significance include Polymerization,
Oxidation and addition including Halogenations, Alkylation’s, Oligomerization,
Hydration and Hydroformylation. Useful commercial products from Ethylene
include PolyEthylene, Ethylene Oxide, Ethylene Glycol, Acetaldehyde, Vinyl
Acetate, Vinyl Chloride, Ethyl Benzene and Ethanol. PolyEthylene is used in
cable/wire covering, in resin manufacturing, as packing material, plastic pipes and
in emulsion and waxes. Ethylene Oxide is used in pharmaceutical industry.
Ethylene Glycol is used in polyester fibers as plasticizer and in electrolytic
capacitors. Unfortunately there is not a single unit in Pakistan which is involved in
cracking of Naphtha for Ethylene production.
P.E. 1.3 The main objective of the project were:-
Feasibility of the design project.
Design of complete manufacturing / production plant on commercial scale to
carry out the whole manufacturing production process at minimum cost and
resources available.
Review design on the basis of engineering standards and codes,
environmental hazards, smooth operation of the plant with less down time.
P.E. 1.4 My design group was organized as per following hierarchy.
* Indicates my position.
P.E. 1.5 Upon well recognition of my good reputation in both academic and
communication capabilities during the Engineering course of study, I was
selected for position # 1 as member (chemical) in all group members of same
discipline of chemical engineering. My group first planned to prepare an
action plan (strategy) in order to accomplish all the objectives concerned and
finally the target. Duties of all group members were set with deadlines and
following were included in my duties:
Play a key role of group leader at same level of all group members and
devise an effective project strategy for implementation.
Prepare progress reports (on monthly basis) to present the group activities
in monthly meeting with the project director.
Perform all design related task of collaboration with other group members.
Take guidelines and time-to-time consultation with project direction in
progression of the group activities.
Establish a strong communication within the group members.
P.E. 1.12 After completion of process selection activity, 1 with my group members
prepared a process block diagram describing each step of the process
completely for material and energy balances application. At the same time1
prepared a Process Flow Diagram (PFD) that after detailed discussion with
group members on process engineering aspects and technical requirement of
the equipments involved, finally approved by the Project Director. All
equipments with accessories involved in PFD were designed according to
relevant Engineering design Equations, Standards & Codes available e.g.
ASME, ASTM, TEMA etc) & Optimization process. Instrumentation and
control system was designed on the basis of process control requirement. A
Piping & Instrumentation diagram (P & ID ) was prepared for this purpose of
control system designing. This was a bit challenging task for me and my group
members for which 1 took a great help from my project director & my
friends, students of Electrical and Instrumentation Engineering.
P.E. 1.13 I did all calculations and estimates relevant to plant design economics like
Capital investment, Production cost estimate and equipment cost. The project
was completed well in time.
P.E. 1.14 Later on in close liaison with PARCO Refinery, near Multan city, a low
capacity pilot plant of this commercial design project was constructed and
installed at the factory area of Refinery to check and verify all design
conditions and operation of the plant. By the grace of Allah Almighty, it was
successful and met all design requirements with little trouble shoots and waste
hazards, which was reviewed and modified later in design. Overall the project
was a successful. Successful operation of the pilot plant and low capital and
production cost of the project was made this project highly attractive in nature
for future installations in Pakistan.
d) SUMMARY
PE 1.15 This project in the beginning of my professional career provided me a lot of
opportunities for multi-dimensional learning.
PE 1.16 The prominent fared features of this project contained time management and
leadership that played an important role in my professional competency skills
to manage all activities in a time bounded frame of work and drives the project
sequentially and systematically by equipping and utilizing effectively the
humans, technical and material resources available and by proper
communication of the planned, progressed and accomplished activities at all
hierarchy level, at every stage of the project.
PE.1.17 By working in a conductive likely environment at very early stage of my
career, 1 got a golden opportunity to learn and exercise the professional norms
and attributes which accelerated the flow of my professional knowledge and
skill accumulation in a steady manner parallel with my work achievements
and enhances my professional confidence to present and develop my
professional image always, as an initiative part of my Engineering career.
