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DSHCV 2016 March

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Duncan Hugall
Duncan Hugall

Duncan Stuart Hugall is a chartered process engineer with over 30 years of experience in process design, operations, commissioning, and technical support roles. He has significant experience managing projects and teams internationally. His career highlights include managing the construction and commissioning of nylon and compounding plants in Saudi Arabia and providing technical support to various petrochemical plants in the UK and Saudi Arabia.

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DUNCAN STUART HUGALL 5, Range Villas, Mill Lane, Whitburn, SR6 7ES, United Kingdom | +44 (0)7753 191975 dshugall@engineer.com EXECUTIVE SUMMARY I am a broadly experienced chartered process engineer, with a proven track record in providing technical design, investigation, and support services to both project and plant teams. I have significant experience and competence in process safety system design and management, relief and blowdown systems design, and all aspects of FEED and detailed design package generation (including but not limited to process simulation and process equipment design). I have significant experience managing operations, commissioning, and technical support of complex projects, including working in and managing multinational teams on several international projects. I also have significant experience of conceptual design (including of lab-scale rigs and experimental program design / execution). I have worked in the UK and abroad, managing and developing engineers in a multi-cultural / national workplace. CAREER HISTORY PCC Ltd, Jubail, Kingdom of Saudi Arabia Aug 2011 to Nov 2015 Nylon Plant Superintendent, Nylon Technical Superintendent I initially worked as the owner’s representative on the detailed design team, before moving to recruit, establish and manage the commissioning and operating teams working on the Nylon and Compounding Plants (including a shared waste water treatment facility) as the Plant Superintendent. Reporting directly to site General Manager, I managed 75 personnel, and handled a budget of $250,000,000. Until July 2014 I was the only dedicated western operational / technical resource for the Nylon and Compounding plants. From July 2014 onwards I worked as the Lead Process Engineer focussed on providing technical support to plant operations, and establishing all process safety management systems and procedures. I was responsible for providing all technical support to the plants, as well as recruitment and development of all technical engineering personnel. I was first responder for all technical queries from both project and operating teams. My main achievements in these roles were;  Led hazard studies on all significant plant modifications.  Managed the Plant Modification control system.  Proactively checked all relief system designs, identifying several issues requiring attention. I designed and specified the new relief stream devices / equipment; all issues were rectified before plant start-up and did not affect the project critical path.  Proactively checked Heat and Mass Balances for the main process and all utility systems.  Proactively checked detailed designs for all pump / exchanger duties (including s/u and s/d conditions).  Proactively identified a significant process safety issue that would have impacted upon plant operation. I played a prominent part in redesigning the system to make it safe, with the issue being rectified prior to plant commissioning resulting in the commissioning schedule being unaffected.  Administered implementation of the Mechanical Integrity of Critical Equipment (MICE) program of work.  Operationally managed the operating team throughout the construction and cold commissioning phases, with zero accidents or incidents being recorded (in a multi-national, and inexperienced team).  Generated and managed budgets for Nylon and Compounding plants. Jacobs Engineering, Glasgow, UK Sep 2005 to Jul 2011 Principal Process Engineer, Process Consultant Led process engineering activities for a variety of EPC projects covering crude oil storage tanks, pipelines, pigging stations refurbishment. Managed FEED to detailed design for a variety of onshore projects. These
included an onshore underground gas storage wellhead refurbishment, a FEED package to convert change natural gas dehydration from TEG to absorbent technology, a detailed design for underground gas storage expansion (build caverns/expand processing plant), a FEED package for new carbon fibre manufacturing line and detailed design support for refinery turnaround work packages and other associated projects. I was responsible for;  Liaising with clients to identify areas for optimization to improve production throughput, utilities usages, and equipment performance. Regularly analysed key process trends; translated findings into actionable recommendations. Worked closely with operations, maintenance, quality control, procurement, project engineering and finance to scope, develop and execute improvement projects.  developing process safety related documentation for key projects (for example, PFDs, heat & mass balances, P&IDs, HAZOP, area classification reports, relief and blowdown, cause & effects matrix, alarm rationalization, etc.).  