PROFESSIONAL EPISODE # 01 a) P.E. .E. 1.1 1.1
INTRODUCTION The The first first episo episode de of my engin engineer eerin ing g caree careerr was was abou aboutt my engin enginee eerin ring g proj project ect start started ed on date date:: Augu August st 2001 2001 when when I was was a fina fina year year stud studen entt of chem chemic ica a engineering session !1""#$2002% at &ni'ersity of the Punjab( )ahore and ended on date. August 2002. The project was for one year. The geographica ocation of the uni'ersity campus is at cana road )ahore( Pa*istan( renowned as +,uaid$e$A-am campus( &ni'ersity of the Punjab )ahore. &ni'ersity has number of academic programs up to ad'anced e'e( which are being offered at 'arious acuties and Institutes. Among them( an institute of /hemica Engineering Technoogy is a pioneer facuty of chemica engineering in Pa*istan we *nown and recogni-ed on nationa as we as internationa e'e.
b) P.E. .E. 1.2 1.2
BACKGROUND As part part of my chem chemic ica a eng enginee ineeri ring ng ua uaif ific icat atio ion n and and comp compet eten ency cy s*i s*i reuirement( I was assigned a pant design project on the + Productio o! "00 To$Da% Et&%'(( !ro Na*&t&a crac+i,- .
aphtha is a composition of hydrocarbons containing carbon atoms from / 3 to /". 4oiin 4oiing g range range for these fractions fractions is "0$563 "0$563 o. aphtha7s which are irritant( fammab fammabe e and to8ic to8ic are deri'e deri'ed d from from both both petro petroeum eum fractio fractions ns and coa tar. tar. aphtha7s aphtha7s are used as organic so'ent for disso'ing or softening wa8es( ois( greases greases(( 'arnis 'arnishes hes and pastics. pastics. The ess famma fammabe be fractio fractions ns are used used in dry ceanin ceaning. g. 9inera 9inera spirit spiritss are aso incud incuded ed under under the headin heading g of aphth aphtha7 a7s. s. aphtha7s aphtha7s can enter into our system through inhaation of 'apors( ingestion and eye or s*in contact. Petroeum aphtha has a ower order of to8icity than coa tar aphtha. 'ere8posure to either type of aphtha may cause centra ner'ous system system depress depression ion with with sympto symptoms ms of inebri inebriati ation on foow foowed ed by headac headache he and nausea. aphtha is a major by product during crude oi refining and major part of naphtha is e8ported. Ethyene ;2/<;2/ is the argest 'oume buiding boc* for many petrochemicas. This oefin is used to produce many end products such as pastics( resins( fibers etc. some of the physica and chemica properties of Ethyene incudes ightest oefin wit a sighty sweet odor. It is a cooress fammabe gas. 4oiing point is
105.61 105.61 o/. Ethyene is a 'ery reacti'e intermediate. The Ethyene doube bond reacts readiy to form saturated hydrocarbons( hydrocarbons( their deri'ati'es deri'ati'es or poymers. poymers. The principe reactions with commercia significance incude Poymeri-ation( 8idation 8idation and addition addition incuding incuding ;aogenatio ;aogenations( ns( A*yation A*yation77s( igomeri-at igomeri-ation( ion( ;ydration ;ydration and ;ydroformy ;ydroformyation ation.. &sefu commercia products products from Ethyene Ethyene incude Po'%Et&%'((. Et&%'(( O/id(. Et&%'(( G'%co'. Ac(ta'd(&%d(. i%' Ac(tat(. i%' C&'orid(. Et&%' B((( ad Et&ao' . PoyEthyene is used in
cabe=wire co'ering( in resin manufacturing( as pac*ing materia( pastic pipes and in emusio emusion n and wa8es. wa8es. Ethye Ethyene ne 8ide 8ide is used used in pharma pharmaceu ceutica tica indust industry ry.. Ethye Ethyene ne >yco >yco is used used in poyes poyester ter fibers fibers as pastic pastici-er i-er and in eectro eectroyt ytic ic capacitors. &nfortunatey there is not a singe unit in Pa*istan which is in'o'ed in crac*ing of aphtha for Ethyene production. P.E. 1.5
The main objecti'e of the proj roject were:$
easibiity of the design project.
?esign of compete manufacturing = production pant on commercia scae to carry out the whoe manufacturing production process at minimum cost and resources a'aiabe.
@e'i @e'iew ew desi design gn on the the basis asis of engi engin neeri eerin ng stan standa dard rdss and and cod codes( es( en'ironmenta ha-ards( smooth operation of the pant with ess down time.
P.E. .E. 1. 1.
9y desi design gn grou group p was was orga organi ni-e -ed d as as per per fo foow owin ing g hier hierar arch chy y.
Project director B01 Professor
C 9em 9ember ber !/h !/hemic emica a%% $01 $01
9emb 9ember er !/h !/hemic emica a%% $02 $02
C Indicates my position.
9emb 9ember erss !/h !/hemic emica a%% B05
P.E. 1.3
&pon we recognition of my good reputation in both academic and communicat communication ion capabiities capabiities during the Engineerin Engineering g course of study( study( I was seected seected for position position D 1 as member member !chemica% !chemica% in a group members of same discip discipin inee of chemic chemica a engine engineeri ering. ng. 9y group group first first panne panned d to prepar preparee an action pan !strategy% !strategy% in order to accompish accompish a the objecti'es objecti'es concerned concerned and finay the target. ?uties of a group members were set with deadines and foowing were incuded in my duties:
Pay a *ey roe of group eader at same e'e of a group members and de'ise an effecti'e project strategy for impementation.
Prepare Prepare progress progress reports !on monthy basis% to present present the group acti'ities in monthy meeting with the project director.
Perform a design reated tas* of coaboration with other group members.
Ta*e guideines guideines and time$to$time time$to$time consutation consutation with project direction direction in progression of the group acti'ities.
c) P.E. .E. 1. 1.
Estabish a strong communication within the group members.
PERSONAL PLACE ACTIIT2 irs irstt of a a I pre prepa pare red d an act actio ion n pan pan !st !stra rate tegy gy%% by con consi side deri ring ng the the maj major or ste steps ps with subseuent specific steps ta*en in order to accompish a objecti'es and finay the target. I tried to manage a these acti'ities according to priority( time time and respon responsib sibiit iity y by assigni assigning ng priori priority ty number number to each acti'i acti'ity ty(( its starting( ending date and the person responsibe to carry out those particuar tas*s. inay I became successfu in preparation of an effecti'e action pan !strategy% !strategy% for appro'a appro'a of the project director director.. This action pan !strategy% was discus discussed sed in detai detai with with group group member memberss and finay finay presen presented ted to projec projectt director. After getting appro'a of the strategy from the project director( my coeague members and I started wor* according to their responsibiities and tas*s.
