PROFESSIONAL EPISODE # 01

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.

Project director –01

Professor

* Member (Chemical) -01 Member (Chemical) -02 Members (Chemical) –03

* 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.

c) PERSONAL PLACE ACTIVITY

P.E. 1.6 First of all I prepared an action plan (strategy) by considering the major steps
with subsequent specific steps taken in order to accomplish all objectives and
finally the target. I tried to manage all these activities according to priority,
time and responsibility by assigning priority number to each activity, its
starting, ending date and the person responsible to carry out those particular
tasks. Finally I became successful in preparation of an effective action plan
(strategy) for approval of the project director. This action plan (strategy) was
discussed in detail with group members and finally presented to project
director. After getting approval of the strategy from the project director, my
colleague members and I started work according to their responsibilities and
tasks.
P.E. 1.7 1 visited Pakistan Council of Scientific and Industrial Research (PCSIR)
center and Lahore Chamber of Commerce & Industry (LCCI) to search and
collect the relevant data for the Ethylene user industries in Pakistan. Second
member of the group visited Export Promotions Bureau (EPB), Pakistan to
collect the import/ export figures of Ethylene / Naphtha in last 10 years. Third
 member of group visited local market to check the prices, consumer demand,
Ethylene consumption, grade & quality , specification and collect / search all
information concerning to the local market position of the chemical .
P.E. 1.8 After completion of the activity my group was in a position to define the scope
of this project (Ethylene) in Pakistan and design capacity of Ethylene
Manufacturing / production plant. The scope of Ethylene in Pakistan is very
wide as per its applications. There is not a single unit in Pakistan that is
producing Ethylene. The design capacity of the said project was set “300 Tons/
Day production of Ethylene”.
P.E. 1.9 After Noticing a great scope of Ethylene in Pakistan and getting design
capacity of the project, research was carried out on all the manufacturing
processes of Ethylene in history. For this purpose I with my group members
visited different libraries at university and city level to search out the various
books, literatures, Journals, Chemical Encyclopedia like Kirkothemer,
Mcketta, internal search and relevant manufacturing industries on internet to
find out multiple references of the desired chemical (Ethylene) manufacturing
processes and design, shared the knowledge and experiences of the plant
personnel related to Ethylene downstream industries. Most important
manufacturing processes are:-
 Thermal Cracking
 Catalytic Cracking
 Hydro Cracking
 Kureha Process
 Catarole Process
 Steam Cracking.
Among all processes described for the production of Ethylene, I selected Steam
Cracking of Naphtha due to the following reasons.
 When steam is introduced along with the feed, it increases the volume of the gas
which decreases the residence time.
 The added steam reduces the partial pressure of the hydrocarbon which increases
the yield of gaseous product and decreases the yield of liquid product.
 The heat required in the endothermic reaction is reduced as steam does not react
and only give its latent heat. It acts as heating medium.
 The introduction of steam reduces the coke formation to greater extent.
  Steam reacts directly with the deposited carbon or coke and gives CO 2 which
helps to clean the furnace. Hydrogen generated in the process is used to convert
Acetylene into Ethylene and Ethylene to Ethane late in the process.
P.E. 1.10 Raw materials for the selected product in process were Naphtha and steam.
Naphtha is produced from Distillation of petroleum while steam is produced in-
house from boilers.
P.E. 1.11 In the selected manufacturing process, Naphtha is cracked in a furnace by steam
cracking resulting in production of Methane, Ethane, Propane, Carbon Mono Oxide,
Sulphur Compounds, Acetylene and Ethylene along with some impurities. The
furnace consists of two sections, which are Radiant Section and Convection
Section. In convection section, Naphtha feed along with process steam is heated
with flue gases of radiant section while in radiant section, feed is heated through gas
fired burners or through hydrocarbons (Recovered during the process). The mixture
obtained after the cracking of Naphtha is technically called “Cracked Gases”. The
cracked gases are then cooled to room temperature for compression. Cooling of
cracked products is done in Quench Boiler with water and in Cold Naphtha
Preheater with cold Naphtha. After this cracked gases are washed in Scrubber with
water to remove any Tar or heavy Hydrocarbons. Heavy hydrocarbons are recycled
back to furnace while cracked gases are fed to Absorber and Stripper for removal of
H2S and CO2 using MEA (Mono Ethanol Amine). Now gas is compressed in
number of stages to increase pressure and to remove any condensate present in the
product gases. At this stage, cracked gases mainly consist of Ethylene, Ethane,
Acetylene, Methane, Propane and Hydrogen (H2). Acetylene present in gas mixture
is then converted to Ethylene and Ethane by passing the mixture through Acetylene
Converter. Reaction of Hydrogenation is carried out in the presence of “Palladium”
catalyst. After the conversion of the Acetylene to Ethylene and Ethane, the mixture
is liquefied for the separation of different products. The first distillation column
used is Demethanizer for separation of Methane. The product obtained from this
column is 99% Methane and 1% Ethylene. The second distillation column used is
De-ethanizer for separation of Ethylene from Propane. In this column, the top
product mainly contains Ethylene, Ethane, Propane and Methane. Where as the
bottom product contain the little quantity of Ethylene, Ethane and Propane and
mainly consist of Propane. The product from the De-ethanizer column is fed to the
Ethane-Ethylene Splitter. Here Ethane and Ethylene are considered for distillation.
 The top product contains 99.5% Ethylene and bottom product contains the major
content of ethane. Hence the product of the plant is collected from the top of
Ethane-Ethylene Splitter and sent for storage.
Design project contained the following main equipments:

 Boiler for steam generation.

 Furnace for Naphtha cracking.
 Quench boiler for cracked gases cooling.
 Two cold Naphtha preheaters.
 Scrubber for washing of cracked gases.
 Five stage compressor for compression of cracked gases.
 Heating / Flashing unit and separator.
 Amine wash tower (Absorber) and Stripper.
 Dehydrator for water removal.
 Acetylene converter.
 Refrigeration system.
 Three Distillation Columns (De-Methanizer, De-Ethanizer, Ethane-Ethylene
Splitter).

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.

Utility Production Unit

 Two gas turbines for power generation with designed power of 26.2 MW each. One
is capable of handling the entire complex.
 Raw water treatment facility including raw water storage, clarification, filtration and
demineralization units.
 Cooling water and cooling tower System.
 Instrument Air supply system for control purpose.
 Steam generation unit with one auxiliary Steam Boiler, one Waste heat recovery
steam generation system, one boiler Feed water system.
Raw Material, Finished Product and Bagging / Shipping
 Final product storage and begging / shipping facilities.
 Raw Material storage tanks.
 Store / warehouses.
Off Sites & Building
 Fire Water system
 A storage area at Port Qasim for Phosphoric Acid unloading.
 Building Includes:-
 Administration
 Warehouse
 Workshop
 Control rooms & electrical rooms.
 Laboratory
  Technical services building
 Technical training centre
 Safety building
 Industrial clinic

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

General Manger Plant

Production Manager
Coordination Engineer
Unit Manager (Ammonia)

* Shift Engineer Shift Engineer Shift Engineer Shift Engineer

A B C D

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.

c) PERSONAL WORK PLACE ACTIVITY

P.E 2.12 Following timely management activities were included in my duties;

a) Orientation at TTC 05 Weeks

b) On Job Training at Ammonia Plant 18 Weeks
 Study of area general course 01 week
 Boiler Feed Water and Auxiliaries + PIDs 04 weeks
 Desulphurization section + PIDs 02 weeks
 Reforming and Shift Conversion + PIDs 02 weeks
 CO2 Absorption Section + PIDs 02 weeks
 Compression Section + PIDSs 02 weeks
 Process Air and Natural Gas Section + PIDs 02 weeks
 Ammonia Synthesis section + PIDs 02 weeks
 Refrigeration Section
 Instrumentation and process control system 01 week
c) Safety training 01 week
d) As training Shift Engineer 24 weeks
Total Training Period 48 weeks (06 Months)
e) Routine shift engineer’s duty 148 weeks

Total experience: Approx 196 weeks OR 4 years, 01 months & 06 days

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.