PROFESSIONAL EPISODE # 2
a) INTRODUCTION
P.E 2.1 The second episode of my Engineering career was about my first job with “Fauji
Fertilizer Bin Qasim Limited” Started on date March 20, 2003 and ended on
April 27, 2007. The title of my position in the company was Shift Engineer. My
work site (Fauji Fertilizer Bin Qasim Limited) was located in Port Qasim
Industrial Area that was about 50 km from the famous city Karachi, Pakistan. This
area was well populated with large industrial units. The duration of this first job
was about four years.
b) BACKGROUND
P.E 2.2 Pakistan is an agricultural country. Its majority of population is attached with
agriculture sector. Fertilizer sector plays an important role for consistent growth
of agriculture sector. Pakistan fertilizer sector can not meet country requirements
so have to import Fertilizer. There is great deal of pressure from government to
obtain maximum fertilizer production within the country. Urea Fertilizer is a
major fertilizer being produced in Pakistan among many other fertilizers.
P.E 2.3 The speciality of Fauji Fertilizer Bin Qasim Limited is its Diammonium
Phosphate (DAP) plant, which is the only DAP manufacturing unit in pakistan.
For DAP manufacturing, raw material which is Phosphoric Acid is being
imported from Jordan. Other product of company includes Urea Fertilizer. The
complex started its commercial production in April 1999 and since than
contributing lot in country’s agriculture and economic growth. FFBL was an ISO
and IMS certified company.
P.E 2.4 As DAP fertilizer is a basic requirement of agriculture sector, the management of
Fauji Fertilizer Bin Qasim Limited has started BMR of it’s DAP unit for
production capacity enhancement. Also after getting approval from GOP, Fauji
Fertilizer Bin Qasim Limited is constructing a Phosphoric Acid and Sulphuric
Acid plants in Jordan as joint venture with Jordan’s national company.
P.E 2.5 Urea and DAP fertilizer are basic requirement of almost all crops. Pakistan
exports some quantity of Urea fertilizer every year as per availability and
government permission. There are six other Urea manufacturing units in Pakistan
while one is under construction.
P.E 2.6 The manufacturing site includes the following process units, off site unit and
Utilities unit.
Process Unit
One Ammonia Production Unit designed to produce 1570 MT / Day of Ammonia
after recent BMR (Balancing, Modernization and Revamp).
One Urea Production unit designed to produce 1670 MT/ Day of Urea Granular
Fertilizer.
One DAP Production Unit designed to produce 1350 MT / Day DAP Granular
Fertilizer.
TECHNOLOGY PRESENTED
Ammonia Plant:
The Ammonia plant was designed by Bechtel Corporation, USA in 1965 and
relocated to Pakistan at present location in 1997.
Urea Plant:
Urea plant was designed by Stemicarbon and constructed by experienced consortium
of nation and multination companies.
DAP Plant:
DAP plant was designed by French company.
P.E 2.7 My first month was a classroom Safety orientation, general plant introduction,
organization profile and study of technical Literature like American Petroleum
Institute (API) pilot, plant various processes etc. in a Technical Training
Center (TTC) of the company designed to train fresh Engineers. After one
month, I was appointed at Ammonia Unit for on job training and
familiarization about Ammonia production process, control and practices.
P.E 2.8 The whole complex excluding DAP unit was planned shutdown every year
due to routine maintenance purpose and some times due to curtailment of
Natural Gas which is raw material for Ammonia and also a fuel for whole
complex.
P.E 2.9 All the manufacturing units were equipped with latest DCS and PLC systems
for controlling, shutdown and emergency handling purpose. Bailey of USA
was awarded the contract for the installation of the state of art digital plant
control and shut down system.
P.E 2.10 Manufacturing plant was organized as per following hierarchy
Managing Director
Production Manager
Coordination Engineer
Unit Manager (Ammonia)
Shift Boardman
02
Operators
08 * Indicate my position in the chart
P.E 2.11 All Shifts constituted of same management and staff structure rotating 24
hours a day per week on continuous Ammonia/Urea/DAP plants. I was at shift
management position highlighting with asterisk (*) in the chart.
P.E 2.13 After 05 weeks Training / Orientation at technical training center, 1 was
appointed at Ammonia unit. I started to follow on job training schedule
provided to me.1 studied plant operational manual daily, visited plant area out
side of the central control room (CCR) to watch, observe and learn different
plant area activities, emergency handling, trouble shooting, maintenance and
routine activities, shut down and start up activities, PLC and other control
instrumentation operations, performed line tracing activity to understand the
process physically in plant area, made discussions with shift personnel at
every level to share their knowledge and experiences over the plant , observed
and learn control room DCS operation of the plant.