P.E. 1.6
1 'isited 'isited Pa*ist Pa*istan an /ounci /ounci of of Fcient Fcientific ific and Indust Industria ria @esea @esearch rch !P/FI@ !P/FI@%% center and )ahore )ahore /hamber /hamber of /ommerce Industry Industry !)//I% to search and coect the ree'ant data for the Ethyene user industries in Pa*istan. Fecond member of the group 'isited E8port Promotions 4ureau !EP4%( Pa*istan to coect the import= e8port figures of Ethyene = aphtha in ast 10 years. Third
member of group 'isited oca mar*et to chec* the prices( consumer demand( Ethyene consumption( grade uaity ( specification and coect = search a information concerning to the oca mar*et position of the chemica . P.E. 1.#
After competion of the acti'ity my group was in a position to define the scope of this project !Ethyene% in Pa*istan and design capacity of Ethyene 9anufacturing = production pant. The scope of Ethyene in Pa*istan is 'ery wide as per its appications. There is not a singe unit in Pa*istan that is producing Ethyene. The design capacity of the said project was set +500 Tons= ?ay production of EthyeneG.
P.E. 1."
After oticing a great scope of Ethyene in Pa*istan and getting design capacity of the project( research was carried out on a the manufacturing processes of Ethyene in history. or this purpose I with my group members 'isited different ibraries at uni'ersity and city e'e to search out the 'arious boo*s( iteratures( Hournas( /hemica Encycopedia i*e ir*othemer( 9c*etta( interna search and ree'ant manufacturing industries on internet to find out mutipe references of the desired chemica !Ethyene% manufacturing processes and design( shared the *nowedge and e8periences of the pant personne reated to Ethyene downstream industries. 9ost important manufacturing processes are:$
Therma /rac*ing
/ataytic /rac*ing
;ydro /rac*ing
ureha Process
/ataroe Process
St(a Crac+i,3
Among a processes described for the production of Ethyene( I seected Fteam /rac*ing of aphtha due to the foowing reasons.
Jhen steam is introduced aong with the feed( it increases the 'oume of the gas which decreases the residence time.
The added steam reduces the partia pressure of the hydrocarbon which increases the yied of gaseous product and decreases the yied of iuid product.
The heat reuired in the endothermic reaction is reduced as steam does not react and ony gi'e its atent heat. It acts as heating medium.
The introduction of steam reduces the co*e formation to greater e8tent.
Fteam reacts directy with the deposited carbon or co*e and gi'es / 2 which heps to cean the furnace. ;ydrogen generated in the process is used to con'ert Acetyene into Ethyene and Ethyene to Ethane ate in the process.
P.E. 1.10
@aw materias for the seected product in process were Na*&t&a ad t(a3 aphtha is produced from ?istiation of petroeum whie steam is produced in$ house from boiers.
P.E. 1.11 In the seected manufacturing process( aphtha is crac*ed in a furnace by steam crac*ing resuting in production of 9ethane( Ethane( Propane( /arbon 9ono 8ide( Fuphur /ompounds( Acetyene and Ethyene aong with some impurities. The furnace consists of two sections( which are @adiant Fection and /on'ection Fection. In con'ection section( aphtha feed aong with process steam is heated with fue gases of radiant section whie in radiant section( feed is heated through gas fired burners or through hydrocarbons !@eco'ered during the process%. The mi8ture obtained after the crac*ing of aphtha is technicay caed +/rac*ed >asesG. The crac*ed gases are then cooed to room temperature for compression. /ooing of crac*ed products is done in ,uench 4oier with water and in /od aphtha Preheater with cod aphtha. After this crac*ed gases are washed in Fcrubber with water to remo'e any Tar or hea'y ;ydrocarbons. ;ea'y hydrocarbons are recyced bac* to furnace whie crac*ed gases are fed to Absorber and Ftripper for remo'a of ;2F and / 2 using 9EA !9ono Ethano Amine%. ow gas is compressed in number of stages to increase pressure and to remo'e any condensate present in the product gases. At this stage( crac*ed gases mainy consist of Ethyene( Ethane( Acetyene( 9ethane( Propane and ;ydrogen !; 2%. Acetyene present in gas mi8ture is then con'erted to Ethyene and Ethane by passing the mi8ture through Acetyene /on'erter. @eaction of ;ydrogenation is carried out in the presence of +PaadiumG catayst. After the con'ersion of the Acetyene to Ethyene and Ethane( the mi8ture is iuefied for the separation of different products. The first distiation coumn used is ?emethani-er for separation of 9ethane. The product obtained from this coumn is ""K 9ethane and 1K Ethyene. The second distiation coumn used is ?e$ethani-er for separation of Ethyene from Propane. In this coumn( the top product mainy contains Ethyene( Ethane( Propane and 9ethane. Jhere as the bottom product contain the itte uantity of Ethyene( Ethane and Propane and mainy consist of Propane. The product from the ?e$ethani-er coumn is fed to the Ethane$Ethyene Fpitter. ;ere Ethane and Ethyene are considered for distiation.
The top product contains "".3K Ethyene and bottom product contains the major content of ethane. ;ence the product of the pant is coected from the top of Ethane$Ethyene Fpitter and sent for storage. D(i, *ro4(ct cotai(d t&( !o''o5i, ai (6ui*(t7
4oier for steam generation.
urnace for aphtha crac*ing.
,uench boier for crac*ed gases cooing.
Two cod aphtha preheaters.
Fcrubber for washing of crac*ed gases.
i'e stage compressor for compression of crac*ed gases.
;eating = ashing unit and separator.
Amine wash tower !Absorber% and Ftripper.
?ehydrator for water remo'a.
Acetyene con'erter.
@efrigeration system.
Three
?istiation
/oumns
!?e$9ethani-er(
?e$Ethani-er(
Ethane$Ethyene
Fpitter%.
P.E. 1.12
After competion of process seection acti'ity( 1 with my group members prepared a process boc* diagram describing each step of the process competey for materia and energy baances appication. At the same time1 prepared a Process ow ?iagram !P?% that after detaied discussion with group members on process engineering aspects and technica reuirement of the euipments in'o'ed( finay appro'ed by the Project ?irector. A euipments with accessories in'o'ed in P? were designed according to ree'ant Engineering design Euations( Ftandards /odes a'aiabe e.g. AF9E( AFT9( TE9A etc% ptimi-ation process. Instrumentation and contro system was designed on the basis of process contro reuirement. A Piping Instrumentation diagram !P I? % was prepared for this purpose of contro system designing. This was a bit chaenging tas* for me and my group members for which 1 too* a great hep
from my project director my
friends( students of Eectrica and Instrumentation Engineering.
P.E. 1.15
I did a cacuations and estimates ree'ant to pant design economics i*e /apita in'estment( Production cost estimate and euipment cost. The project was competed we in time.
P.E. 1.1
)ater on in cose iaison with PA@/ @efinery( near 9utan city( a ow capacity piot pant of this commercia design project was constructed and instaed at the factory area of @efinery to chec* and 'erify a design conditions and operation of the pant. 4y the grace of Aah Amighty( it was successfu and met a design reuirements with itte troube shoots and waste ha-ards( which was re'iewed and modified ater in design. 'era the project was a successfu. Fuccessfu operation of the piot pant and ow capita and production cost of the project was made this project highy attracti'e in nature for future instaations in Pa*istan.
d) PE 1.13
SU88AR2 This project in the beginning of my professiona career pro'ided me a ot of opportunities for muti$dimensiona earning.