 Desulpharization and Hydrogenation vessels

 Natural Gas booster compressor
 Primary Reformer (Furnace)
 Secondary Reformer
 Steam Boiler / Steam Drum
 High Temperature / Low Temperature Shift Converters
 Absorption and Regeneration Towers
 Ammonia Synthesis Gas Compressors
 Ammonia separator vessel
 Ammonia Converters
 Process Air Compressors
 Deaerator
 Refrigeration Compressors
 Condensers
 Auxiliary Boilers.
 Hydrogen Recovery Unit
 Methanator
 Centrifugal Pumps
 Steam Turbines
 Gas Turbine as driver for Synthesis Gas Compressor

P.E 2.16 Ammonia Production process described here is based on reaction of Hydrogen
with Nitrogen. Ammonia production is accomplished in following sections:

 Pressurization and Desulpharization of Natural Gas

 Steam Reforming in Primary and Secondary Reformer
 Conversion of CO into CO2
 Removal of CO2 by Absorption
 Methenation
 Compression of Synthesis Gas
  Synthesis of Ammonia
 Refrigeration Cycle
 Boiler Feed Water
 Steam Generation

Pressurization and Desulpharization of Natural Gas

 First of all NG (Natural Gas) is pressurized up to 40 KG/CM 2 (required pressure for

reaction) through centrifugal compressor.
 Then Sulphur compounds are removed from NG by passing through CO-MO
catalyst bed along with addition of H2 and ZnO catalyst bed. In CO-MO bed,
hydrogenation of Sulphur compound converts them to H2S and in ZnO bed, H2S is
absorbed in catalyst bed.

Steam Reforming in Primary and Secondary Reformer

 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.

Conversion of CO into CO2

 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 CO2 absorption, small quantity of CO2 and CO is removed by passing

reformed gases through Nickel based catalyst where CO2 and CO is converted to
CH4 which is inert in ammonia synthesis process.

Compression of Synthesis Gas

 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 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/CM2, 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.

Boiler Feed Water (Deaerator)

 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.

P.E 2.23 This section was organized as per following hierarchy.

 General Manger Plant

Production Manager BMR Manager Technical Services Manager

Unit Manager
Ammonia

*
Shift Engineer * Indicates my Position.

P.E 2.24 I started in companionship of my senior colleagues to identify the critical

bottlenecks and technical design problems of Ammonia plant subjected for
higher management attention and modification requirements.
P.E 2.25 I organized and compiled all of the historical technical and operational data of
the Ammonia plant in hard and soft copies formulation for easy references.
P.E 2.26 The first assignment handed over to me was load limitation in CO2 removal
system. There was no further margin of load increment in CO2 removal
system in order to achieve BMR production of 1570 MT/ Day. I along with
my other colleagues after consulting some multinational designing companies
suggested a proposal (after completely analyzing the system) to replace the
older design tray type columns with packed columns along with addition of
semi lean Benfield solution flash vessel. This proposal was realized and
appreciated by my section head and at senior plant management level, and
kept under special consideration for further discussion regarding its execution.
P.E 2.27 The second accomplishment was suggestion of Hydrogen Recovery Unit
(HRU) installation. By installing HRU, the basic constituent H2 which is
required in ammonia synthesis can be recovered from purge gas which was
being burnt in boilers (In the form of purge gas fuel). By adding this unit,
 plant production can be increased by 48 MT/Day. Higher management also
appreciated and agreed with this suggestion.
P.E 2.28 During turn around activity at plant I worked in collaboration with process
group of technical service department. I supervised installation of Hydrogen
Recovery Unit (HRU) structure and its control system. Also performed the
cleaning, flushing and blowing of all the equipments installed in HRU.
P.E 2.29 I supervised the absorber / regenerator’s trays unloading and packing loading
activity of the CO2 removal unit from ammonia unit side.. All these turn
around activities were successfully carried out and were appreciated by the
senior plant management.
P.E 2.30 I worked with senior professional people in highly technical and designed
environment and learn a lot about technical design modification and
engineering problem solving and analytical techniques.

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:

 Detailed understanding of plant process parameters.

