Engineer Operation

POSITION SUMMARY

Purpose

Reporting to the Sr. Plant Manager, shift engineer is responsible for the day-to-day shift operation of the 2 SMRs, ASU, Syngas and integrated gas turbine plants based on the Air Products Kochi Plant and ensuring shift operating teams operate the plants safely and efficiently to facilitate attainment of the company’s standards.  

Reporting to the Plant Manager, the shift engineer will ensure the smooth and reliable operation of all the operating units of the Air Products Kochi facility.

Nature and Scope

The Kochi Plant is Air Products first fully owned and operated plant in India; it represents a significant investment and includes “State of the Art” technology which makes it the most advanced Hydrogen Plant within the Corporation.

The plant consists of 5 main elements: -

• 2 x Large Technip Steam Methane Reformers (SMR) with Air Products PSA’s for H2 purification.
• An 18 MW Kawasaki Gas Turbine, integrated with both reformers.
• An Air Products Air Separation Unit (ASU) Producing Nitrogen and Oxygen.
• Amine System for CO2 removal (aMDEA)
• Cryogenic separation and purification of CO.

The customer is Bharat Petroleum Corporation Ltd. (BPCL), Kochi refinery and the Air Products plant is located within the customer’s site. The products from the Air Products plants go directly to the customer as part of their refinery expansion. There is a high level of integration between BPCL and Air Products with respect to feedstock’s, products and utilities. The products are critical to refinery unit operations.

The plants run on continuous basis and there is a strong emphasis of high reliability and high efficiency with contractual penalties against Air Products for underperformance.

Air Products owns, operates and maintains Hydrogen Plants and ASUs around the globe with Operations in over 50 countries, in excess of 80 hydrogen plants and 350 ASUs. As such we have a wealth of expertise and have well established work processes in place for the reliable and efficient operation of our plants.

DIMENSIONS

Plant Products (Approximate):

H2:                               16        t/h                   

H2:CO:                         14        t/h                   

N2:                               10,000 Nm3/h  

O2:                               160       Nm3/h

Power:                          18        MW

Number of Direct Reports (approximate): NIL. He shall be one of the 4 shift engineers who work in shifts of 8 hours duration.

PRINCIPAL RESPONSIBILITIES

• A high regard for the safety of self and others.
• Understand and have working knowledge of Air Products EH&S systems processes including emergency preparedness and incident management.
• Responsible for the day-to-day operation of the HYCO plant in 8-hour shifts, including troubleshooting plant process problems, directly supervising daily plant activities and reporting to management. The Shift Engineer is required to be able to start up, shut down or put the process into a safe position, escalating any abnormal situations to the PM.
• Work alongside the Operations shift team to ensure adequate continuous operating cover, and additional cover if required in case of unplanned situations, start up and operation, ensuring 24-hour stable operation.
• Identifying maintenance concerns and bringing it to the notice of the Plant Management promptly and then coordinating with the maintenance team and implementing corrective / preventative measures.
• Working with other Shift Engineers and support resources to achieve productivity targets.
• Facilitate the use of, and compliance to AP EH&S standards such that EH&S performance continually improves, and performance targets are met. Issue permits, ensure logout tag out to facilitate hand over and take back equipments as per the safety protocol. Control maintenance activities associated with the process of plant equipment. Understand various safe systems of work that are important to safe plant operation.
• Capability to implement emergency plans or react to abnormal situations in a measured and proactive way.
• Report production daily and generate daily production reports and other plant related reports as is required by the plant management.
• Maintaining CW, BFW parameters as stipulated and ensure monitoring of the parameters including doing analysis of a few critical parameters like pH, conductivity etc.
• Shall coordinate with the customer BPCL regarding product requirements and ensuring communication protocols during normal and plant emergency situations.
• Ensure that the plant emissions and effluent are in accordance with the Air Products requirements and ensure proper communication with the plant management for all plant requirements.
• Issue permits related to confined space, hot work and all areas of safety after going through proper safety training as will be provided based on the company’s training program.