PE 1.1
The prominent fared features of this project contained time management and eadership that payed an important roe in my professiona competency s*is to manage a acti'ities in a time bounded frame of wor* and dri'es the project seuentiay and systematicay by euipping and utii-ing effecti'ey the humans( technica and
materia
resources a'aiabe
and
by proper
communication of the panned( progressed and accompished acti'ities at a hierarchy e'e( at e'ery stage of the project. PE.1.16
4y wor*ing in a conducti'e i*ey en'ironment at 'ery eary stage of my career( 1 got a goden opportunity to earn and e8ercise the professiona norms and attributes which acceerated the fow of my professiona *nowedge and s*i accumuation in a steady manner parae with my wor* achie'ements and enhances my professiona confidence to present and de'eop my professiona image aways( as an initiati'e part of my Engineering career.
PROFESSIONAL EPISODE # 9
a) P.E 2.1
INTRODUCTION The second episode of my Engineering career was about my first job with + Fau4i F(rti'i(r Bi :ai Liit(dG Ftarted on date 9arch 20( 2005 and ended on
Apri 26( 2006. The tite of my position in the company was Fhift Engineer. 9y wor* site !auji ertii-er 4in ,asim )imited% was ocated in Port ,asim Industria Area that was about 30 *m from the famous city arachi( Pa*istan. This area was we popuated with arge industria units. The duration of this first job was about four years.
b) P.E 2.2
BACKGROUND Pa*istan is an agricutura country. Its majority of popuation is attached with agricuture sector. ertii-er sector pays an important roe for consistent growth of agricuture sector. Pa*istan fertii-er sector can not meet country reuirements so ha'e to import ertii-er. There is great dea of pressure from go'ernment to obtain ma8imum fertii-er production within the country. &rea ertii-er is a major fertii-er being produced in Pa*istan among many other fertii-ers.
P.E 2.5
The speciaity of auji ertii-er 4in ,asim )imited is its Diaoiu P&o*&at( ;DAP) pant( which is the ony ?AP manufacturing unit in pa*istan.
or ?AP manufacturing( raw materia which is Phosphoric Acid is being imported from Hordan. ther product of company incudes Ur(a F(rti'i(r3 The compe8 started its commercia production in Apri 1""" and since than contributing ot in country7s agricuture and economic growth. 4) was an IF and I9F certified company. P.E 2.
As ?AP fertii-er is a basic reuirement of agricuture sector( the management of auji ertii-er 4in ,asim )imited has started 49@ of it7s ?AP unit for production capacity enhancement. Aso after getting appro'a from >P( auji ertii-er 4in ,asim )imited is constructing a Phosphoric Acid and Fuphuric Acid pants in Hordan as joint 'enture with Hordan7s nationa company.
P.E 2.3
&rea and ?AP fertii-er are basic reuirement of amost a crops. Pa*istan e8ports some uantity of &rea fertii-er e'ery year as per a'aiabiity and go'ernment permission. There are si8 other &rea manufacturing units in Pa*istan whie one is under construction.
P.E 2.
The manufacturing site incudes the foowing process units( off site unit and &tiities unit.
Proc( Uit
ne Ammonia Production &nit designed to produce 1360 9T = ?ay of Ammonia after recent 49@ !4aancing( 9oderni-ation and @e'amp%.
ne &rea Production unit designed to produce 160 9T= ?ay of &rea >ranuar ertii-er.
ne ?AP Production &nit designed to produce 1530 9T = ?ay ?AP >ranuar ertii-er.
Uti'it% Productio Uit
Two gas turbines for power generation with designed power of 2.2 9J each. ne is capabe of handing the entire compe8.
@aw water treatment faciity incuding raw water storage( carification( fitration and deminerai-ation units.
/ooing water and cooing tower Fystem.
Instrument Air suppy system for contro purpose.
Fteam generation unit with one au8iiary Fteam 4oier( one Jaste heat reco'ery steam generation system( one boier eed water system.
Ra5 8at(ria'( Fii&(d Product ad Ba,,i, $ S&i**i,
ina product storage and begging = shipping faciities.
@aw 9ateria storage tan*s.
Ftore = warehouses.
O!! Sit( < Bui'di,
ire Jater system
A storage area at Port ,asim for Phosphoric Acid unoading.
Bui'di, Ic'ud(7=
Administration
Jarehouse
Jor*shop
/ontro rooms eectrica rooms.
)aboratory
Technica ser'ices buiding
Technica training centre
Fafety buiding
Industria cinic
TEC>NOLOG2 PRESENTED
Ammonia Pant: The Ammonia pant was designed by 4echte /orporation( &FA in 1"3 and reocated to Pa*istan at present ocation in 1""6.
&rea Pant: &rea pant was designed by Ftemicarbon and constructed by e8perienced consortium of nation and mutination companies.
?AP Pant: ?AP pant was designed by rench company.
P.E 2.6
9y first month was a cassroom Fafety orientation( genera pant introduction( organi-ation profie and study of technica )iterature i*e American Petroeum Institute !API% piot( pant 'arious processes etc. in a Technica Training /enter !TT/% of the company designed to train fresh Engineers. After one month( I was appointed at Ammonia &nit for on job training and famiiari-ation about Ammonia production process( contro and practices .
P.E 2.#
The whoe compe8 e8cuding ?AP unit was panned shutdown e'ery year due to routine maintenance purpose and some times due to curtaiment of atura >as which is raw materia for Ammonia and aso a fue for whoe compe8.
P.E 2."
A the manufacturing units were euipped with atest ?/F and P)/ systems for controing( shutdown and emergency handing purpose. 4aiey of &FA was awarded the contract for the instaation of the state of art digita pant contro and shut down system.
P.E 2.10
9anufacturing pant was organi-ed as per foowing hierarchy
9anaging ?irector
>enera 9anger Pant
Production 9anager /oordination Engineer &nit 9anager !Ammonia%
C Fhift Engineer A
Fhift Engineer 4
Fhift Engineer /
Fhift Engineer ?
Fhift 4oardman 02
perators 0#
P.E 2.11
C Indicate my position in the chart
A Fhifts constituted of same management and staff structure rotating 2 hours a day per wee* on continuous Ammonia=&rea=?AP pants. I was at shift management position highighting with asteris* !C% in the chart.
c)
PERSONAL ?ORK PLACE ACTIIT2
P.E 2.12
oowing timey management acti'ities were incuded in my dutiesL
a%
rientation at TT/
03 Jee*s
b%
n Hob Training at Ammonia Pant
1# Jee*s
Ftudy of area genera course
01 wee*
4oier eed Jater and Au8iiaries M PI?s
0 wee*s
?esuphuri-ation section M PI?s
02 wee*s
@eforming and Fhift /on'ersion M PI?s
02 wee*s
/2 Absorption Fection M PI?s
/ompression Fection M PI?Fs
Process Air and atura >as Fection M PI?s 02 wee*s
Ammonia Fynthesis section M PI?s
@efrigeration Fection
Instrumentation and process contro system
02 wee*s 02 wee*s
02 wee*s
01 wee*
c%
Fafety training
01 wee*
d%
As training Fhift Engineer
2 wee*s
Tota Training Period
# wee*s !0 9onths%
@outine shift engineer7s duty
1# wee*s
e%
Tota e8perience:
P.E 2.15
Appro8 1" wee*s @ years( 01 months 0 days
After 03 wee*s Training = rientation at technica training center( 1 was appointed at Ammonia unit. I started to foow on job training schedue pro'ided to me.1 studied pant operationa manua daiy( 'isited pant area out side of the centra contro room !//@% to watch( obser'e and earn different pant area acti'ities( emergency handing( troube shooting( maintenance and routine acti'ities( shut down and start up acti'ities( P)/ and other contro instrumentation operations( performed ine tracing acti'ity to understand the process physicay in pant area( made discussions with shift personne at e'ery e'e to share their *nowedge and e8periences o'er the pant ( obser'ed and earn contro room ?/F operation of the pant.