P.E 2.14 The plant has total seven (07) centrifugal compressors. The specialty of this
Ammonia plant is that its Back End has a duel train. The CO 2 absorption
system is based on Benfield Solution. The refrigeration system is based on
Ammonia (NH3).
P.E 2.15 The plant contained following major equipments.
P.E 2.16 Ammonia Production process described here is based on reaction of Hydrogen
with Nitrogen. Ammonia production is accomplished in following sections:
Main reaction starts with the addition of process steam in desulpharized NG and
passing through primary reformer where reforming of NG takes place in the
presence of Nickel catalyst. Primary reformer is NG fired induced draft furnace.
In secondary reformer, further reforming of reformed gases takes place in the
presence of same catalyst along with addition of process air. The process air is
required to get nitrogen from it. At the outlet of secondary reformer, the reformed
gases mainly consist of H2, N2, CO2, CO, CH4 and traces of Argon.
In order to remove CO from reformed gases, shift reaction occurs in which gases are
passed through firstly from Fe based catalyst where bulk of CO present in reformed
gases is converted to CO2.
In second step, the remaining CO present is converted to CO 2 by passing reformed
gases through Cu based catalyst. In this step, almost all CO has been converted to
CO2.
Removal of CO2
After CO conversion to CO2, the reformed gas is fed to Absorption tower where
CO2 is absorbed in Benfield solution during countercurrent flow.
After absorption of CO2, the rich Benfield solution is fed to Regenerators where
CO2 from Benfield solution is removed and sent to Urea section for Urea
production. Carbon Di Oxide obtained in this process is 99.9% pure.
Methanation
After removing all impurities from synthesis gas, it is ready for ammonia synthesis.
The components present now are mainly H2 and N2 and few percents of CH4 and
Ar which are inert in the remaining process.
For ammonia synthesis, high pressure and high temperature is required which is
obtained by compression of synthesis gas in centrifugal synthesis compressor. The
high temperature is obtained by gaining heat from ammonia converter effluent gases
as the reaction is highly exothermic.
During compression, synthesis gas is pressurized up to 180 KG/CM2 in a multi
stage steam turbine/gas turbine driven centrifugal compressors.
Synthesis of Ammonia
After compression and passing trough number of heat exchangers, this high pressure
and high temperature synthesis gas is fed to specially Topsoe designed S-200
Ammonia Converters where N2 and H2 reacts chemically in the presence of iron
(Fe) based catalyst.
The conversion obtained per pass is nearly 14%. The mixture of synthesis gas and
product ammonia is then separated in centrifugal separators. The 99.8% liquid
ammonia is obtained which is fed to ammonia storage.
Refrigeration Cycle
For the preparation of BFW (Boiler Feed Water), the Deminerlized Water
received from utilities section is fed to deaerator where its mechanical and
chemical deaeration is carried out to remove oxygen. For chemical deaeration,
Hydrazine (N2H4) is added.
This BFW is used for stem production in boilers.
Steam Generation
Steam is an essential raw material for ammonia production and is also used for
heating / stem turbines operation.
On ammonia unit, high pressure (40 KG/CM2) steam is produced from HRSG
(heat recovery and steam generation) and Auxiliary boiler.
Almost all compressors, pumps and turbines present on ammonia unit are steam
driven.
P.E 2.17 I worked hard and learned all plant activities and practices in time and started to
perform my shift duty as shift engineer independently. I gained much experience
in operation of Ammonia plant and as much knowledge as possible of other
plants like Urea, Utilities and DAP plant.
P.E 2.18 Being deputed as a shift engineer, my main responsibility was to manage the
production as well as the shift management at the plant. The two supervisors per
shift were deputed on front end and back end boards, controlling the whole plant
with the help of DCS Control system in central control room (CCR), having one
area operator for each area of the plant. These board man supervisors were
responsible to fill a daily DCS log sheet at DCS panel to monitor and record the
daily DCS control performance of the plant. Each area operator was responsible
for all operational and maintenance activities at his particular area of the plant
and remained alert on call from the board man for physically handling the
emergencies within his area. He was also responsible to fill area log sheet at
local control panel/instrumentation to monitor and record the daily area control
performance of the plant. I was responsible to fill daily shift Engineer’s log book
to record any maintenance / abnormality / emergency/ trouble shooting / start
up / shut down activities of the complete plant. I prepared a daily maintenance
program for any electrical/mechanical maintenance activities performed in my
shift and issued work permit (cold, hot) to area operators at the start of the shift
for safe execution of the activity.
