Aspen Plus
Youssef E. (CPEng-NER-MIEAust)
Process Engineer, Ammonia, Nitric Acid, Ammonium Nitrate, ANEmulsion
Summary
Ingenious Process Engineer with more than 15 years of experience, tirelessly seeks operational improvements and detects performance weaknesses. Dedicated to expanding throughput and reducing unnecessary project waste. Eager to wring every drop of performance from available budgets and resources.
Overview
15
15
years of professional experience
5
5
years of post-secondary education
2
2
Languages
Work History
Process Engineer, Engineering and Reliability
INCITEC PIVOT LIMITED
04.2022 - Current
- Evaluated proposed project economics and identified alternative solutions and designs producing improved results.
- Created process simulations to test operational outcomes without causing service disruptions.
- Met weekly with team members to discuss project implementations and alleviate any issues.
- Participated in project reviews to enable ongoing status tracking and reporting.
- Reviewed processes, identifying areas requiring improvement.
- Provided technical assistance to production team when issues arose.
- Developed documentation, diagrams, and specifications to meet project requirements and regulatory standards.
- Managed third-party contractors, inspecting completed work and ongoing efforts to confirm quality and adherence to prescribed guidelines.
- Conducted root cause analysis to identify, prioritize and eliminate process losses.
- Collaborated with technologists to address operating issues and support rapid recovery.
- Established clear measurable goals and objectives for projects, prioritizing tasks for team members.
- Developed and maintained test and evaluation strategies for testing to show operational readiness and suitability with planned project decision points.
- Provided solutions to various technical problems of varying scope and complexity.
- Created comprehensive test plans, test scripts, and use cases to support testing objectives.
Ammonia plant DCS operator, Process Engineer
Incitec Pivot Limited
04.2020 - 04.2022
- In addition to operating ammonia plant, my daily duties include initiating plant optimization and performance improvement, perform risk assessment and initiate and Implement plant modification with direct collaboration with Engineering & Reliability department
- Create and review operating procedures
- Initiate control system logic improvements and follow up implementation plans
- Investigate long term plant issues and propose corrective solutions
- Define Process Operating and design limits based on plant risk studies and document related actions and response plans.
- Prepared scope of work documentation for use in project planning
Process Specialist
Allnex Resins
12.2017 - 04.2020
- Responsible for processing product batch cards
- Focus on precise raw material preparation as a critical factor of batch processing
- Lab testing of product compliance with quality standards
- Preparation of chemical charges as per formulation
- One recent key achievement has been the proposal and implementation of many modification to plant procedures and equipment.
- Collaborated with team to define business requirements for organizational processes, achieve productivity standards, and adhere to accuracy standards.
- Performed quality assurance checks on transactions and account actions to assess compliance with state and federal regulations.
- Identified and resolved process issues to drive optimal workflow and business growth.
- Conducted training and applied change management to achieve desired outcomes.
- Developed production techniques and production processes to meet customer and organizational needs.
- Offered data-driven recommendations to align company strategies and process improvement initiatives.
Operations Engineer
QAFCO, Qatar Fertilizers Company
11.2011 - 05.2017
- For 7 years as part of my QAFCO tenure, I attended the construction and commissioning of a 2200 TPD Ammonia plant, then, continued as a part of the operations team
- I have participated in all commissioning operation activities related to ammonia process and utilities including process and catalyst evaluation, safety, quality and environment auditing, technical report writing, performance evaluation, process modification and mentoring trainees to achieve the training outcome
- As well, due to the high complexity of Ammonia manufacturing process, I was exposed to a variety of process equipment and techniques
- Control ammonia plant parameters and conduct essential process tweaks to ensure steady operation and highest production yield
- Drafted and updated operations and maintenance manuals to correspond to owned hardware and software assets within overseen equipment.
- Completed walk-downs and on-site inspections during equipment installations and change management phases.
- Performed operational design reviews to determine feasibility and budgetary impacts of new proposals.
- Provided independent technical reviews of operational procedures and plans to eliminate functional bottlenecks.
- Conducted evaluations of equipment and machinery to verify optimal performance and efficiency.
- Response to plant upsets and participate in the investigation in plant abnormal incidents such as loss of power, instrument air, cooling water.
