Introducing Fertilizer Industry Operational Risks Database (FIORDA) Independent Technical Advisors team

Fertilizer Industry Operational Risks Database (FIORDA) is supported by the team of independent technical advisors for Ammonia, Urea, Reliability & Maintenance, Corrosion and Process Safety who review and provide input on specific case studies and technical queries coming from FIORDA members according with their expertise to increase the accuracy of root cause failure identification and corrective recommendations.

FIORDA project is about learning from incidents and changing the “react to failure” culture to “proactively identify work” approach to prevent failures before they occurred. In some cases, the optimisation program involves changes to operating conditions, company internal standards, future project design, maintenance/repair standards and maintenance procedures.

Figure 1 below represents an Optimisation Program Process based on good industry practice [Ref 1] and details the role of FIORDA technical experts’ team and FIORDA company members in this process.

Figure 1. Improvement Program Process

FIORDA technical experts’ team is represented by the following engineers:

Jo Eijkenboom

Mechanical Engineering Urea

Jo Eijkenboom was born in 1950 graduated in Mechanical Engineering. Jo joined Stamicarbon in 1974 as Mechanical Engineer to advise and assist construction and commissioning teams. Improvements of mechanical details of rotating as well as stationary equipment in urea plants from his hands and brains are widely used today.

Practical experience with maintenance and repair of High Pressure Equipment has become Jo’s specialty. Jo grew up with urea and melamine related materials in relation to welding, corrosion, maintenance and troubleshooting.

Jo was one of the founders of Safurex®, the super duplex material applied now the standard in any Stamicarbon urea plant. He retired in 2012 as Vice-President responsible for Equipment and Mechanical Services from Stamicarbon.

After that and since January 2013, Jo started up a company called JO EIJKENBOOM CONSULTANCY BV and became Director of UreaKnowHow.com.

Giel Notten

Corrosion Expert

Giel Notten is a Materials and Corrosion Expert who, before his retirement, spent thirty eight years working with DSM in The Netherlands. After gaining his Chemical Engineering degree he joined DSM Research, where he held several positions as a materials and corrosion expert. Giel was heading the Corrosion Department as Managing Senior Corrosion Engineer.

In this job he was involved in selection of materials of construction for numerous chemical and petrochemical plants as well as other corrosion consultancy activities in these plants.

For Stamicarbon Giel set up programs for lifetime extension studies in urea and ammonia plants and supervised these studies. Giel was also involved in the development of Safurex®, the super-duplex stainless steel grade for application in Stamicarbon urea plants.

He was a board member of NACE Benelux and a member of the Contact Group Corrosion of the Dutch Chemical Process Industry and the Studiekern Corrosion of the Dutch Corrosion Society (NCC).

Since his retirement, Giel started his own company NTT Consultancy and has remained active as a close partner of UreaKnowHow.com.

Giel Notten collected his knowledge and experience, illustrated with numerous cases of corrosion, in a book entitled Corrosion Engineering Guide (ISBN 9789073168299).

Mark Brouwer

Urea Process Advisor

Mark graduated in 1989 at the Technical University of Eindhoven at the faculty of Chemical Engineering. Mark further graduated the postgraduate continuing professional education Safety for Engineers in The Netherlands.

After military service he joined DSM where he worked first seven years as a Process Engineer in an ethylene plant during which he was involved in several turnarounds and revamp projects. In 1996 he joined Stamicarbon as Licensing Manager Urea Revamps. Later he became Manager Stamicarbon Services responsible for all Stamicarbon’s activities in existing urea plants, such as After Sales, Plant Inspections, Debottlenecking Projects, Hardware supply projects etc. In these nearly fifteen years he did visit about one hundred urea plants worldwide and was involved in numerous revamp, relocation, debottlenecking and grass root projects.

Since January 1, 2009, Mark Brouwer left Stamicarbon and started up UreaKnowHow.com. UreaKnowHow.com’s mission is to support, facilitate and promote the exchange of technical information in the urea industry with the target to improve the Safety and Performance of all urea plants worldwide.

Bogdan Brătescu

Reliability & Maintenance Advisor

Bogdan is a maintenance engineer in Fertilizer Industrial Services. He has a wide range of experience gained during the 27 years spent in the field of construction, commissioning, maintenance and operation of Oil & Gas Facilities in Upstream and Refineries and Petrochemical Plants in Downstream.

During these years he held the following positions: Mechanical Supervisor; Maintenance Superintendent; Mechanical Superintendent Construction; Project Engineer; Maintenance Engineer; Operability & Maintainability Coordinator; Head of Maintenance Engineering Department; Shutdown Coordinator; Senior Reliability Engineer; Project Manager, Maintenance Manager; Operation Readiness & Assurance Lead.