process modelling, including models of phased developments on operating sites (how they would impact on process operations and utility usages). Identifying improvement opportunities to either save capital or increase capacity/efficiency. DuPontSA, Teesside, UK Apr 2005 to Aug 2005 Lead Process Engineer This company manufactured pure Terephthalic Acid (PTA) on multiple plants around the world. The company had a project to build one new PTA plant. An EPCM company produced the detail design ISBL package for the core PTA plant. I was recruited to produce an OSBL package for building the plant in Teesside on a brownfield site. Reporting to the Project Director, I was responsible for; • developing a Utilities OSBL FEED package for the core PTA plant design at Wilton site, • all process safety studies (HAZOP, Area Classification, Relief and Blowdown, Cause & Effects Matrix, Alarm Rationalisation, siting and layout studies, etc.), My main achievements in this role included; • liaising effectively with both ISBL and site teams to deliver a robust, accurate OSBL Utilities detailed design package (P&ID’s, H&MB’s, equipment datasheets, etc.). • delivering the completed package ahead of schedule to the required quality. DuPont / Invista Nylon, Teesside, UK Apr 2002 to Mar 2005 Lead Process Engineer This company manufactured multiple Petrochemical products on a single site, with the objective of producing a wide range of Nylon products. Reporting to Site Technical Manager, I was responsible for; • supporting installation and commissioning of a modern DCS based control system on two Nitric Acid plants (replaced original pneumatic controllers), • developed FEED package for replacement of the operational Site Cooling Tower, while minimising disruption to operational plants, • designed an upgraded Batch Nylon Reactors relief system, then managed the installation, commissioning, and handover to operations. • managed HMDA Isotank loading trial, then produced all trial (modified) operating and laboratory procedures, updated P&ID’s, held Hazard Studies and drove PSSR review action items to closure. Commissioned and operated the export facility, then wrote report containing recommendations on what permanent changes should be made, • worked as Commissioning Engineer on the Nylon KA Plant following major redesign of the process. My main achievements in this role included; • Nitric Acid DCS commissioned and fully operational on schedule, • Running a successful HMDA export trial, which generated a report and recommended design that facilitated a successful permanent modification.
Ibn Rushd, Yanbu, K.S.A Aug 2000 to Mar 2002 Process Engineering Supervisor This company manufactured multiple Petrochemical products on a single site in Yanbu, Saudi Arabia. There I managed the process engineering support to the Aromatics and PTA world scale plants, and all their associated utility plants (including waste water treatment plant). Reporting to the Site Engineering Manager, I managed a multi-national team of five young engineers. I was responsible for; • ensuring the team worked safely wherever they were, • developed team capability to provide a professional support service to the operating team. • provided strategic direction to development / capability of the technical support team, • supported all commissioning and operating activities across both plants and their utilities, • Lead all hazard studies and process safety investigations, My main achievements in this role included; • successfully commissioned the PTA and all Utility plants. • completed detailed investigation into major process safety incident, identifying the root cause, ICI Chemicals & Polymers, Teesside, UK Jul 1989 to Jul 2000 Senior Process Engineer This company manufactured multiple Petrochemical products on multiple sites, with a large centralised process engineering design group. I initially worked as Process Development Manager attached to several plants where my duties were focussed on process optimisation and operational support. I then transferred to the central Process Engineering Group attached to the PET and PTA businesses, where I initially focussed on developing new process technologies, before moving onto detailed design support and commissioning of new PET plants. Reporting to the Process Engineering Section Head for PET Plastic, I managed a design team of five young engineers. I was responsible for; • managed the identification and execution of all development work on the plants I was attached to, • managing the quality and timely delivery of all process engineering output to both the project and operating teams, • coordinating commissioning support for two world-scale PET plants, followed by the support provided to the operating team to commission / initially operate these plants. My main achievements in this role included; • developed an innovative, conceptual PET chemical recycling process which was used by the business to benchmark all future recycling proposals, • successfully commissioning / operating two world-scale PET plants. • debottlenecked the cold end of a Paraxylene plant resulting in 50% increase in throughput with no impact upon product quality, • developed cleaner, more efficient, inherently safer TA Oxidation process (which was patented), • designing, installing, and commissioning of a modified control system on catalyst addition in a Petroleum Resins plant. This change produced an order of magnitude improvement in the accuracy of catalyst addition, resulting in significant Improvements to both product quality and plant operating margins. Cleveland Iron, British Steel Corporation, Teesside, UK Sep 1984 to Jun 1989 Blast Furnace Shift Foreman, Ironmaking Technologist This company manufactured Pig Iron and Ferromanganese on one of two Blast Furnaces, and had a short period of two years producing Basic Iron on both furnaces at maximum capacity, while a local modern large Blast Furnace was relined. Reporting to the Blast Furnace manager, I managed a shift of 22 operators responsible for operating both Blast Furnaces simultaneously. I later transferred to the Coke Ovens as Ironmaking Technologist, where part of my duties included ;