P.E 2.19 Quality conformances to meet the company’s quality standards at plant was
another major responsibility and I monitored and analyzed the laboratory test
results of the samples taken out at different samples spots of the plant site to
ensure the quality of the product as per defined standards.
P.E 2.20 I strictly followed the safely checks and house keeping of the plant areas during
my shift and conducted a safety and emergency talk in every night shift of my
shift schedule. Feedbacks from the shift personnel were appreciated and sent
after reviewing them to the safety section of the plant through Production
manager for further review and implementation purpose.
P.E 2.21 By performing shift duties, I faced different operational / emergency problems
which I tried to resolve by utilizing my technical knowledge and experience at
the plant e.g. a problem occurred during my shift was high CO2 slippage
problem from CO2 removal system which was affecting all downstream plant. I
conducted the thorough investigation along with area operator of the whole CO2
absorption and Regeneration process. Checked all the flow, pressure and
temperature parameters. After detailed investigation, it was revealed that flow of
lean solution to absorber has dropped to zero due to stucking problem of control
valve in closed position while the flow meter was showing normal reading due
to fault. Immediately bypass of control valve was opened and conditions
normalized after some time. Afterwards control valve was removed to workshop
for overhauling and flow meter was purged to normalize its indication. Higher
management appreciated me for this improvement in achieving better plant
efficiency.
P.E 2.22 Due to well recognition of my performance, technically and problem solving
skills at plant management level, I was selected for appointment in a newly
established BMR (Balancing, Modernization and Revamp) team at plant site
from ammonia unit along with some senior members of the unit. In this new
assignment, following tasks were included in my duties.
Identification of major bottlenecks with reference to increase plant production
from 1270 MT/Day to 1570 MT/Day.
Evaluation of the available solution and recommending the optimized solution.
Carried out environmental, safety and hazards review of the existing plant and
new projects.
Addition of new process equipments like Hydrogen Recovery Unit (HRU) and
modification in existing ones like change in internals of Absorption /
Regeneration Towers from Trays to Packing.
Improving the quality of the product to conform the customer requirement.
Identifying areas for the plant for improvement with regard to safety, reliability,
production, cost reduction and plant efficiency.
Unit Manager
Ammonia
*
Shift Engineer * Indicates my Position.
d) SUMMARY
P.E 2.31 This job was beginning of my professional career. The prominent fared
features of this project were on job training and independent shift
management, which provided me the opportunity to review my strength and
enhance my professional competency by physically, and actually working and
participation in a professional environment. I learnt a lot from this career job
and developed my professional skills to such an extent where I am quite able
to justify my professional weightage. Multifaceted problems of the plant,
challenging environment were contributed a lot in enhancing my professional
confidence. My performance was highly appreciated by the management.
PROFESSIONAL EPISODE # 03
a) INTRODUCATION
P.E 3.1 The third episode of my engineering career was about my job with “Dawood
Hercules Chemicals Limited (DHCL)”, being as Shift Engineer (Ammonia
Plant). DHCL is a fertilizer plant which is producing Urea fertilizer. Dawood
Hercules Chemicals Limited plant site is located about 30 km from city of
Lahore, near Sheikhupura, Pakistan. This Professional episode was started on
dated May 07, 2007 and ended on dated August 27, 2007.
b) BACKGROUND
P.E 3.2 Fertilizer sector plays an important role in country agricultural and economic
growth. As Pakistan is big importer of fertilizer so this reason makes this
sector more valuable. This sector on one side provides valuable fertilizers for
agriculture sector, on the other hand provides skilled manpower a good forum
of technical knowledge and jobs. There is a continuous growth in this sector
for last three decades and still two new Fertilizer plants are in phase of
designing and construction. Urea Fertilizer is a major fertilizer being
produced in Pakistan among many other fertilizers like DAP, CAN and mixed
fertilizer etc.
P.E 3.3 The Dawood Hercules Chemicals Limited is a Urea production plant as a
major product while limited quantity of Liquid Ammonia is also sold for
commercial uses. DHCL is one of the pioneer plants in Pakistan which started
its commercial production in 1969.
