Ashok Gunapache

• Used coordination and planning skills to achieve results according to schedule.
• Inter department Co-ordination, Man-hour estimation, Manpower Planning.
• Supervise, Guide, and Train team of 10 to 40 engineers working on multiple projects.
• Prepare project specific Stress Analysis Design criteria, load cases as applicable.
• Prepare Critical Line list and Stress system formation.
• Stress analysis of lines running on Pipe Rack, Column Re-boiler, Tall tower Piping, Different type of Pumps piping, Air Cooler, PSV, Flare header analysis, Double Stack exchangers, Blowers, Compressors, Turbines, Heaters, API 650 Storage Tank, Dynamic Analysis (Modal analysis), Two phase flow analysis, Cryogenic / Refrigerant piping analysis, Piping associated to Module / Skid etc.
• Stress analysis for Underground piping, Non-metallic piping like GRP / FRP.
• Nozzle load qualification using WRC107 / Nozzle Pro software.
• Flange leakage qualification using Caesar II Module / ASME and Pressure Equivalent method.
• Qualification of piping attachments like Shoe, Saddle, Dummy legs, etc.,
• Preparation of Standards like Work Instruction, Pipe Support standards.
• Review of Tower bracket Schedule, Equipment Spring, Line Spring specification, Slide plate, Expansion joint Specification, Specials like Strut etc.,
• Review MR / TBA for piping specials like Springs, Slide plate, Expansion joints, etc.,
• Field Exposure in trouble shooting of stress analysis work.

Projects handled in Petrofac Engineering Services:

I was worked as Lead Engineer Piping Stress on Vedanta Limited (CAIRN OIL & GAS) – (Development of Integrated Gas Surface Facilities for Raageshwari Deep Gas Field), Barmer, Rajasthan, India. (Green Field & Brownfield)

Project : Thai Oil Refinery: CFP (Clean Fuel Project)

Client : THAI OIL Private Company (Thailand).

Units: SWS, SRU, HCR & Interconnecting Pipe Rack.

I was worked as a Lead Engineer Piping Stress for Al Taweelah Alilumina Refinery (Abu-Dhabi) with Bechtel Petrofac Joint Venture (BPJV).

I have handled 25 members stress team.

Project Name: Al Taweelah Alumina

Capacity : 2 MTPA – Smelter grade Alumina

(Refinery Construction in 3 phases-Each 2 MTPA; total of 6 MTPA)

Project Scope: Refinery Phase-1: 2 MTPA Greenfield Alumina Refinery

BPJV- Bechtel /Petrofac Emirates LLC Joint Venture

Feasibility Study, Execution Design, Procurement & Construction

(EPCM services reimbursable)

Adaptation of Yarwun2 Alumina Refinery, Gladstone, Queensland

Client /Owner: Emirates Global Aluminium (EGA) (First Venture into Alumina Refinery)

Locations : Jobsite: Al Taweelah, Khalifa Industrial Zone, Abu Dhabi, UAE (KIZAD)

(Adjacent to EMAL Aluminium Smelter)

Feasibility Study locations: Brisbane and Al Taweelah

Pre-Feasibility Study: Pre-Feasibility Study: SNC Lavalin & Hatch JV

Raw Material Source: Bauxite: Compagnie des Bauxites de Guinea (CBG), Africa

Technology Partners:

HOT (Hatch Outotec JV) Technology License & Engineering for Tube Digestion

(Scope includes Digestion, Condensate Storage and Acid Preparation)

RTA (Rio Tinto Alcan International Ltd.) Technology, Process design & Operations Input

(Validation of Scope, PFDs for process area, Process Guarantees, Operational readiness)

Project : KNPC CFP-2020 MAB1 (Clean Fuel Project)

Client : Kuwait National Petrochemical Company.

Responsibilities:

• I have worked as a Deputy Lead Piping Stress & ICPR U-148 (interconnecting Pipe Rack)
• Quality Assurance & Quality Check of KNPC project. For HCR (U-114, 214 & 314) CCR (U-127) & ICPR (U-148)
• Interface Co-ordination with CBI, Samsung, Fluor & MEC.
• Co-ordination with JV partners and MAB-2 contractor.
• To follow all relevant Group Procedure and Departmental Working Instructions in the engineering of piping systems.
• To check internal pipe support drawings.
• To lead groups of designers and draftsmen on specific projects.
• To follow all applicable and relevant legislation, standards and codes in piping engineering.
• To answer general queries arising from clients, contractors or internal Company departments on pipe work aspects of the Company’s systems.
• To attend and contribute to internal Company / departmental / project meetings when required.
• To investigate and report on piping failure or underperformance on the Company’s products.
• To attend the model design review.

Project : Jamnagar Gasification Complex

Client : Reliance Industries Limited

Location : Reliance Jamnagar Refinery, Gujarat, India.