 Detailed study of all control loops.
 To prepare conversion plan of control loops from manual to DCS.
 To prepare procedure of conversion and supervise the conversion of
control loops. Non critical loops were converted first.
 Educate and give practical training to field operators and particularly DCS
boardmans.
P.E 3.9 Being hired as particularly for conversion of plant operational control from
manual to DCS, my main responsibility was to give suggestions for safe
execution of the project along with training of all related staff. I shared my
previous experience and emergencies I faced during my job in Fauji Fertilizer
Bin Qasim limited. Gave different tips and suggestions for training of staff and
Boardman.
P.E 3.10 First of all I developed the concept of DCS operation amongst the field staff
and Boardman. Gave them the basic theme of control philosophy and
organized meetings with different shift groups. Also conducted attitude
interviews of field operators for training of future DCS Boardman. The main
step was training of other shift engineers as they were the key of project
 success. The all project activates were highly appreciated by higher
management.
P.E 3.11 The main challenge, I faced during the implementation phase of DCS operated
control loops was approach of experienced area operators and Boardman. Due
to their vast experience on manual plant, they were reluctant to accept change
in process controlling. But with the passage of time and introduction of more
approachable and easy controlling features of DCS, they accept the change
and started to enjoy working on the new controlling system.

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.

Utilities Production Units

These units include:
 Two Power generation units with capacity of 07 MW each.
 Raw water treatment facility including raw water storage, clarification,
filtration and demineralization units.
 Cooling water system and cooling towers.
 Nitrogen storage vessel.
 Heating ventilation and air conditioning.
 Steam generation unit.
 Product storage system.
 Instrument Air System

TECHNOLOGY PRESENTED
 The Ammonia plant was designed Kellogg, USA in 1969.

P.E 3.13 Ammonia production unit was constituted as per following hierarchy:

General Manger Plant

Production Manager

Assistant Production Manager

Coordination Engineer
Unit Manager (Ammonia)

* Shift Engineer Shift Engineer Shift Engineer Shift Engineer

A B C D

Shift Boardman 02
Trainee Boardman 02

Operators 06 * Indicate my position in the chart

Trainee Operators
03

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 3.15 Following timely management activities were included in my duties

a) Orientation and safety training 01 week
b) On job training at polymer plant 06 weeks
  Study of area general course 1 week
 Reforming and Steam Generation + PIDs 1 week
 Ammonia Storage + PIDs 1 week
 Compressor section + PIDs 1 week
 Synthesis loop and ammonia converters + PIDS 1 week
 CO2 removal system + PIDs 1 week
c) Independent shift Engineer duties 09 weeks
Total 16 weeks

c) PERSONAL WORK PLACE ACTIVITY

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.

P.E 3.18 The plant contained following major equipments:

 Desulpharization and Hydrogenation vessels
 Natural Gas booster compressor
 Primary Reformer (Furnace)
 Secondary Reformer
 Steam Boiler / Steam Drum
  High Temperature / Low Temperature Shift Converters
 Absorption and Regeneration Tower
 Ammonia Synthesis Gas Compressor
 Ammonia separator vessel
 Ammonia Converter
 Process Air Compressor
 Deaerator
 Refrigeration Compressor
 Condensers
 Methanator
 Centrifugal Pumps
 Steam Turbines
P.E 3.19 Ammonia Production process described here is based on reaction of Hydrogen
with Nitrogen. Ammonia production is accomplished in following sections:

 Desulpharization of Natural Gas

 Steam Reforming in Primary and Secondary Reformer
 Conversion of CO into CO2
 Removal of CO2 by Absorption
 Methenation
 Compression of Synthesis Gas
 Synthesis of Ammonia
 Refrigeration Cycle
 Boiler Feed Water
 Steam Generation

Desulpharization of Natural Gas

 After pressurization of NG (Natural Gas) up to 44 KG/CM 2 (required pressure for

reaction) through positive displacement compressor, the Sulphur compounds are
removed from NG by passing through CO-MO catalyst bed along with addition of
H2 and afterwards ZnO catalyst bed. In CO-MO bed, hydrogenation of Sulphur
compound converts them to H2S and in ZnO bed, H2S is absorbed in catalyst bed.
 Steam Reforming in Primary and Secondary Reformer

 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.

Conversion of CO into CO2

 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.

Compression of Synthesis Gas

 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.