P.E 3.4 After thorough studies and considering the potential future demands, the
management of Dawood Hercules Chemicals Limited started BMR of the
plant in phases. The first major phase of BMR was completed in 1990 while
the second major phase is being carried out. The major advancement in second
phase is conversion of plant control from manual to DCS. The basis of my
appointment in DHCL is the conversion of plant operational control from
manual to DCS as my previous experience was DCS based. The ammonia
plant was designed by Kellogg USA.
P.E 3.5 In Pakistan with addition of DHCL, there are six other Urea manufacturing
units in Pakistan while one is under construction. One specialty of DHCL is
that it sells commercial liquid ammonia which is an important raw material
for many valuable products. Also DHCL was upgrading their control system
with latest version of DCS i.e. windows based DCS.
P.E 3.6 Urea fertilizer is basic need of all crops. Its increased production shall save lot
of foreign exchange. On the other hand liquid ammonia is an essential raw
material for many commercially viable products. Ammonia is used in
hospitals, in Soda Ash industry (ICI Soda Ash Plant) and for production of
NH4CL / NH4OH (In Sitara Chemical Indutries).
P.E 3.7 Considering my previous experience at Ammonia plant which was DCS
operated and professional capabilities, Dawood Hercules Chemicals limited
assigned me the project to help in conversion of ammonia plant operational
control from manual to DCS / PLC and training of unit personnel with
reference of DCS.
P.E 3.8 The out lines of the project were:
P.E 3.12 The Ammonia Plant at Dawood Hercules Chemicals Limited includes the
following process units and utilities.
Process Units
One Ammonia production unit designed to produce 815 MT/ day (After BMR)
of liquid ammonia.
One Urea production unit designed to produce 1400 MT/ day (After BMR) of
Prilled Urea Fertilizer.
TECHNOLOGY PRESENTED
The Ammonia plant was designed Kellogg, USA in 1969.
P.E 3.13 Ammonia production unit was constituted as per following hierarchy:
Production Manager
Shift Boardman 02
Trainee Boardman 02
P.E 3.14 All shifts constituted of same management and staff structure rotating 8 hours
per shift per day on continuous ammonia production plant. I was at shift
management position highlighting with asterisk (*) in the above chart.
P.E 3.16 After one week plant orientation and safety training at technical training
department, I was shifted to plant site. I started detail learning of all the plant
processing sections, equipments and observed the activities of all plant site. I first
divided the plant into individual segments according to processing steps, then for
each segment I studied its operations, controlling parameters, line tracing, control
loops, instrumentation, interlockings, emergency handling, trouble shootings,
maintenance, startup & shutdown activities and shift management activities. I
made discussions with shift personnel and senior engineers at every level to share
their knowledge and professional experience over the plant, observed and learned
DCS process control system of the plant which has been shifted so far.
P.E 3.17 The plant was designed to produce 815 MT/ Day of liquid ammonia. The plant
was controlled through manual Yokogawa controllers which was being replaced
with latest DCS control system. The main by-product of ammonia plant was
carbon di-oxide which was the basic raw material for urea production.
Main reaction starts with the addition of process steam in desulpharized NG and
passing through primary reformer where reforming of NG takes place in the
presence of Nickel catalyst. Primary reformer is NG fired induced draft furnace.
In secondary reformer, further reforming of reformed gases takes place in the
presence of same catalyst along with addition of process air. The process air is
required to get nitrogen from it. At the outlet of secondary reformer, the reformed
gases mainly consist of H2, N2, CO2, CO, CH4 and traces of Argon.
In order to remove CO from reformed gases, shift reaction occurs in which gases
are passed through firstly from Fe based catalyst where bulk of CO present in
reformed gases is converted to CO2.
In second step, the remaining CO present is converted to CO2 by passing reformed
gases through Cu based catalyst. In this step, almost all CO has been converted to
CO2.
Removal of CO2
After CO conversion to CO2, the reformed gas is fed to Absorption tower where
CO2 is absorbed in Catacarb solution during countercurrent flow.
After absorption of CO2, the rich Catacarb solution is fed to Regenerator where CO 2
from Catacarb solution is removed and sent to Urea section for Urea production.
