CV Dynamic Simulation Engineer UniSim Design / HYSYS & ASPEN Plus Honeywell Automation India

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CV/Resume ID no.: 115401

Total work experience of 7 years with 5.5 years in Steady State & Dynamic Process simulation with expertise in Operator Training Simulators.

Dynamic Simulation Expertise with UniSim Design / HYSYS
 Fluid package selection & fine-tuning
 Distillation, Absorption, Stripping & Liquid-Liquid extraction columns
 Centrifugal & reciprocating compressors & pumps
 Shell & tube exchangers, Kettle type exchangers, Fired Heaters.
 Two phase-Three phase separators
 Relief Valves, Control valves ,Solids modeling
 Reactors: FCC, Unionfining, Platforming, Isomer, Tatoray, LLDPE polymerization.

A) Present Employer : Honeywell Automation India Limited, SP infocity ,Saswad Road,Pune,India.
Industry Type : Controls & Automation
Technology : Design of Operator Training Simulator (OTS).
Duration : 09th Apr 2007- 08 Nov 2010 (Relieving date from Honeywell India)
Designation : Project Lead
Job Profile as a Project Lead at Honeywell
• As a Project lead & owner of the project, responsible for successful project management.
• Leading the Project Kick-Off meetings for finalizing scope of the OTS & assessing the input database required for the design of OTS.
• Preparing the “Functional Design Specification” describing scope, process modeling approach, assumptions, customized & detailed dynamic modeling areas, & deliverable OTS hardware system.
• Developing Fluid package (Property Estimation method) & preparing the steady state model in UniSim (HYSYS).
• Preparing the dynamic process model for the critical sections & troubleshooting the problems in dynamic simulation for the entire scope of the project.
• Working with other front offices for Research & development of new simulation modules.
• Responsible for independently handling the model acceptance tests (MAT) between the Honeywell & Client. Resolving the deviations identified during MAT to meet the client’s expectations from the OTS model.
• Responsible for leading the DCS & ESD integration phase of the OTS design.
 Overcoming the challenges in emulating the Non-Honeywell DCS & ESD systems.
 Detecting & rectifying the mistakes found in the ESD, DCS in the received database.
 Emulating the third party ESD logic in Honeywell supported ESD systems.
• Responsible for independently handling the Factory Acceptance Test (FAT) & Site Acceptance Test (SAT) of OTS to deliver it up to the clients level of expectation. Responsible for overall quality of the project & on schedule delivery.
• Responsible for delivering the OTS Instructor & System administrator training to the client to demonstrate the effective utilization of the OTS.
• Also responsible for delivering advanced training courses on TRICONEX, EPKS,UnisSim Design, UniSim Operations.
• Responsible for efficient utilization of the resources .Motivating team members to achive objectives. Allocating Manhrs to the team involved in the project & tracking weekly progress.
• Maintaining the level of skills within the team by delivering classroom training, share & learn sessions & on job training.
• To serve as a technical consultant to answer the queries in other ongoing OTS projects.


Training delivered to the domestic & international clients while in Honeywell

Client Place Duration Training content Date
KPPC(EQUATE) Kuwait 10 days UniSim Design,UniSim Operations,EPKS,TRICONEX May-09
Borouge, OCU Abu Dhabi 7 days UniSim Operations,EPKS Nov-09
IOCL Panipat, India 5 days UniSim Operations,TRICONEX Aug-10
Reliance Jamnagar,India 12 days UniSim Design,UniSim Operations,Foxboro,TRICONEX Sep-10


Projects Executed at Honeywell as a Project Lead

1) Operator Training Simulator for IOCL, India

OTS Project Technology Responsibility in project Client Completion
SWING LLDPE Nova Chemicals Project Lead IOCL, Panipat, India Aug-10

It was a Green Field OTS project. The project scope covered the Nova Chemical’s SWING LLDPE process based on a solution phase reaction system using cyclohexane as the solvent.
The plant has four areas.
Reaction area where the reactants (i.e., ethylene, hydrogen, Butene and Octene) are dissolved in recycled solvent and catalytically polymerized. Catalyst residues in the solution are deactivated and then the resin is separated from the solvent, unreacted monomers and comonomers and impurities.
Recycle area where the unreacted ethylene and impurities are separated from solvent and comonomers which can then be recycled. Ethylene column has a propylene refrigeration system for condenser.
Finishing area where the polymer product is palletized, devolatized and prepared for packaging
Utilities area includes the flare knock-out drums, hot nitrogen systems, steam systems, Dowtherm (DTA) fired heater systems.

The complete dynamic simulation was done in UniSim Design & UniSim Operations. The project involved development of new ZN reactor simulation modules within UniSim.
Rigorous dynamic testing of the newly developed reactor was a major challenge besides high pressure process modeling & Extruder modeling & solids modeling.

It was an emulated OTS project. All the YOKOGAWA DCS, Triconex ESD and other PLCs from ABB, JSW, and GSBI were emulated in UniSim Operations.