Boiler Feed Water (Deaerator)

 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

 Product Liquid Ammonia from ammonia separator vessel is pumped to Ammonia

Storage Vessel whose capacity was 5000 MT and from storage to urea section
(mostly ammonia was being shifted to urea directly from plant).
 Two compressors were installed at ammonia storage for vapors liquefaction
produced in storage vessel.
P.E 3.20 I worked hard and learnt all plant operations, activities and practices within
short time and started to handle shift duty independently being as Shift
Engineer. I gained much experience in operation of ammonia plant of different
design and control strategy.
P.E 3.21 Being as shift engineer, I performed following responsibilities:
  Provided technical support to plant operation and production
management.
 Investigated diagnosed and recommended correction for technical,
operational problems
 Monitored, controlled process parameters through DCS control system
and supervised trouble shootings.
 Contributed in the plant continuous improvement in health, safety &
environment performance and in potential safety or environmental
hazards identification.
 Developed and prepared operation manuals training materials especially
with reference to DCS, daily / monthly production and inventory reports.
P.E 3.22 Quality conformance to meet the company’s quality management system ISO
at ammonia unit was another major responsibility and 1 monitored/checked
the laboratory test results of samples taken at different sample points of the
plant site and supplied raw materials to ensure the quality of production.
P.E 3.23 During my shift engineer duty, I faced different operational/emergency
situations where I tried to rectify by applying my technical skills/knowledge
and experience at the plant. One situation was, level sensor of Ammonia
separator vessel was failed to transmit its signal/reading to DCS control
system. As there was control loop which controls the level in Reactor and if
level sensor fails to give signals to controller, controller would not be able to
generate its control signals to control valve. This situation could seriously
affect the down stream equipments as high level in the vessel could be resulted
in liquid carry over which could ultimately damage the synthesis gas
compressor or on the other hand, low level in the vessel could be resulted in
high pressure gas break through in low pressure designed piping/vessels. After
considering some alternate actions, I put the separator vessel level on manual
mode and deputed area operator to physically observe the level through sight
glass. Afterward, put the control on by pass valve and rectified the problem in
level transmitter. By doing such in required timely manner, saved the whole
ammonia plant from shutdown. My unit manager and senior management
appreciated me.
P.E 3. 24 During plant emergency shutdown activity due to leakage in secondary
reformer downstream HRSG boiler, I worked along with senior and junior
technical personnel. 1 performed pre shut down activities as:-
 Organized the activities assigned to me with shutdown plan.
 Maintained Nitrogen purge on as long as possible.
 Supervised plant maintenance jobs assigned.
P.E 3. 25 I was assigned the duty to purge out all ammonia vessels for vessel entry
purpose. By doing this activity, I paid special attention with respect to safety.
As Ammonia is very dangerous to exposure through breath and skin contact.
During this clearing procedure, I keenly observed for leakage of ammonia
which Flows, drops into insulation, from lose flange connections, could cause
injury and skin burn on contact.
All these turn round activities were successfully carried out and were well
appreciated by the senior management.
P.E 3.26 I worked with senior people in totally technical and designed environment and
learnt a lot about technical design modification and engineering problem
solving and analytical techniques.

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.

P. E 4.4 The key strength of the company includes;

 Product acceptability in all areas of Pakistan.

 Own Transmission and Distribution network along with compressor stations.
 Quality Customer Services.
 Being in a process of getting ISO 9000-2000 & 14001 certification.
 Only company operating in more than half of Pakistan with no competitor so
far.

P. E 4.5 Company vision & Mission are:-

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.

P. E 4.6 The company is divided itself into four major departments:-

 Projects Department
 Transmission Department
 Distribution department
  Compression Department
 Customer Services Department

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.

P.E 4.7 The Transmission Department in Headquarter is constituted as per

following hierarchy:

General Manager (T)

Chief Engineer (Gas Control)

Executive Engineer (GC)

*Engineer GC Engineer GC Engineer GC Engineer GC

Morning Shift Evening Shift Night Shift On Rest

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).

Following activities are included in my job description:

  Primary responsibility is to maintain continuous flow of Natural Gas
from source up to city gates.
 Continuous monitoring of all gas related parameters like flow,
temperature and pressure etc.
 Continuous monitoring of all gas sources and addition / deletion of
gas sources as per requirement / instruction.
 Coordination with all gas sources and compressor stations on regular
basis in order to identify any preventive actions.
 Emergency handling in case of any compressor station tripping or gas
field tripping.
 Preparation of daily status report i.e. input of gas in the transmission
system and gas delivered distribution department along with
calculation of gas losses (UFG).
 To maintain pressure of gas in transmission network and in case of
pressure drop due to any reason, inform all concerns in order to
curtail gas usage.

c) PERSONAL WORK PLACE ACTIVITY

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.