Responsibilities:

• I was worked as a Area Lead Piping Stress of Unit SWS (Sour Water Stripper 1 & 2) and Open Arts
• Drove operational improvements which resulted in savings and improved profit margins.
• Worked flexible hours across night, weekend and holiday shifts.
• Developed team communications and information for meetings.
• Resolved problems, improved operations and provided exceptional service.

Project : YANBU EXPORT REFINERY PROJECT

Client : SAUDI ARAMCO

Responsibility :

I have hands-on experience in analyzing critical piping systems of FEED project and detailed Engineering like pumps, turbines, compressor, Air Cooler and other high pressure / temperature piping arrangement including jacketed piping systems.

· Conduct 3D model review with client & process licensor using PDMS design review & PDS Smart Plant Review.

· Checking of stress documentation & pipe supports.

· Prepare, Monitor & Control project schedule for piping discipline.

· Responsible for carrying out all detail engineering activities related to piping engineering in Petrochemical and Refinery projects.

Project Description : Guangdong 20 MMTPA Heavy Crude Oil Refinery Project

Front End Engineering Design (FEED) 3.7 MMTPA Hydrocracking units.

Client : Petro China – PDVSA

Project : BEWW Twin Platform Topsides Modification Project. (Offshore)

Client : Chevron Offshore Thailand Ltd. (COTL)

Responsibility :

• Responsible for carrying out all detail engineering activities related to piping engineering in Oil & Gas, Offshore platform.
• Prepare, Monitor & Control project schedule for piping discipline.
• Man-hour estimation for piping discipline.
• Co-ordination with other disciplines & client.
• Preparation & checking of Equipment layout.
• Preparation & checking of piping layout support GA, nozzle orientation & isometrics.
• Conduct 3D model review with client & process licensor using PDMS design review & PDS Smart Plant Review.
• Checking of stress documentation & pipe supports.
• Technical Bid Evaluation & vendor drawing approval for piping items.

Project : Gorgon LNG Plant, Barrow Island, Australia

SALIENT FEATURES OF THE PLANT

- This is a turnkey project involving detailed engineering, procurement. & Construction of a

- Plant done on 3-D PDMS system and stress analysis done on Caesar-II ,Ver. 5.1

Responsibility:

• Co-ordination with other disciplines & client.
• Conduct 3D model review with client & process licensor using PDMS design review.
• Checking of stress documentation & pipe supports.
• Worked on onshore LNG project as well as offshore projects.
• Carryout Stress Analysis of piping systems for Oil & Gas plants and support engineering.
• Review of the piping systems using CAESAR-II software package, post process the results, optimize the system on stress criteria and code compliance.
• Suggest any layout changes in compliance with the code, Stress limits and system level requirements.
• Develop specifications for special supports including spring hangers.
• Lead the team on support engineering and development of final support construction drawings.
• Well documentation of design work.

Responsibility : Lead Engineer Piping Stress

Project : Mumbai High North (MHN) Project (Offshore)

Client : Oil and Natural Gas Corporation Limited, Mumbai

SALIENT FEATURES OF THE PLANT

• This is a turnkey project involving detailed engineering, procurement. & Construction of a Plant done on 3-D PDS system and stress analysis done on Caesar-II ,Ver. 5.1
• Piping involves CS, SS Piping, Steam, and FRP Services.
• Air Cooler, Heat exchanger, Compressor Piping.
• Checking of Stress Analysis for the offshore process/ utility lines by meeting stringent process requirements.
• Stress analysis of complicated systems, which includes Bridge Piping, Compressors and Air Coolers etc.
• Close interaction with mechanical department for nozzle loads.
• Slug Flow Calculation, Flange Leakage Evaluation, and Transportation case Calculation.
• Prepare, Monitor & Control project schedule for piping discipline.
• Co-ordination with other disciplines & client.
• Interaction with Vendor for skid tie-in connection.

Project : Platong Gas II Development Project (Offshore) Central Processing Platform.

Client : Chevron Thailand Exploration and Production

SALIENT FEATURES OF THE PLANT

• This is a turn key project involving detailed engineering, procurement. & Construction of a
• Plant done on 3-D PDMS system and stress analysis done on Caesar-II ,Ver. 5.1
• Number of lines in Project: 2000 nos.
• Piping involves CS, SS Piping, Steam, and Hydrogen Services, Tower Re-Boiler Piping, Air Cooler, Heat exchanger, Compressor Piping.
• Bridge connected lines and flare system.

Project : Saudi Kayan Petrochemical Complex – SK Olefins Plant

Description : Ethylene, Propylene and Benzene unit.

Client : Saudi Kayan, Al-Jubail Saudi Arabia

SALIENT FEATURES OF THE PLANT

• This is a turnkey project involving detailed engineering, procurement. & Construction of a 1,350,000 tons per Annum (1350KTA) ethane butane cracker (olefins plant )for the production of Polymer grade ethylene, Propylene, benzene & associated by-products derived from ethane & butane feedstock’s.
• Number of lines in Project: 20000 nos.
• Number of lines in handled area: Approx.700 nos.
• Number of equipment in handled area: 60 nos.
• Piping involves CS, SS, Alloy Steel, LTCS Piping, Steam, High Temperature / High Pressure and Hydrogen Services.
• Tower Re-Boiler Piping, Series of heat exchanger, Reactor, Compressor and Turbine Piping,

Project: Qatar Gas LNG Projects.