• Monitoring the quality of process water being recycled back to the plant, • Maintaining the utility plant efficiencies (systems included seawater cooling, water cooling, compressed air, gas cleaning, storage and recycling, etc.) • Efficient operation and use of energy EDUCATION, EXPERTISE AND PROFESSIONAL QUALIFICATIONS Academic Qualifications BSc (Hons) Degree Chemical Engineering Newcastle University, UK Jul 1984 Professional Organizations Consultant Chemical Engineer: Saudi Council of Engineers (registration number 216980) – Mar 2015 Chartered Chemical Engineer: Institution of Chemical Engineers (member number 222275) - Mar 1993 Chartered Engineer: UK Engineering Council (registration number 448018) – May 1993 Software Proficiency Aspen Plus; HYSIS; Microsoft Office (Excel, Word, Powerpoint, Access, Visio and Project); Microsoft Dynamics; AutoCAD; Navisworks Professional Development Courses Process Safety Management Best Practice (ABB) Edinburgh Nov 2013 Full UK Driving Licence Full Saudi Arabia Driving Licence British Citizen Born : Sunderland, UK Date : 01 Oct 1960 REFERENCES AVAILABLE ON REQUEST

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DSHCV 2016 March

  • 1. DUNCAN STUART HUGALL 5, Range Villas, Mill Lane, Whitburn, SR6 7ES, United Kingdom | +44 (0)7753 191975 dshugall@engineer.com EXECUTIVE SUMMARY I am a broadly experienced chartered process engineer, with a proven track record in providing technical design, investigation, and support services to both project and plant teams. I have significant experience and competence in process safety system design and management, relief and blowdown systems design, and all aspects of FEED and detailed design package generation (including but not limited to process simulation and process equipment design). I have significant experience managing operations, commissioning, and technical support of complex projects, including working in and managing multinational teams on several international projects. I also have significant experience of conceptual design (including of lab-scale rigs and experimental program design / execution). I have worked in the UK and abroad, managing and developing engineers in a multi-cultural / national workplace. CAREER HISTORY PCC Ltd, Jubail, Kingdom of Saudi Arabia Aug 2011 to Nov 2015 Nylon Plant Superintendent, Nylon Technical Superintendent I initially worked as the owner’s representative on the detailed design team, before moving to recruit, establish and manage the commissioning and operating teams working on the Nylon and Compounding Plants (including a shared waste water treatment facility) as the Plant Superintendent. Reporting directly to site General Manager, I managed 75 personnel, and handled a budget of $250,000,000. Until July 2014 I was the only dedicated western operational / technical resource for the Nylon and Compounding plants. From July 2014 onwards I worked as the Lead Process Engineer focussed on providing technical support to plant operations, and establishing all process safety management systems and procedures. I was responsible for providing all technical support to the plants, as well as recruitment and development of all technical engineering personnel. I was first responder for all technical queries from both project and operating teams. My main achievements in these roles were;  Led hazard studies on all significant plant modifications.  Managed the Plant Modification control system.  Proactively checked all relief system designs, identifying several issues requiring attention. I designed and specified the new relief stream devices / equipment; all issues were rectified before plant start-up and did not affect the project critical path.  Proactively checked Heat and Mass Balances for the main process and all utility systems.  Proactively checked detailed designs for all pump / exchanger duties (including s/u and s/d conditions).  Proactively identified a significant process safety issue that would have impacted upon plant operation. I played a prominent part in redesigning the system to make it safe, with the issue being rectified prior to plant commissioning resulting in the commissioning schedule being unaffected.  Administered implementation of the Mechanical Integrity of Critical Equipment (MICE) program of work.  Operationally managed the operating team throughout the construction and cold commissioning phases, with zero accidents or incidents being recorded (in a multi-national, and inexperienced team).  Generated and managed budgets for Nylon and Compounding plants. Jacobs Engineering, Glasgow, UK Sep 2005 to Jul 2011 Principal Process Engineer, Process Consultant Led process engineering activities for a variety of EPC projects covering crude oil storage tanks, pipelines, pigging stations refurbishment. Managed FEED to detailed design for a variety of onshore projects. These