P.E 2.1
The pant has tota se'en !06% centrifuga compressors. The speciaty of this Ammonia pant is that its 4ac* End has a due train. The / 2 absorption
system is based on 4enfied Foution. The refrigeration system is based on Ammonia !;5%. P.E 2.13
The pant contained foowing major euipments.
?esuphari-ation and ;ydrogenation 'esses
atura >as booster compressor
Primary @eformer !urnace%
Fecondary @eformer
Fteam 4oier = Fteam ?rum
;igh Temperature = )ow Temperature Fhift /on'erters
Absorption and @egeneration Towers
Ammonia Fynthesis >as /ompressors
Ammonia separator 'esse
Ammonia /on'erters
Process Air /ompressors
?eaerator
@efrigeration /ompressors
/ondensers
Au8iiary 4oiers.
;ydrogen @eco'ery &nit
9ethanator
/entrifuga Pumps
Fteam Turbines
>as Turbine as dri'er for Fynthesis >as /ompressor
P.E 2.1
Ammonia Production process described here is based on reaction of ;ydrogen with itrogen. Ammonia production is accompished in foowing sections:
Pressuri-ation and ?esuphari-ation of atura >as
Fteam @eforming in Primary and Fecondary @eformer
/on'ersion of / into / 2
@emo'a of /2 by Absorption
9ethenation
/ompression of Fynthesis >as
Fynthesis of Ammonia
@efrigeration /yce
4oier eed Jater
Fteam >eneration
Pr(uriatio ad D(u'*&ariatio o! Natura' Ga
irst of a > !atura >as% is pressuri-ed up to 0 >=/9 2 !reuired pressure for reaction% through centrifuga compressor.
Then Fuphur compounds are remo'ed from > by passing through /$9 catayst bed aong with addition of ;2 and Nn catayst bed. In /$9 bed( hydrogenation of Fuphur compound con'erts them to ; 2F and in Nn bed( ; 2F is absorbed in catayst bed.
St(a R(!ori, i Priar% ad S(codar% R(!or(r
9ain reaction starts with the addition of process steam in desuphari-ed > and passing through primary reformer where reforming of > ta*es pace in the presence of ic*e catayst. Primary reformer is > fired induced draft furnace.
In secondary reformer( further reforming of reformed gases ta*es pace in the presence of same catayst aong with addition of process air. The process air is reuired to get nitrogen from it. At the outet of secondary reformer( the reformed gases mainy consist of ;2( 2( /2( /( /; and traces of Argon.
Co@(rio o! CO ito CO 9
In order to remo'e / from reformed gases( shift reaction occurs in which gases are passed through firsty from e based catayst where bu* of / present in reformed gases is con'erted to / 2.
In second step( the remaining / present is con'erted to / 2 by passing reformed gases through /u based catayst. In this step( amost a / has been con'erted to /2.
R(o@a' o! CO9
After / con'ersion to /2( the reformed gas is fed to Absorption tower where /2 is absorbed in 4enfied soution during countercurrent fow.
After absorption of /2( the rich 4enfied soution is fed to @egenerators where /2 from 4enfied soution is remo'ed and sent to &rea section for &rea production. /arbon ?i 8ide obtained in this process is ""."K pure.
8(t&aatio
After /2 absorption( sma uantity of /2 and / is remo'ed by passing reformed gases through ic*e based catayst where /2 and / is con'erted to /; which is inert in ammonia synthesis process.
Co*r(io o! S%t&(i Ga
After remo'ing a impurities from synthesis gas( it is ready for ammonia synthesis. The components present now are mainy ;2 and 2 and few percents of /; and Ar which are inert in the remaining process.
or ammonia synthesis( high pressure and high temperature is reuired which is obtained by compression of synthesis gas in centrifuga synthesis compressor. The high temperature is obtained by gaining heat from ammonia con'erter effuent gases as the reaction is highy e8othermic.
?uring compression( synthesis gas is pressuri-ed up to 1#0 >=/92 in a muti stage steam turbine=gas turbine dri'en centrifuga compressors.
S%t&(i o! Aoia
After compression and passing trough number of heat e8changers( this high pressure and high temperature synthesis gas is fed to speciay Topsoe designed F$200 Ammonia /on'erters where 2 and ;2 reacts chemicay in the presence of iron !e% based catayst. The
con'ersion obtained per pass is neary 1K. The mi8ture of synthesis gas and product ammonia is then separated in centrifuga separators. The "".#K iuid ammonia is obtained which is fed to ammonia storage.
R(!ri,(ratio C%c'(
or cooing purpose of synthesis gas and separation of iuid=gas( Ammonia is used as cooing media. In refrigeration cyce( first of a( ammonia is e'aporated by e8changing heat with gas to be cooed in chiers then these 'apors are fed to mutistage centrifuga compressors. After compressing these 'apors to 1 >=/92( these are fed in condensers where ammonia 'apors are condensed with the hep of cooing water. This iuid is then again recyced for cooing purpose in chiers.
Boi'(r F((d ?at(r ;D(a(rator)
or the preparation of 4J !4oier eed Jater%( the ?emineri-ed Jater recei'ed from utiities section is fed to deaerator where its mechanica and chemica deaeration is carried out to remo'e o8ygen. or chemica deaeration( ;ydra-ine !2;% is added.
This 4J is used for stem production in boiers.
St(a G((ratio
Fteam is an essentia raw materia for ammonia production and is aso used for heating = stem turbines operation.
n ammonia unit( high pressure !0 >=/92% steam is produced from ;@F> !heat reco'ery and steam generation% and Au8iiary boier.
Amost a compressors( pumps and turbines present on ammonia unit are steam dri'en.
P.E 2.16
I wor*ed hard and earned a pant acti'ities and practices in time and started to perform my shift duty as shift engineer independenty. I gained much e8perience in operation of Ammonia pant and as much *nowedge as possibe of other pants i*e &rea( &tiities and ?AP pant.
P.E 2.1#
4eing deputed as a shift engineer( my main responsibiity was to manage the production as we as the shift management at the pant. The two super'isors per shift were deputed on front end and bac* end boards( controing the whoe pant with the hep of ?/F /ontro system in centra contro room !//@%( ha'ing one area operator for each area of the pant. These board man super'isors were responsibe to fi a daiy ?/F og sheet at ?/F pane to monitor and record the daiy ?/F contro performance of the pant. Each area operator was responsibe for a operationa and maintenance acti'ities at his particuar area of the pant and remained aert on ca from the board man for physicay handing the emergencies within his area. ;e was aso responsibe to fi area og sheet at oca contro pane=instrumentation to monitor and record the daiy area contro performance of the pant. I was responsibe to fi daiy shift Engineer7s og boo* to record any maintenance = abnormaity = emergency= troube shooting = start up = shut down acti'ities of the compete pant. I prepared a daiy maintenance program for any eectrica=mechanica maintenance acti'ities performed in my shift and issued wor* permit !cod( hot% to area operators at the start of the shift for safe e8ecution of the acti'ity.