Job Description and Responsibilities:

• Stress Analysis of LNG rundown, Thermal Bowing, High pressure/ high temperature process/ utility lines by meeting stringent process requirements.
• Study of stress concentration of overstressed pipe WRC 107 and WRC 297 methods.
• Stress analysis of complicated systems, which includes Fired Heaters, Compressors and Air Coolers etc.
• Preparation of critical line list.
• Close interaction with mechanical department for nozzle loads /pipe clips on process critical equipment’s.
• Preparation and issue of data sheets for springs, sliding plate etc.
• Wind and Seismic analysis of critical systems.

Organization Profile : Chemtex is an independently managed subsidiary of Gruppo M&G, Italy. A full service-engineering partner, Chemtex has engineering procurement & construction management expertise in manmade fibers, Polymer, Carbon black, Refining operations & Petrochemicals. The company engages in designing of polyester Plants with Dupont Technologies.

• Basic and detailed Piping engineering related to various fields of Chemical technologies, mainly Dupont Polyester, Petrochemical, Oil and Gas, Pharmaceutical, Chemical, Refinery and Carbon Black etc.
• Working with Caesar-II 4.5, 5.0 and CAE pipe.
• Good communication, analytical and interpersonal skills.
• Ability to work independently and in a team as well.

Job Description and Responsibilities:

Description: Working as Lead Engineer Piping Stress for the Detail Engineering of the project.

Job Responsibilities:

• Responsible for all Stress and Support related activities.
• Ensure work carried out per Procedures and Design Basis.
• Establish the Contract Design Data and Design Philosophy.
• Issue Stress and Support Design note.
• Establish Stress Critical Line List.
• Stress Group Progress Reporting, Man-hours allocation and Forecast.
• Raise the Change order to reflect additional work.
• Supervise Stress and Support activities.

Projects Details:

1. Client: M&G POLYMEROS BRASIL S.A., (BRASIL)

Project Brief: 1500 TPD PET PLANT ESTRILA (Largest pet plant in the world)

Technology: Dupont

2. Client: GARDEN SILK MILLS LIMITED, SURAT

Project Brief: 480 TPD POLYESTER MELT/CHIP PRODUCTION PLANT Technology: BARMAG (Germany)

3. Client: HANGZHOU BAY ACRYLIC FIBER CO., LTD

Project Brief: 60,000 TPA Acrylic Fiber plant

Technology: Faserwerke Lingen (Germany)

4 Client: Chengold NG-3. CHINA

Project Brief: EPC (750 TPD Bottle Grade Polyester Plant)

Technology: Dupont (NG)

5. Client: Hangzhou Xiangsheng Textile Co. Ltd., CHINA

Project Brief: 900 TPD Textile Grade Polyester Plant

Technology: Dupont

Project: Amir Kabir LLDPE olefin project.

Responsible for all Stress and Support related activities.

• Ensure work carried out per Procedures and Design Basis.
• Establish Stress Critical Line List.
• Supervise Stress and Support activities.

Job Responsibilities :

• Carry out Flexibility analysis.
• Identify all the load cases to be considered in analysis.
• Review Study Drawing to ensure sufficient flexibility in critical piping.
• Identify and review all critical piping supports.
• Summaries Equipment Nozzle Loading communicates to others.
• Perform flange leakage calculation for high-pressure piping.
• Communicate critical support loading to civil.
• Identify requirement of reinforcement pad due to stress consideration.
• Decide on position of fixed saddle of horizontal Heat Exchanger and Vessels.
• Review vendor data regarding nozzle loading etc.
• Documentation of Analysis reports.

Project Details:

1) Client: Lyondell Chemicals Netherlands, Rotterdam

Project Brief: 118000 TPA (Butanediol Plant)

Technology: Lyondell Chemicals

2) Client: ATOFINA, Antwerp

Project Brief: 200,000 TPA (Polyethylene Plant)

Technology: ATOFINA

Project : M/s. Indian Oil Corporation Ltd. (DHDS Plant - Mathura Refinery)

Checking of Piping Layout drawings and AFC Isometric drawings, Civil & mechanical information drawings, Preparation of Piping Specifications, Generation of MTO reports and lists for pipes, fittings, valves and other on-line items, Review of Vendor Drawings & Documents and Vendor Co-ordination, Pipe Stress Analysis using Caesar-II version 4.1, Caepipe 3.72.

Project - M/s. Hindustan Petroleum Corporation limited.

Preparation & finalization of routing of pipelines through existing unit by taking actual measurements & design pipe supports. Preparation of MTO and checking of Piping Isometric drawings.

Stress Analysis

Worked on CAEPIPE Version 3.72/3.74 to carry out stress analysis of critical lines.