- Communicate effectively with field technicians while performing process parameters modification or equipment maintenance activity
- Revise operating procedures/instructions and recommend operational changes
- Develop plant technicians' knowledge by guiding them through daily routines and field actions during plant upsets
- Continuously, review and evaluate process condition and practices and their compliance with standard operating procedures and limits
- Assist shift superintendent to train process plant technicians and coach them during their probation period
- Perform safety, quality and environment walk downs, list out observation and take proper corrective actions
- Replace shift superintendent as an incident commander during emergencies and perform all required actions including communication with relief command, emergency center, fire brigade and first aiders
- As well, to manage plant emergency operation and trade activities
- Act as an auxiliary emergency member with a monthly training of Emergency procedures and practical emergency actions such as Fire Fighting, Casualty Rescuing, Ammonia Tight Suit in action and SCBA (Self-Contained Breathing Apparatus)
- Prepare procedures for catalyst regeneration, reduction, loading, unloading and start up
- Advices optimum plant operation by considering safety, quality, operation and economics
- Participate in long-term studies to improve and enhance plant performance and to resolve major plant problems
- Review/update alarms and Emergency Shut Down System ESD, checklists, plant drawings, Control Valve sheets, and process-related data at regular intervals
- Performs comprehensive monitoring of catalyst in use
- Recommends any process changes in the plant operation to the contact Engineer, which will improve the catalyst cycle, increase profitability, and improve safety and reliability of the unit
- Provide necessary technical advises
- Evaluate major/chronic unit problems and recommend economical and safe solution based on inspection findings
- Keep record of operational units history especially new projects and developments, which have been implemented
Commissioning Engineer
QAFCO, Qatar Fertilizers Company
03.2010 - 11.2011
- I joined QAFCO on 26th March 2010 as a commissioning team member for the construction and commissioning of a 2200 MTD Ammonia plant where I was responsible for:
- As the operation department representative, I successfully delivered the trip alarm data and scenarios required for the implementation of the dynamic alarm management project
- Managed daily reports from different disciplines and trades and wrote the major shutdown report for plant documentation
- Coordinated with technical liaisons and construction team members to address technical issues for meeting project requirements.
- I was assigned as Safety representative during Qafco 5 major shut down in which I delivered daily reports and statistics of safety performance and proudly participated in the safest shutdown in qafco history
- I have proposed and created the calculation sheets of a reformer convection bank temperature profile to improve energy consumption
- Prepared proposals for modifications of facilities, control & safety schemes and process operating parameters to enhance safety, reliability and process performance
- Carried out detailed plant checkout against PFD, P&ID, rotating equipment installation
- As well, I ensured equipment preservation procedures were implemented
- Prepared equipment list, lube oil flushing schedule and marked up system scope P&Ids
- Preparation of line diagrams, data sheets, utilities summaries
- Participated in risk assessment
- Also, reviewed operations manual and write-up, standard operating procedures and on time project completion.
Process Engineer
Delta Fertilizers Company
EGYPT
2009 - 2010
- Read and interpreted blueprints, technical drawings, schematics, and computer-generated reports.
- Interacted with subject matter experts to develop training material and tools for personnel.
- Wrote, reviewed and edited technical document in accordance with template requirements.
- Trained and mentored competent and flexible workforce to meet project needs and promote positive work environment.
Education
Bachelor of Science - Petroleum refining and Petrochemical Engineering
Suez Canal University
Suez, EGYPT 07.2003 - 07.2008
Skills
Engineering
Software
SAP
Microsoft 365
System Auditor
Timeline
Process Engineer, Engineering and Reliability
INCITEC PIVOT LIMITED
04.2022 - Current
Ammonia plant DCS operator, Process Engineer
Incitec Pivot Limited
04.2020 - 04.2022
Process Specialist
Allnex Resins
12.2017 - 04.2020
Operations Engineer
QAFCO, Qatar Fertilizers Company
11.2011 - 05.2017
Commissioning Engineer
QAFCO, Qatar Fertilizers Company
03.2010 - 11.2011
Process Engineer
Delta Fertilizers Company
2009 - 2010
Bachelor of Science - Petroleum refining and Petrochemical Engineering
Suez Canal University
07.2003 - 07.2008
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