P.E 2.1"
,uaity conformances to meet the company7s uaity standards at pant was another major responsibiity and I monitored and anay-ed the aboratory test resuts of the sampes ta*en out at different sampes spots of the pant site to ensure the uaity of the product as per defined standards.
P.E 2.20
I stricty foowed the safey chec*s and house *eeping of the pant areas during my shift and conducted a safety and emergency ta* in e'ery night shift of my shift schedue. eedbac*s from the shift personne were appreciated and sent after re'iewing them to the safety section of the pant through Production manager for further re'iew and impementation purpose.
P.E 2.21
4y performing shift duties( I faced different operationa = emergency probems which I tried to reso'e by utii-ing my technica *nowedge and e8perience at the pant e.g. a probem occurred during my shift was high /2 sippage probem from /2 remo'a system which was affecting a downstream pant. I conducted the thorough in'estigation aong with area operator of the whoe /2 absorption and @egeneration process. /hec*ed a the fow( pressure and temperature parameters. After detaied in'estigation( it was re'eaed that fow of ean soution to absorber has dropped to -ero due to stuc*ing probem of contro
'a'e in cosed position whie the fow meter was showing norma reading due to faut. Immediatey bypass of contro 'a'e was opened and conditions normai-ed after some time. Afterwards contro 'a'e was remo'ed to wor*shop for o'erhauing and fow meter was purged to normai-e its indication. ;igher management appreciated me for this impro'ement in achie'ing better pant efficiency. P.E 2.22
?ue to we recognition of my performance( technicay and probem so'ing s*is at pant management e'e( I was seected for appointment in a newy estabished 49@ !4aancing( 9oderni-ation and @e'amp% team at pant site from ammonia unit aong with some senior members of the unit. In this new assignment( foowing tas*s were incuded in my duties.
Identification of major bottenec*s with reference to increase pant production from 1260 9T=?ay to 1360 9T=?ay.
E'auation of the a'aiabe soution and recommending the optimi-ed soution.
/arried out en'ironmenta( safety and ha-ards re'iew of the e8isting pant and new projects.
Addition of new process euipments i*e ;ydrogen @eco'ery &nit !;@&% and modification in e8isting ones i*e change in internas of Absorption = @egeneration Towers from Trays to Pac*ing.
Impro'ing the uaity of the product to conform the customer reuirement.
Identifying areas for the pant for impro'ement with regard to safety( reiabiity( production( cost reduction and pant efficiency.
P.E 2.25
This section was organi-ed as per foowing hierarchy.
>enera 9anger Pant
Production 9anager
49@ 9anager
Technica Fer'ices 9anager
&nit 9anager Ammonia
C
Fhift Engineer
P.E 2.2
C
Indicates my Position.
I started in companionship of my senior coeagues to identify the critica bottenec*s and technica design probems of Ammonia pant subjected for higher management attention and modification reuirements.
P.E 2.23
I organi-ed and compied a of the historica technica and operationa data of the Ammonia pant in hard and soft copies formuation for easy references.
P.E 2.2
The first assignment handed o'er to me was oad imitation in /2 remo'a system. There was no further margin of oad increment in /2 remo'a system in order to achie'e 49@ production of 1360 9T= ?ay. I aong with my other coeagues after consuting some mutinationa designing companies suggested a proposa !after competey anay-ing the system% to repace the oder design tray type coumns with pac*ed coumns aong with addition of semi ean 4enfied soution fash 'esse. This proposa was reai-ed and appreciated by my section head and at senior pant management e'e( and *ept under specia consideration for further discussion regarding its e8ecution.
P.E 2.26
The second accompishment was suggestion of ;ydrogen @eco'ery &nit !;@&% instaation. 4y instaing ;@&( the basic constituent ;2 which is reuired in ammonia synthesis can be reco'ered from purge gas which was being burnt in boiers !In the form of purge gas fue%. 4y adding this unit(
pant production can be increased by # 9T=?ay. ;igher management aso appreciated and agreed with this suggestion. P.E 2.2#
?uring turn around acti'ity at pant I wor*ed in coaboration with process group of technica ser'ice department. I super'ised instaation of ;ydrogen @eco'ery &nit !;@&% structure and its contro system. Aso performed the ceaning( fushing and bowing of a the euipments instaed in ;@&.
P.E 2.2"
I super'ised the absorber = regenerator7s trays unoading and pac*ing oading acti'ity of the /2 remo'a unit from ammonia unit side.. A these turn around acti'ities were successfuy carried out and were appreciated by the senior pant management.
P.E 2.50
I wor*ed with senior professiona peope in highy technica and designed en'ironment and earn a ot about technica design modification and engineering probem so'ing and anaytica techniues.
d)
P.E 2.51
SU88AR2
This job was beginning of my professiona career. The prominent fared features of this project were on job training and independent shift management( which pro'ided me the opportunity to re'iew my strength and enhance my professiona competency by physicay( and actuay wor*ing and participation in a professiona en'ironment. I earnt a ot from this career job and de'eoped my professiona s*is to such an e8tent where I am uite abe to justify my professiona weightage. 9utifaceted probems of the pant( chaenging en'ironment were contributed a ot in enhancing my professiona confidence. 9y performance was highy appreciated by the management.
PROFESSIONAL EPISODE # 0" a) INTRODUCATION
P.E 5.1
The third episode of my engineering career was about my job with +?awood ;ercues /hemicas )imited !?;/)%G( being as Fhift Engineer !Ammonia Pant%. ?;/) is a fertii-er pant which is producing &rea fertii-er. ?awood ;ercues /hemicas )imited pant site is ocated about 50 *m from city of )ahore( near Fhei*hupura( Pa*istan. This Professiona episode was started on dated 9ay 06( 2006 and ended on dated August 26( 2006.
b) BACKGROUND
P.E 5.2
ertii-er sector pays an important roe in country agricutura and economic growth. As Pa*istan is big importer of fertii-er so this reason ma*es this sector more 'auabe. This sector on one side pro'ides 'auabe fertii-ers for agricuture sector( on the other hand pro'ides s*ied manpower a good forum of technica *nowedge and jobs. There is a continuous growth in this sector for ast three decades and sti two new ertii-er pants are in phase of designing and construction. &rea ertii-er is a major fertii-er being produced in Pa*istan among many other fertii-ers i*e ?AP( /A and mi8ed fertii-er etc.
P.E 5.5
The ?awood ;ercues /hemicas )imited is a &rea production pant as a major product whie imited uantity of )iuid Ammonia is aso sod for commercia uses. ?;/) is one of the pioneer pants in Pa*istan which started its commercia production in 1"".
P.E 5.
After thorough studies and considering the potentia future demands( the management of ?awood ;ercues /hemicas )imited started 49@ of the pant in phases. The first major phase of 49@ was competed in 1""0 whie the second major phase is being carried out. The major ad'ancement in second phase is con'ersion of pant contro from manua to ?/F. The basis of my appointment in ?;/) is the con'ersion of pant operationa contro from manua to ?/F as my pre'ious e8perience was ?/F based. The ammonia pant was designed by eogg &FA.