2) Operator training simulator for KPPC, Kuwait

OTS Project Technology Responsibility in project Client Completion
Aromatics Complex UOP Project Lead KPPC(EQUATE),Kuwait Mar-09

It was a Green Field OTS project. The project scope covered the UOP Naphtha Unionfining, CCR Platforming,Xylenes Fractionation,Parex ,Isomar, Benzene Toluene Fractionation ,Tatoray & Shell Sulfolane Process.
The complete dynamic simulation was done in UniSim Design & UniSim Operations. The project involved development of new simulation modules within UniSim by UOP .Rigorous dynamic testing of the newly developed modules was a major challenge besides volume of the process modeling.

It was a Direct connect OTS project with ExperionPKS DCS & Triconex ESD.The entire project took more than 1.5 year with more than six months project execution at site in Kuwait.

Awards & recognitions: The KPPC project team received the Team Award in recognition of a high degree of team spirit & hard work. This project was also published as one of the most successful Green Field OTS projects by Honeywell with high level of customer satisfaction & hence is a bench mark to the on-going OTS projects.

3) Processes modeled in other projects:
 UOP Fluid catalytic cracking process Unit
 Refinery simulation and feedstock characterization. Experience of modeling Crude, Vacuum Unit
 Hydrotreater

B) Previous Employer: Reliance Industries Limited, MIDC Kurkumbh, Dist: Pune.
Industry Type : Refining & Petrochemicals
Technology : Manufacture of MEG, licensor: Scientific Design
Manufacture of ethylene from Ethanol, licensor: Petron
Duration : 20th Jan 2005- 02 Apr 2007
Designation : Manager Central Technical Services department.
Job Profile:
• Performing feasibility & conceptual studies using ASPEN Plus. Preparing steady state simulation model for petrochemical processes in Reliance & crosschecking suggested process modifications using ASPEN plus.
• Develop specifications for process equipments & instrumentation. Prepare Heat and material balances, process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), system design parameters and design or rating of equipment such as vessels, towers, exchangers, and pumps.
• On the engineering side work on major improvement/debottlenecking efforts, from developing improved designs for the process, evaluating new technology.
• Lead and support projects as necessary. Prepare cost/benefit analyses, project planning, implementation, and post-implementation monitoring and follow-up.
• Answering technical inquires. Review projects and correspondence for technical accuracy and clarity. Review & approve vendor technical quotations
• Analyze process data for performance & deviations. Identify opportunities and contribute to the development of solutions for quality, yield, efficiency, safety , & reliability to improve plant economics
• Responsible for providing technical support to operations, developing and designing process enhancement projects

Major projects executed:
Prepared steady state engineering study model in ASPEN plus for EO-MEG (Technology: Scientific Design) plants at Reliance Kurkumbh & Reliance Gandhar complex.
Executed debottlenecking project for Reliance Kurkumbh plant in consultation with Sulzer India.

C) Previous Employer: Alkyl Amines Chemicals Limited, MIDC Kurkumbh, Dist: Pune.
Industry Type : Amines & specialty chemicals
Technology : Manufacture of H2 by steam reforming of Methanol, licensor: Mahler
Duration : 01st Oct 2003-19th Jan 2005
Designation : Process Engineer

Job Profile:
• Plant monitoring for production of H2 & hydrogenation reactions for manufactures of Amines. Analyze process data for performance & deviations. Give improvement suggestions & participate in modifications. Prepare cost/benefit analysis.
• Develop specifications for process equipments & instrumentation.
• Preparing piping and instrumentation diagrams (P&IDs) for new units.
• Prepare necessary reports for management review.

Professional qualification: Bachelor of Technology in Chemical Engineering.

Academic Record: (Education equivalent to qualifications in United Kingdom as per UK NARIC)

Course Duration Institute Result
MBA 2009-2010 Karnataka State Open University, India Awaited
B.Tech 1999-2003 LIT, Nagpur University, Maharashtra State, India 69.27%
HSSC Mar-99 Amravati Board, Maharashtra State, India 85.17%

• Excellent hands on experience in Dynamic Process simulation using UniSim Design/HYSYS. Executed Greenfield & Brownfield operator training simulator engineering projects in, Refinary, polymers and Petrochemicals domain.
• Excellent Knowledge of UniSim Design /HYSYS & ASPEN Plus steady state process simulation.
• Excellent hands on experience in DCS & ESD. Sound knowledge in design of control philosophy. Executed Direct Connect operator training simulator projects integrating EPKS, FOXBORO, and TRICONEX. Executed emulated operator training simulator integrating YOKOGAWA DCS, & ABB, JSW, GSBI – (Govoni Sim Bianca Impianti ) PLCs.

Delivered several trainings to domestic & international clients on UniSim Design, UniSim Operate, EPKS, and TRICONEX.Also coaching and development of junior engineers in a team.
Effective communication, organizational and leadership skills.