Carbon Di Oxide obtained in this process is 99.9% pure.
Methanation
After CO2 absorption, small quantity of CO2 and CO is removed by passing
reformed gases through Nickel based catalyst where CO 2 and CO is converted to
CH4 which is inert in ammonia synthesis process.
After removing all impurities from synthesis gas, it is ready for ammonia synthesis.
The components present now are mainly H2 and N2 and few percents of CH4 and Ar
which are inert in the remaining process.
For ammonia synthesis, high pressure and high temperature is required which is
obtained by compression of synthesis gas in centrifugal synthesis compressor. The
high temperature is obtained by gaining heat from ammonia converter effluent
gases as the reaction is highly exothermic.
During compression, synthesis gas is pressurized up to 150 KG/CM2 in a multi
stage steam turbine driven centrifugal compressors.
Synthesis of Ammonia
After compression and passing trough number of heat exchangers, this high
pressure and high temperature synthesis gas is fed to specially Topsoe designed S-
200 Ammonia Converter where N2 and H2 reacts chemically in the presence of iron
(Fe) based catalyst.
The conversion obtained per pass is nearly 14%. The mixture of synthesis gas and
product ammonia is then separated in centrifugal separators. The 99.8% liquid
ammonia is obtained which is fed to ammonia storage.
Refrigeration Cycle
For cooling purpose of synthesis gas and separation of liquid/gas, Ammonia is used
as cooling media. In refrigeration cycle, first of all, ammonia is evaporated by
exchanging heat with gas to be cooled in chillers then these vapors are fed to
multistage centrifugal compressors. After compressing these vapors to 14 KG/CM 2,
these are fed in condensers where ammonia vapors are condensed with the help of
cooling water. This liquid is then again recycled for cooling purpose in chillers.
For the preparation of BFW (Boiler Feed Water), the Deminerlized Water received
from utilities section is fed to deaerator where its mechanical and chemical
deaeration is carried out to remove oxygen. For chemical deaeration, Hydrazine
(N2H4) is added.
This BFW is used for steam production in boilers.
Steam Generation
Steam is an essential raw material for ammonia production and is also used for
heating purpose and steam turbines operation.
On ammonia unit, high pressure (44 KG/CM2) steam is produced from HRSG (heat
recovery and steam generation) at the downstream of secondary reformer.
Almost all compressors, pumps and turbines present on ammonia unit are steam
driven.
Ammonia Storage
d) SUMMARY
P.E 3.27 These jobs provided me in depth knowledge and expertise in my occupation.
The prominent fared features of these project were professional environment
which provided me the opportunity to further refined and learned engineering
approaches and techniques for better engineering and management problem
solving skills. I learnt a lot from these jobs and developed my professional
skills to such an extent where I am quite able to justify my professional
weightage. Multi faced problems of the plant, challenging environmental were
contributed a lot in enhancing my professional confidence. My performance
was highly appreciated by the plant management.
PROFESSIONAL EPISODE # 4
a) INTRODUCTION
P. E 4.1 The fourth episode of my professional career is about my third current job
with “Sui Northern Gas Pipelines Limited” started on dated September 03,
2007 and is continued.
Sui Northern Gas Pipelines Limited (SNGPL) is an engineering based
company. It is one of the two companies in Pakistan working in this field. The
other one is Sui Southern Gas Company Limited which is a small company as
compared to SNGPL The Company Head Office is located in Lahore, Pakistan
with business in Provinces of Punjab, NWFP, Azad Kashmir, federal capital
and few parts of Sindh and Balochistan. My present work site is transmission
headquarter in Faisalabad, Pakistan. The title of my position in this company
is presently Transmission Engineer (Gas Control).
b) BACKGROUND
P. E 4.2 Sui Northern Gas Pipelines Limited (SNGPL) was founded in 1963 and has a
status of public limited company since 1964. It was the first such kind of
company in Pakistan. The main business of company is supply of Natural gas
to Domestic, Commercial and Industrial consumers. Areas of operation
include Punjab, NWFP, Federal Capital and Azad Kashmir. The infrastructure
of company is spread all over in Pakistan including province of Sindh and
Balochistan. The transmission lines (From gas producing source upto city
gates) on company network are nearly 6500 kilometers and distribution lines
(From city gates to consumer’s doorstep) on company network are nearly
52000 kilometers. There are nearly three million consumers of company. All
these facilities and pipeline networks are laid and maintained by SNGPL
itself. Other than pipeline network, facilities include filtration plants and
compressor units. There are 09 compressor stations on company network.