P.E 5.3
In Pa*istan with addition of ?;/)( there are si8 other &rea manufacturing units in Pa*istan whie one is under construction. ne speciaty of ?;/) is
that it ses commercia iuid ammonia which is an important raw materia for many 'auabe products. Aso ?;/) was upgrading their contro system with atest 'ersion of ?/F i.e. windows based ?/F. P.E 5.
&rea fertii-er is basic need of a crops. Its increased production sha sa'e ot of foreign e8change. n the other hand iuid ammonia is an essentia raw materia for many commerciay 'iabe products. Ammonia is used in hospitas( in Foda Ash industry !I/I Foda Ash Pant% and for production of ;/) = ; ; !In Fitara /hemica Indutries%.
P.E 5.6
/onsidering my pre'ious e8perience at Ammonia pant which was ?/F operated and professiona capabiities( ?awood ;ercues /hemicas imited assigned me the project to hep in con'ersion of ammonia pant operationa contro from manua to ?/F = P)/ and training of unit personne with reference of ?/F.
P.E 5.#
The out ines of the project were:
?etaied understanding of pant process parameters.
?etaied study of a contro oops.
To prepare con'ersion pan of contro oops from manua to ?/F.
To prepare procedure of con'ersion and super'ise the con'ersion of contro oops. on critica oops were con'erted first.
Educate and gi'e practica training to fied operators and particuary ?/F boardmans.
P.E 5."
4eing hired as particuary for con'ersion of pant operationa contro from manua to ?/F( my main responsibiity was to gi'e suggestions for safe e8ecution of the project aong with training of a reated staff. I shared my pre'ious e8perience and emergencies I faced during my job in auji ertii-er 4in ,asim imited. >a'e different tips and suggestions for training of staff and 4oardman.
P.E 5.10
irst of a I de'eoped the concept of ?/F operation amongst the fied staff and 4oardman. >a'e them the basic theme of contro phiosophy and organi-ed meetings with different shift groups. Aso conducted attitude inter'iews of fied operators for training of future ?/F 4oardman. The main step was training of other shift engineers as they were the *ey of project
success. The a project acti'ates were highy appreciated by higher management. P.E 5.11
The main chaenge( I faced during the impementation phase of ?/F operated contro oops was approach of e8perienced area operators and 4oardman. ?ue to their 'ast e8perience on manua pant( they were reuctant to accept change in process controing. 4ut with the passage of time and introduction of more approachabe and easy controing features of ?/F( they accept the change and started to enjoy wor*ing on the new controing system.
P.E 5.12
The Ammonia Pant at ?awood ;ercues /hemicas )imited incudes the foowing process units and utiities.
Proc( Uit
ne Ammonia production unit designed to produce #13 9T= day !After 49@% of iuid ammonia. ne &rea production unit designed to produce 100 9T= day !After 49@% of Pried &rea ertii-er.
Uti'iti( Productio Uit
These units incude:
Two Power generation units with capacity of 06 9J each.
@aw water treatment faciity incuding raw water storage( carification( fitration and deminerai-ation units.
/ooing water system and cooing towers. itrogen storage 'esse.
;eating 'entiation and air conditioning.
Fteam generation unit.
Product storage system.
Instrument Air Fystem
TEC>NOLOG2 PRESENTED
The Ammonia pant was designed eogg( &FA in 1"".
P.E 5.15
Ammonia production unit was constituted as per foowing hierarchy:
>enera 9anger Pant
Production 9anager
Assistant Production 9anager /oordination Engineer &nit 9anager !Ammonia%
C Fhift Engineer A
Fhift Engineer 4
Fhift Engineer /
Fhift Engineer ?
Fhift 4oardman 02 Trainee 4oardman 02 perators 0 Trainee perators 05
P.E 5.1
C Indicate my position in the chart
A shifts constituted of same management and staff structure rotating # hours per shift per day on continuous ammonia production pant. I was at shift management position highighting with asteris* !C% in the abo'e chart.
P.E 5.13
oowing timey management acti'ities were incuded in my duties a%
rientation and safety training
01 wee*
b%
n job training at poymer pant
0 wee*s
Ftudy of area genera course
1 wee*
@eforming and Fteam >eneration M PI?s
1 wee*
Ammonia Ftorage M PI?s
1 wee*
/ompressor section M PI?s
1 wee*
Fynthesis oop and ammonia con'erters M PI?F
1 wee*
/2 remo'a system M PI?s
1 wee*
c%
Independent shift Engineer duties
Tota'
c)
P.E 5.1
0" wee*s 1 5((+
PERSONAL ?ORK PLACE ACTIIT2
After one wee* pant orientation and safety training at technica training department( I was shifted to pant site. I started detai earning of a the pant processing sections( euipments and obser'ed the acti'ities of a pant site. I first di'ided the pant into indi'idua segments according to processing steps( then for each segment I studied its operations( controing parameters( ine tracing( contro oops( instrumentation( interoc*ings( emergency handing( troube shootings( maintenance( startup shutdown acti'ities and shift management acti'ities. I made discussions with shift personne and senior engineers at e'ery e'e to share their *nowedge and professiona e8perience o'er the pant( obser'ed and earned ?/F process contro system of the pant which has been shifted so far.
P.E 5.16
The pant was designed to produce #13 9T= ?ay of iuid ammonia. The pant was controed through manua Oo*ogawa controers which was being repaced with atest ?/F contro system. The main by$product of ammonia pant was carbon di$o8ide which was the basic raw materia for urea production.
P.E 5.1#
The pant contained foowing major euipments:
?esuphari-ation and ;ydrogenation 'esses atura >as booster compressor
Primary @eformer !urnace%
Fecondary @eformer
Fteam 4oier = Fteam ?rum
P.E 5.1"
;igh Temperature = )ow Temperature Fhift /on'erters
Absorption and @egeneration Tower
Ammonia Fynthesis >as /ompressor
Ammonia separator 'esse
Ammonia /on'erter
Process Air /ompressor
?eaerator
@efrigeration /ompressor
/ondensers
9ethanator
/entrifuga Pumps
Fteam Turbines
Ammonia Production process described here is based on reaction of ;ydrogen with itrogen. Ammonia production is accompished in foowing sections:
?esuphari-ation of atura >as
Fteam @eforming in Primary and Fecondary @eformer
/on'ersion of / into / 2
@emo'a of /2 by Absorption
9ethenation
/ompression of Fynthesis >as
Fynthesis of Ammonia
@efrigeration /yce
4oier eed Jater
Fteam >eneration
D(u'*&ariatio o! Natura' Ga
After pressuri-ation of > !atura >as% up to >=/9 2 !reuired pressure for reaction% through positi'e dispacement compressor( the Fuphur compounds are remo'ed from > by passing through /$9 catayst bed aong with addition of ;2 and afterwards Nn catayst bed. In /$9 bed( hydrogenation of Fuphur compound con'erts them to ; 2F and in Nn bed( ; 2F is absorbed in catayst bed.
St(a R(!ori, i Priar% ad S(codar% R(!or(r
9ain reaction starts with the addition of process steam in desuphari-ed > and passing through primary reformer where reforming of > ta*es pace in the presence of ic*e catayst. Primary reformer is > fired induced draft furnace.
