Review of MT 2024

Performance Review of Assistant Manager (Designate) – 2023-24
Ammonia Complex – UC (2-Year Overview)
Key Job Roles and Technical Responsibilities:

1. Front End (Field) Engineer:
• Periodic Inspections: Conducted comprehensive field inspections across the Front-End Section,
including primary reformers, fired heaters, steam boilers, and associated rotating equipment
(e.g., pumps, blowers, fans, turbines). Ensured operational integrity and compliance with
standard operating procedures (SOPs).
• Field Technicians Supervision: Led and coordinated work with field technicians during both
routine and emergency situations, ensuring compliance with safety and operational protocols.
• Critical Equipment Monitoring: Continuously monitored key equipment, such as the

Reformer/Fired Heater Furnace, Boiler Systems, and Rotating Equipment (pumps, fans, blowers,
turbines), tracking performance metrics like pressure, temperature, and flow rates.
• Emergency Coordination: Acted as a liaison between the control room and field technicians
during equipment upsets or emergency situations, facilitating corrective actions to restore
operations.
• Shift Log Maintenance: Documented critical operating parameters, incidents, and deviations,
providing real-time feedback to the control room for effective troubleshooting and process
optimization.
2. Synthesis (Field) Engineer:
• Routine Field Inspections: Regularly inspected equipment in the Synthesis Section, with a focus
on the loop boilers and compressor systems (e.g., K421, K431, K441). Ensured that equipment
functioned within the prescribed limits.
• Rotating Equipment Monitoring: Oversaw the operation of critical compressors (K421, K431,
K441), turbines, pumps, and blowers. Managed vibration, temperature, and pressure readings,
ensuring all parameters were within operational limits.
• DM Plant Monitoring: Actively monitored the Demineralized (DM) Water Plant for correct
storage, backwash, and regeneration cycles of ion-exchange vessels, ensuring water quality met
process requirements.
• Effluent Treatment Oversight: Inspected the effluent treatment plant to verify that the effluent
parameters were within prescribed regulatory limits. Ensured that the effluent monitoring
system performed to standard and initiated corrective actions as required.
• Shift Log Documentation: Logged critical field parameters, performance anomalies, and
maintenance activities, providing detailed reports for trend analysis and future process
improvement.
3. Synthesis (Control Room) Engineer:
• Process Control: Managed the Synthesis Section process from the control room via the
Distributed Control System (DCS), ensuring smooth operations and compliance with safety and
performance standards.
• Parameter Monitoring: Continuously analyzed real-time data on graphical screens to ensure

critical process parameters (temperature, pressure, flow rates) remained within the optimal
operating range. Identified and addressed any deviations promptly.
• Compressor Monitoring: Focused on real-time performance analysis of compressor units (K431,

K441) via the Woodward control panels, using trend analysis and condition monitoring
techniques to assess system health and predict maintenance needs.
• Lab Data Integration: Monitored lab analysis for critical feedstock and product quality, including
converter inlet (IN) analysis, DMW/ BFW, effluent, and cooling water quality. Took corrective
actions in case of any anomalies or deviations from process specifications.
• Shift Log Documentation: Systematically recorded shift activities, key operational parameters,
incidents, and any deviations, maintaining a comprehensive log for future analysis and
operational transparency.
4. Start-up Activities:
• Compressor Start-up: Facilitated the start-up of key compression systems, including the K431 and
K441 compressors, through the Woodward control panel. Managed the safe initiation of
extraction steam systems and compressor loading sequences.
• Process System Line-ups: Coordinated and executed line-up activities for critical process systems
such as the Synthesis Loop and Recovery Section. Ensured all systems were prepared for
operation with all valves, vents, and instrumentation correctly set up.
• Condensate Stripper: Managed the startup of the Process Condensate Stripper, ensuring proper
pressure and temperature profiles for efficient separation.
5. ATA Activities (2024):
• Pipeline Modifications: Contributed to the PV217 line modification and R202 vent line renewal,
performing detailed assessments and design modifications to improve system reliability and
performance.
• RLA (Remaining Life Assessment): Supported the RLA study of critical equipment such as the RG
Boiler, Steam Drum, and Loop Boiler. Provided data on component life expectancy, analyzing
corrosion rates, wear patterns, and pressure vessel integrity.
• Dry Ice Cleaning of Reformer Exchangers: Led the dry ice cleaning process for primary reformer
flue gas exchangers, enhancing heat exchange efficiency and extending the operational lifespan
of critical components.
• Inspection and Maintenance: Conducted detailed inspections and assessments of the primary
reformer, secondary reformer (catalyst), CO2 absorber, and flue gas ducts, ensuring proper
function and addressing potential issues before they affected plant operations.
• K204 Overhaul & Heat Exchanger Maintenance: Managed K204 compressor overhaul, including
disassembly, component inspection, and reassembly. Coordinated tube cleaning and tube
plugging activities in heat exchangers, improving heat transfer efficiency and reducing the risk of
mechanical failure.
• Trim Heater Replacement: Oversaw the installation of a new trim heater as part of equipment
upgrades, ensuring compliance with process requirements and maintaining system efficiency.
Summary of Technical Competencies:

• Process Monitoring and Control: Extensive experience in DCS, Woodward control systems, and
real-time data analysis for process optimization and troubleshooting.
• Mechanical Equipment Expertise: Proficient in the operation, troubleshooting, and maintenance

of high-pressure compressors, turbines, boilers, heat exchangers, and rotating machinery.
• System Line-up and Start-up Procedures: Deep understanding of the safe and effective start-up
of critical process systems, including compressors, synthesis loops, recovery sections, and
condensate strippers.
• Maintenance & Overhaul Experience: Hands-on involvement in overhauls, repairs, and the
implementation of maintenance strategies for key plant components like heat exchangers,
reformers, and compressor systems.
• Effluent and Water Treatment Systems: Strong background in ensuring effluent quality and
managing DM water plant operations, crucial for maintaining compliance with environmental
regulations.
Conclusion:
The role involved a mix of field engineering, control room operations, start-up management, and
maintenance activities. The work required expertise in plant systems, proactive monitoring of
operational parameters, and effective coordination between the field and control room. Contributions to
ATA activities and system modifications have led to increased reliability, performance, and compliance
with operational standards.

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Review of MT 2024

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Performance Review of Assistant Manager (Designate) – 2023-24

Ammonia Complex – UC (2-Year Overview)

Key Job Roles and Technical Responsibilities:

• Critical Equipment Monitoring: Continuously monitored key equipment, such as the

2. Synthesis (Field) Engineer:

• Parameter Monitoring: Continuously analyzed real-time data on graphical screens to ensure

• Compressor Monitoring: Focused on real-time performance analysis of compressor units (K431,

5. ATA Activities (2024):

Summary of Technical Competencies:

• Mechanical Equipment Expertise: Proficient in the operation, troubleshooting, and maintenance

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