P. E 4.3 Sui Northern Gas Pipelines Limited (SNGPL) is also in the process of getting
projects in other countries. Recently a agreement was signed with Algeria
National Gas Company for lying of transmission lines in Algeria as a Joint
venture with this Company. SNGPL has provided its services to many other
companies within Pakistan like PARCO refinery for laying of pipeline from
Karachi to Multan and gas pipeline for Fauji Fertilizer Company in Sadiqabad.
VISION:
Our vision - the future we are striving for is that:
To be the leading integrated Natural Gas provider in the region seeking to
improve the quality of life of our customers and achieve maximum benefit for
our stakeholders by providing an uninterrupted and environment friendly
energy resources.
THE MISSION:
A commitment to deliver natural gas to all door steps in our chosen areas
through continuous expansion of our network, by optimally employing
technological, human and organizational resources, best practices and high
ethical standards.
Company has divided into 08 regions which are further divided into sub-
regions. All area offices are functioning according to above main segments.
After joining the company, a comprehensive orientation was given by actually
passing time in all the major departments of the company i.e. Distribution,
Transmission, Compression and Projects.
SCADA Boardman
02
* Indicates my Position
P.E 4.8 I am working as Transmission Engineer in Gas Control. Gas control system is
equipped with latest controlling system called Supervisory Control And
Data Acquisition (SCADA).
P.E 4.9 After getting orientation about the company, its vision, hierarchy, products,
strategic objectives & business Policies. I started work as per my job
description.
P.E 4.10 The gas control room where I am responsible has the following major
workings.
Monitoring of SNGPL transmission network on 24 hours basis.
Identification and rectification of any abnormality appeared in gas flow
system.
Emergency handling in case any gas line rupture.
Allocation of gas to big industrial units in case of low gas input and
particularly in winter season.
Operating Performance checks.
Reply of different technical enquiries rose from higher management.
Technical suggestions for continuous, safe and smooth gas flow.
P.E 4.11 During my job, I faced various challenging situation. The main emergency
was sudden drop in pressure of gas in Sui-Bhong section of SNGPL network.
There could be many reasons of pressure drop like faulty pressure gauge,
tripping of compressor or restriction in SCADA data system. But I investigate
the whole situation in no time and it was revealed that main gas supply line
has been ruptured by terrorist attack in Sui, Balochistan where from much of
SNGPL network gas is coming. Immediately gas supply control valve from
Sui and control valve from Bhong was closed and conditions were partially
normalized after routing some flow of gas from second line. Due to stoppage
of gas from main source, pressure in network started to decrease. Immediately
I informed all concerns and restricted the gas supply to industrial and
commercial users in order to maintain gas supply to domestic consumers and
to maintain minimum pressure in the system.
P.E 4.12 In above described challenging situation, I was interacted with Mechanical,
Maintenance, Operations and Commercial departments and proved my
professional competencies and business skills.
P.E 4.13 I am doing hard work and keep learning more in this vast field of industrial
sales and marketing so that I can better perform in my further projects and
assignments. My company shall sponsor me for higher studies, after
completion of two years in company, in order to enhance my skills and
competencies in gas transportation field.
d) SUMMARY
P.E 4.14 The current job is more challenging and interesting in nature for me. The
prominent fared features of this Project are business relationship with gas
sources, industrial customer’s satisfaction, Innovation, Technical expertise
interaction with different types of industries and multidisciplinary
Professionals to achieve more accurate and comparatively better technical
targets and objectives which are highly demanded by management of the
company. The management focuses & concentrates full attentions on
Industrial/commercial and domestic segment so that by the improvement in
sales and technical activities company conforms its quality of services,
customer satisfaction, reliable products supply and establish a strong business
relationships with all its potential clients and earn a significant annual profit
to fulfill its business growth, extension in Project and objectives requirement
of giving a fair return to share holders and achieve maximum benefit for its
stakeholders. My previous experiences help me a lot in facing the new
challenges of the current job with strong commitment and dedications. I think
myself to be able to carry out these challenging assignments quite
successfully and confidently and will be even appreciated by present
management of the company as before in previous experiences of my
engineering professional career.