In secondary reformer( further reforming of reformed gases ta*es pace in the presence of same catayst aong with addition of process air. The process air is reuired to get nitrogen from it. At the outet of secondary reformer( the reformed gases mainy consist of ; 2( 2( /2( /( /; and traces of Argon.
Co@(rio o! CO ito CO 9
In order to remo'e / from reformed gases( shift reaction occurs in which gases are passed through firsty from e based catayst where bu* of / present in reformed gases is con'erted to / 2.
In second step( the remaining / present is con'erted to / 2 by passing reformed gases through /u based catayst. In this step( amost a / has been con'erted to /2.
R(o@a' o! CO9
After / con'ersion to / 2( the reformed gas is fed to Absorption tower where /2 is absorbed in /atacarb soution during countercurrent fow.
After absorption of / 2( the rich /atacarb soution is fed to @egenerator where / 2 from /atacarb soution is remo'ed and sent to &rea section for &rea production. /arbon ?i 8ide obtained in this process is ""."K pure.
8(t&aatio
After /2 absorption( sma uantity of /2 and / is remo'ed by passing reformed gases through ic*e based catayst where / 2 and / is con'erted to /; which is inert in ammonia synthesis process.
Co*r(io o! S%t&(i Ga
After remo'ing a impurities from synthesis gas( it is ready for ammonia synthesis. The components present now are mainy ; 2 and 2 and few percents of /; and Ar which are inert in the remaining process.
or ammonia synthesis( high pressure and high temperature is reuired which is obtained by compression of synthesis gas in centrifuga synthesis compressor. The high temperature is obtained by gaining heat from ammonia con'erter effuent gases as the reaction is highy e8othermic.
?uring compression( synthesis gas is pressuri-ed up to 130 >=/92 in a muti stage steam turbine dri'en centrifuga compressors.
S%t&(i o! Aoia
After compression and passing trough number of heat e8changers( this high pressure and high temperature synthesis gas is fed to speciay Topsoe designed F$ 200 Ammonia /on'erter where 2 and ;2 reacts chemicay in the presence of iron !e% based catayst.
The con'ersion obtained per pass is neary 1K. The mi8ture of synthesis gas and product ammonia is then separated in centrifuga separators. The "".#K iuid ammonia is obtained which is fed to ammonia storage.
R(!ri,(ratio C%c'(
or cooing purpose of synthesis gas and separation of iuid=gas( Ammonia is used as cooing media. In refrigeration cyce( first of a( ammonia is e'aporated by e8changing heat with gas to be cooed in chiers then these 'apors are fed to
mutistage centrifuga compressors. After compressing these 'apors to 1 >=/9 2( these are fed in condensers where ammonia 'apors are condensed with the hep of cooing water. This iuid is then again recyced for cooing purpose in chiers.
Boi'(r F((d ?at(r ;D(a(rator)
or the preparation of 4J !4oier eed Jater%( the ?emineri-ed Jater recei'ed from utiities section is fed to deaerator where its mechanica and chemica deaeration is carried out to remo'e o8ygen. or chemica deaeration( ;ydra-ine !2;% is added.
This 4J is used for steam production in boiers.
St(a G((ratio
Fteam is an essentia raw materia for ammonia production and is aso used for heating purpose and steam turbines operation.
n ammonia unit( high pressure ! >=/92% steam is produced from ;@F> !heat reco'ery and steam generation% at the downstream of secondary reformer.
Amost a compressors( pumps and turbines present on ammonia unit are steam dri'en.
Aoia Stora,(
Product )iuid Ammonia from ammonia separator 'esse is pumped to Ammonia Ftorage esse whose capacity was 3000 9T and from storage to urea section !mosty ammonia was being shifted to urea directy from pant%.
Two compressors were instaed at ammonia storage for 'apors iuefaction produced in storage 'esse.
P.E 5.20
I wor*ed hard and earnt a pant operations( acti'ities and practices within short time and started to hande shift duty independenty being as Fhift Engineer. I gained much e8perience in operation of ammonia pant of different design and contro strategy.
P.E 5.21
4eing as shift engineer( I performed foowing responsibiities:
Pro'ided technica
support
to pant
operation
and
production
management.
In'estigated diagnosed and recommended correction for technica( operationa probems
9onitored( controed process parameters through ?/F contro system and super'ised troube shootings.
/ontributed in the pant continuous impro'ement in heath( safety en'ironment performance and in potentia safety or en'ironmenta ha-ards identification.
?e'eoped and prepared operation manuas training materias especiay with reference to ?/F( daiy = monthy production and in'entory reports.
P.E 5.22
,uaity conformance to meet the company7s uaity management system IF at ammonia unit was another major responsibiity and 1 monitored=chec*ed the aboratory test resuts of sampes ta*en at different sampe points of the pant site and suppied raw materias to ensure the uaity of production.
P.E 5.25
?uring my shift engineer duty( I faced different operationa=emergency situations where I tried to rectify by appying my technica s*is=*nowedge and e8perience at the pant. ne situation was( e'e sensor of Ammonia separator 'esse was faied to transmit its signa=reading to ?/F contro system. As there was contro oop which contros the e'e in @eactor and if e'e sensor fais to gi'e signas to controer( controer woud not be abe to generate its contro signas to contro 'a'e. This situation coud seriousy affect the down stream euipments as high e'e in the 'esse coud be resuted in iuid carry o'er which coud utimatey damage the synthesis gas compressor or on the other hand( ow e'e in the 'esse coud be resuted in high pressure gas brea* through in ow pressure designed piping='esses. After considering some aternate actions( I put the separator 'esse e'e on manua mode and deputed area operator to physicay obser'e the e'e through sight gass. Afterward( put the contro on by pass 'a'e and rectified the probem in e'e transmitter. 4y doing such in reuired timey manner( sa'ed the whoe ammonia pant from shutdown. 9y unit manager and senior management appreciated me.
P.E 5. 2
?uring pant emergency shutdown acti'ity due to ea*age in secondary reformer downstream ;@F> boier( I wor*ed aong with senior and junior technica personne. 1 performed pre shut down acti'ities as:$
rgani-ed the acti'ities assigned to me with shutdown pan.
9aintained itrogen purge on as ong as possibe.
P.E 5. 23
Fuper'ised pant maintenance jobs assigned.
I was assigned the duty to purge out a ammonia 'esses for 'esse entry purpose. 4y doing this acti'ity( I paid specia attention with respect to safety. As Ammonia is 'ery dangerous to e8posure through breath and s*in contact. ?uring this cearing procedure( I *eeny obser'ed for ea*age of ammonia which ows( drops into insuation( from ose fange connections( coud cause injury and s*in burn on contact. A these turn round acti'ities were successfuy carried out and were we appreciated by the senior management.
P.E 5.2
I wor*ed with senior peope in totay technica and designed en'ironment and earnt a ot about technica design modification and engineering probem so'ing and anaytica techniues.
d)
SU88AR2
P.E 5.26
These jobs pro'ided me in depth *nowedge and e8pertise in my occupation. The prominent fared features of these project were professiona en'ironment which pro'ided me the opportunity to further refined and earned engineering approaches and techniues for better engineering and management probem so'ing s*is. I earnt a ot from these jobs and de'eoped my professiona s*is to such an e8tent where I am uite abe to justify my professiona weightage. 9uti faced probems of the pant( chaenging en'ironmenta were contributed a ot in enhancing my professiona confidence. 9y performance was highy appreciated by the pant management.
