Sr. Process Engineer – Operations at Suncor Energy (2023-03 – Present)
Providing operations support to Water Treatment, HRSGs, COGEN, Amine Absorption & Regeneration, Sour Water Stripper, Sulphur Recovery Units, Tail Gas Treating Units.
- Responsible for developing and maintaining Safe Operating Limits (SOL), Stand Limits (SL) and target operating conditions to support safe, reliable, and efficient operation within environmental and regulatory approval limits.
- Conduct daily monitoring and troubleshooting for reliable operation.
- Support and provide process recommendations to operations on adjustments required for optimized operation of equipment and catalyst performance.
- Lead and actively participate in PSM activities related to unit cyclic PHA, MOC risk reviews and pre-startup safety reviews (PSSR).
- Support for the planning and execution of plant and unit turnarounds by monitoring plant shutdown, performing equipment inspection, reviewing and developing inspection/repair scopes, participating plant startup.
- Support continuous improvement efforts through alarm/SOL/SL rationalization, disabled alarm, interlock bypass and overdue MOC reduction.
- Performed day-to-day monitoring, optimization and troubleshooting of Sulphur Recover Units (SRU).
- Developed fully functioning of Hysys model of the Sulphur Recovery Unit (SRU). Useful tool used for running case studies and What-If scenarios.
- Provided support to Turn Around (TA) by inspecting towers, furnaces, reactors, providing recommendations, performing vessel closures and Pre-startup Safety Reviews (PSSR) in Hydrotreating and SRU plants.
- Performed day-to-day monitoring, optimization and troubleshooting of Water Treatment plant
- Led Management of Change (MOC) projects e.g. Temporary Instrument compressors, temporary pumps to support Turnround (TA) activities.
- Led MOC project to transfer pond water during Turnaround (TA) outage which saved company $48 MM.
- Performed day-to-day monitoring, optimization and troubleshooting of the Cogeneration and Heat Recovery Steam Generation (HRSG) plants.
- Prepared weekly steam and Boiler Feed Water (BFW) production plans for the Utilities plants which also feeds side wide production planning.
- Provided process data for the Steam Methane Reforming plants to reliability team as part of the Equipment Strategy (ES) team.
- Marked up isolation P&IDs for coke 3 boilers, Flue Gas Desulphurization plant to minimize dead legs as part decommissioning project.
- Participated the investigation of Root Cause of frequently tripping oil transfer pumps, conducted NPSH calculations to the investigation team.
Process Engineer, Contractor at Suncor Energy (2022-07 – 2023-03)
Providing process data to Reliability and the equipment strategy group for the hydrogen plants. This was part of the effort to proactively plan equipment for shutdown, inspection and potentially maintain equipment based on process data provided.
- Collected max and min process data for specific process equipment, using different sources PI-Vision, PFDs, datasheets, P&IDs, LDTs, vendor drawings, electrical area classifications.
- Provided summary of the process data to the Reliability group to be used as a decision making for inspection and planning maintenance work.
Process Engineer – Major Capital Projects at NOVA Chemicals (2017-07 – 2019-09)
- Investigated, collected data, analyzed and completed the sizing, design and selection of Pressure Safety Valves (PSVs) using IPRSM software.
- Investigated, and developed, Front End Loading (FEL) of 3 major projects to install Emergency Shutdown Valves (ESDs) to mitigate Loss of Process Containment (LOPC) in ethylene pipeline system of high pressure 10,000 kPag C2H4 (ethylene) with a cost saving of $47 MM.
- Investigated exchanger performance, of shell and tube exchangers.
- Collected, analyzed, reviewed and verified process conditions relevant to equipment design.
- Conducted feasibility studies, Root cause analysis and came up with corrective actions.
- Prepared RFQ, equipment orders, reviewed engineering drawings, HAZOP, execution and commissioning of the project.
- Provided site technical engineering and process safety support, coordinated site material and shipping
Project Design Engineer – In-House Capital Projects at NOVA Chemical (2015-10 – 2017-07)
- Run relevant software models to validate vendor proposed design using Aspen Plus, Exchanger Design and Rating (EDR) and Fluid flow.
- Coordinated passivation work of newly installed exchangers in an ethylene plant.
- Prepared equipment datasheets for vendor. Interfaced with different stakeholders, EPC, Operations, and discipline leads.
- Developed Front End Loading (FEL) stage report for fouling Plate and Fin exchanger in an ethylene, ethane service resulting in 20% production increase and subsequent annual total annual gain of ~ $28MM.
- Reviewed Internal, and external standards e.g. API, ASME, NFPA, and specific industry related standards e.g. TEMA, ALPEMA, as well as local regulatory codes e.g. Building and Fire Code, ABSA for equipment design.
- Conducted Experimental Operating Instructions (EOI) – for a new plate and fin exchanger. Run performance evaluation, monitored data trends through Aspen Process Explorer, analyzed data, prepared report and presented results.
Process Safety Engineer – Water Treatment Plant at NOVA Chemicals (2013-09 – 2015-10)
- Facilitated and led Process Hazard Analysis which include Hazop, What-if-Analysis, Failure Mode & Effect Analysis (FMEA), Layer and Protection Analysis (LOPA) for various projects.
- Conducted Ad-hoc risk assessments as needed e.g. N2 building Safety for buildings identified that are being at risk.
- Scheduled, facilitated the revalidation for ethylene, water treatment and plant (PHA) Database as part of 5-year cycle reviews.
- Provided technical support for Emergency Response to company Emergency Operations Centre (EOC) for over 5 years.
- Performed release simulation scenarios on SAFER during an Emergency Response and drills.
Process Safety Engineer Rep – Ethylene Plants at NOVA Chemicals (2012-03 – 2013-09)
- Participated in substantially significant incident investigation. Sulphuric acid, Alum incident in water treatment Manufacturing Facility. Been one of two engineers to investigate, prepare the cause map, and present recommendations to leadership.
- Gave Process Safety Management (PSM) orientation to new employees as required by company for 4 years.
- Reviewed and approved new chemicals to site as a Process Safety representative 2 years.
- Conducted audits on closed capital and Unit Expense (UE) project as part of Management of Change program