In the last 24 years he worked with one of the biggest IOC’s, NOC’s & EPCC’s companies such as Shell, Exxon Mobil, BP, ENI, OMV, Snamprogetti, UHDE GmbH, Technip, NNPC (Nigerian National Petroleum Company, NIOC (National Iranian Oil Company, NOC (Libyan National Oil Company), SOCAR (Azerbaijan National oil Company).

Liviu Oroviceanu

Ammonia Process Advisor

Liviu Oroviceanu has over 17 years of experience in Engineering and Operation of Ammonia and Methanol technologies.
His experience cover projects like:

  • tkis Uhde Arabia Ltd. Umm Wu’Al Phosphate Project, Ammonia Plant;
  • tkis Uhde ENPC Project OMV-Petrom Asset II Gas – Development;
  • UHDE GmbH Fertil 2 Project;
  • UHDE GmbH Ma’aden I & II Ammonia Project;
  • UHDE GmbH MOPCO Ammonia Urea Project;
  • UHDE GmbH SAFCO IV Ammonia Project;
  • PETROVIETNAM -Phu-My-Ammonia Plant
  • Romanian National Oil Company as Process Engineer for Methanol and Ammonia Plant

Involved in Engineering, Commissioning and Operation of the new ammonia facilities, he coordinates the process design as well as preparation and review of data, diagrams (PFD’s and P&ID’s), documentation, reports and schedules required to support engineering and construction, commissioning and turnover of major projects.

Alex Toma

Engineering, Guidelines and Procedures development

Alex Toma is Ammonia Process Specialist with a total of 20+ years’ experience in Process/Project Implementation, Pre-Commissioning, Commissioning and Troubleshooting. His expertise includes Engineering, Design, Procurement, Pre-commissioning/ Commissioning, Start-up and FAT, Turn-Over and Warranty.

He started his career as Field Operator in ammonia plant, moving through commissioning and startup as well as engineering and design activities. Alex is working with Fertilizer Industrial Services as Ammonia Process Consultant involved in multiple projects in Europe and Asia.

Alex is responsible with embedding FIORDA case studies experience and lesson learned in guidelines and procedures developed for the fertilizer industry operators.

Dan Cojocaru

Process Safety Advisor

He has over 16 years of engineering and consultancy experience in fertilizer and gas projects from the following countries: Australia, Germany, Vietnam, UAE, Saudi Arabia, Romania and Russia, and was involved in design for projects developed in countries like Egypt, Algeria, Slovak Republic and China.

Dan started his career as Field Operator in Ammonia plant, following by DCS Operator and Supervisor. He gains an extensive experience in engineering and process safety consultancy services to EPCM companies and their clients including the preparation of Safety Reports, hazard identification and analysis, consequence and risk modelling of major accidents.

He has experience in all project phases starting from Concept and Front-End Engineering (FEED) through Commissioning and Operation. Dan also provides advice and process safety input to various safety studies such as Hazard Identification (HAZID), HAZOP, Layers of Protection Analysis (LOPA), 3D model review, design review and Simultaneous Operations (SIMOPS) during the project lifecycle.

Dan is responsible for FIORDA project development and represent the interface between FIORDA member companies (operators) and Technical Assessment team.

Donald Law

Senior Process Safety Engineer (Consequence Modelling)

Donald is a Senior Process Safety Engineer with over 13 years of experience in safety engineering and consultancy. His experience covers the offshore and onshore oil and gas industries providing expertise services such as, but not limited to, fire and gas consequence analysis, quantitative risk analysis, production availability assessment, ALARP demonstration, and safety case / report development.

Donald has a MEng in Chemical Engineering and he is Chartered Member of IChemE. His key skills are in area of: Dispersion Analysis, Fire and Explosion Analysis (FEA), Quantitative Risk Assessment (QRA), Fault Tree Analysis (FTA), Reliability Availability and Maintainability (RAM) Analysis, Flare Radiation Analysis, Structural Survivability Calculation and other Formal Safety Assessment associated studies.

Donald has performed numerous safety studies for various onshore and offshore facilities in Australia and Saudi Arabia, which include studies such as FEA, Sour Gas Dispersion Study, Escape Muster Evacuation and Rescue Analysis (EMERA), and QRA, Safety Equipment Layouts, Fire Fighting Foam Requirement Calculations, and Safety Equipment Datasheets.

Donald has performed multiple RAM analysis to assess and optimise the availability and reliability of production systems to maximise Life Cycle Profit for various facilities. These facilities include heavy oil production using Steam Assisted Gravity Drainage (SAGD) process located in Alberta, Canada, and Crude oil transport pipeline located in Alberta, Canada, through to Texas, USA.

 

References:

  1. Michael P. Broadribb, C.Eng., F.I.Chem.E., Senior Principal Consultant, Stephen Wheeler, Principal Consultant, Baker Engineering and Risk Consultants – “How Many Process Safety Engineers does it take to Change a Culture?“ IChemE Hazard 25 Safety Symposium 2015
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