PROFESSIONAL EPISODE # a)
INTRODUCTION
P. E .1
The fourth episode of my professiona career is about my third current job with Sui Nort&(r Ga Pi*('i( Liit(d- started on dated Feptember 05( 2006 and is continued. Fui orthern >as Pipeines )imited !F>P)% is an engineering based company. It is one of the two companies in Pa*istan wor*ing in this fied. The other one is Fui Fouthern >as /ompany )imited which is a sma company as compared to F>P) The /ompany ;ead ffice is ocated in )ahore( Pa*istan with business in Pro'inces of Punjab( JP( A-ad ashmir( federa capita and few parts of Findh and 4aochistan. 9y present wor* site is transmission headuarter in aisaabad( Pa*istan. The tite of my position in this company is presenty Transmission Engineer !>as /ontro%.
b)
BACKGROUND
P. E .2
Fui orthern >as Pipeines )imited !F>P)% was founded in 1"5 and has a status of pubic imited company since 1". It was the first such *ind of company in Pa*istan. The main business of company is suppy of atura gas to ?omestic( /ommercia and Industria consumers. Areas of operation incude Punjab( JP( edera /apita and A-ad ashmir. The infrastructure of company is spread a o'er in Pa*istan incuding pro'ince of Findh and 4aochistan. The transmission ines !rom gas producing source upto city gates% on company networ* are neary 300 *iometers and distribution ines !rom city gates to consumer7s doorstep% on company networ* are neary 32000 *iometers. There are neary three miion consumers of company. A these faciities and pipeine networ*s are aid and maintained by F>P) itsef. ther than pipeine networ*( faciities incude fitration pants and compressor units. There are 0" compressor stations on company networ*.
P. E .5
Fui orthern >as Pipeines )imited !F>P)% is aso in the process of getting projects in other countries. @ecenty a agreement was signed with Ageria ationa >as /ompany for ying of transmission ines in Ageria as a Hoint 'enture with this /ompany. F>P) has pro'ided its ser'ices to many other
companies within Pa*istan i*e PA@/ refinery for aying of pipeine from arachi to 9utan and gas pipeine for auji ertii-er /ompany in Fadiabad.
P. E .
The *ey strength of the company incudesL
Product acceptabiity in a areas of Pa*istan.
wn Transmission and ?istribution networ* aong with compressor stations.
,uaity /ustomer Fer'ices.
4eing in a process of getting IF "000$2000 1001 certification.
ny company operating in more than haf of Pa*istan with no competitor so far.
P. E .3
/ompany 'ision 9ission are:$
ISION :
ur 'ision $ the future we are stri'ing for is that:
To be the eading integrated atura >as pro'ider in the region see*ing to impro'e the uaity of ife of our customers and achie'e ma8imum benefit for our sta*ehoders by pro'iding an uninterrupted and en'ironment friendy energy resources.
T>E 8ISSION7
A commitment to dei'er natura gas to a door steps in our chosen areas through continuous e8pansion of our networ*( by optimay empoying technoogica( human and organi-ationa resources( best practices and high ethica standards.
P. E .
The company is di'ided itsef into four major departments:$
Projects ?epartment
Transmission ?epartment
?istribution department
/ompression ?epartment
/ustomer Fer'ices ?epartment
/ompany has di'ided into 0# regions which are further di'ided into sub$ regions. A area offices are functioning according to abo'e main segments. After joining the company( a comprehensi'e orientation was gi'en by actuay passing time in a the major departments of the company i.e. ?istribution( Transmission( /ompression and Projects.
P.E .6
The Transmission ?epartment in ;eaduarter is constituted as per foowing hierarchy:
>enera 9anager !T% /hief Engineer !>as /ontro% E8ecuti'e Engineer !>/%
Engineer >/ 9orning Fhift
Engineer >/ E'ening Fhift
Engineer >/ ight Fhift
Engineer >/ n @est
F/A?A 4oardman 02 Indicates my Position
P.E .#
I am wor*ing as Transmission Engineer in >as /ontro. >as contro system is euipped with atest controing system caed Su*(r@ior% Cotro' Ad Data Ac6uiitio ;SCADA)3
oowing acti'ities are incuded in my job description:
Primary responsibiity is to maintain continuous fow of atura >as from source up to city gates.
/ontinuous monitoring of a gas reated parameters i*e fow( temperature and pressure etc.
/ontinuous monitoring of a gas sources and addition = deetion of gas sources as per reuirement = instruction.
/oordination with a gas sources and compressor stations on reguar basis in order to identify any pre'enti'e actions.
Emergency handing in case of any compressor station tripping or gas fied tripping.
Preparation of daiy status report i.e. input of gas in the transmission system and gas dei'ered distribution department aong with cacuation of gas osses !&>%.
To maintain pressure of gas in transmission networ* and in case of pressure drop due to any reason( inform a concerns in order to curtai gas usage.
c)
PERSONAL ?ORK PLACE ACTIIT2
P.E ."
After getting orientation about the company( its 'ision( hierarchy( products( strategic objecti'es business Poicies. I started wor* as per my job description.
P.E .10
The gas contro room where I am responsibe has the foowing major wor*ings.
9onitoring of F>P) transmission networ* on 2 hours basis. Identification and rectification of any abnormaity appeared in gas fow system.
Emergency handing in case any gas ine rupture. Aocation of gas to big industria units in case of ow gas input and particuary in winter season.
perating Performance chec*s.
@epy of different technica enuiries rose from higher management.
Technica suggestions for continuous( safe and smooth gas fow.
P.E .11
?uring my job( I faced 'arious chaenging situation. The main emergency was sudden drop in pressure of gas in Fui$4hong section of F>P) networ*. There coud be many reasons of pressure drop i*e fauty pressure gauge( tripping of compressor or restriction in F/A?A data system. 4ut I in'estigate the whoe situation in no time and it was re'eaed that main gas suppy ine has been ruptured by terrorist attac* in Fui( 4aochistan where from much of F>P) networ* gas is coming. Immediatey gas suppy contro 'a'e from Fui and contro 'a'e from 4hong was cosed and conditions were partiay normai-ed after routing some fow of gas from second ine. ?ue to stoppage of gas from main source( pressure in networ* started to decrease. Immediatey I informed a concerns and restricted the gas suppy to industria and commercia users in order to maintain gas suppy to domestic consumers and to maintain minimum pressure in the system.
P.E .12
In abo'e described chaenging situation( I was interacted with 9echanica( 9aintenance( perations and /ommercia departments and pro'ed my professiona competencies and business s*is.
P.E .15
I am doing hard wor* and *eep earning more in this 'ast fied of industria saes and mar*eting so that I can better perform in my further projects and assignments. 9y company sha sponsor me for higher studies( after competion of two years in company( in order to enhance my s*is and competencies in gas transportation fied.
d)
P.E .1
SU88AR2
The current job is more chaenging and interesting in nature for me. The prominent fared features of this Project are business reationship with gas sources( industria customer7s satisfaction( Inno'ation( Technica e8pertise interaction
with
different
types
of
industries
and
mutidiscipinary