  • 2. included an onshore underground gas storage wellhead refurbishment, a FEED package to convert change natural gas dehydration from TEG to absorbent technology, a detailed design for underground gas storage expansion (build caverns/expand processing plant), a FEED package for new carbon fibre manufacturing line and detailed design support for refinery turnaround work packages and other associated projects. I was responsible for;  Liaising with clients to identify areas for optimization to improve production throughput, utilities usages, and equipment performance. Regularly analysed key process trends; translated findings into actionable recommendations. Worked closely with operations, maintenance, quality control, procurement, project engineering and finance to scope, develop and execute improvement projects.  developing process safety related documentation for key projects (for example, PFDs, heat & mass balances, P&IDs, HAZOP, area classification reports, relief and blowdown, cause & effects matrix, alarm rationalization, etc.).  process modelling, including models of phased developments on operating sites (how they would impact on process operations and utility usages). Identifying improvement opportunities to either save capital or increase capacity/efficiency. DuPontSA, Teesside, UK Apr 2005 to Aug 2005 Lead Process Engineer This company manufactured pure Terephthalic Acid (PTA) on multiple plants around the world. The company had a project to build one new PTA plant. An EPCM company produced the detail design ISBL package for the core PTA plant. I was recruited to produce an OSBL package for building the plant in Teesside on a brownfield site. Reporting to the Project Director, I was responsible for; • developing a Utilities OSBL FEED package for the core PTA plant design at Wilton site, • all process safety studies (HAZOP, Area Classification, Relief and Blowdown, Cause & Effects Matrix, Alarm Rationalisation, siting and layout studies, etc.), My main achievements in this role included; • liaising effectively with both ISBL and site teams to deliver a robust, accurate OSBL Utilities detailed design package (P&ID’s, H&MB’s, equipment datasheets, etc.). • delivering the completed package ahead of schedule to the required quality. DuPont / Invista Nylon, Teesside, UK Apr 2002 to Mar 2005 Lead Process Engineer This company manufactured multiple Petrochemical products on a single site, with the objective of producing a wide range of Nylon products. Reporting to Site Technical Manager, I was responsible for; • supporting installation and commissioning of a modern DCS based control system on two Nitric Acid plants (replaced original pneumatic controllers), • developed FEED package for replacement of the operational Site Cooling Tower, while minimising disruption to operational plants, • designed an upgraded Batch Nylon Reactors relief system, then managed the installation, commissioning, and handover to operations. • managed HMDA Isotank loading trial, then produced all trial (modified) operating and laboratory procedures, updated P&ID’s, held Hazard Studies and drove PSSR review action items to closure. Commissioned and operated the export facility, then wrote report containing recommendations on what permanent changes should be made, • worked as Commissioning Engineer on the Nylon KA Plant following major redesign of the process. My main achievements in this role included; • Nitric Acid DCS commissioned and fully operational on schedule, • Running a successful HMDA export trial, which generated a report and recommended design that facilitated a successful permanent modification.
  • 3. Ibn Rushd, Yanbu, K.S.A Aug 2000 to Mar 2002 Process Engineering Supervisor This company manufactured multiple Petrochemical products on a single site in Yanbu, Saudi Arabia. There I managed the process engineering support to the Aromatics and PTA world scale plants, and all their associated utility plants (including waste water treatment plant). Reporting to the Site Engineering Manager, I managed a multi-national team of five young engineers. I was responsible for; • ensuring the team worked safely wherever they were, • developed team capability to provide a professional support service to the operating team. • provided strategic direction to development / capability of the technical support team, • supported all commissioning and operating activities across both plants and their utilities, • Lead all hazard studies and process safety investigations, My main achievements in this role included; • successfully commissioned the PTA and all Utility plants. • completed detailed investigation into major process safety incident, identifying the root cause, ICI Chemicals & Polymers, Teesside, UK Jul 1989 to Jul 2000 Senior Process Engineer This company manufactured multiple Petrochemical products on multiple sites, with a large centralised process engineering design group. I initially worked as Process Development Manager attached to several plants where my duties were focussed on process optimisation and operational support. I then transferred to the central Process Engineering Group attached to the PET and PTA businesses, where I initially focussed on developing new process technologies, before moving onto detailed design support and commissioning of new PET plants. Reporting to the Process Engineering Section Head for PET Plastic, I managed a design team of five young engineers. I was responsible for; • managed the identification and execution of all development work on the plants I was attached to, • managing the quality and timely delivery of all process engineering output to both the project and operating teams, • coordinating commissioning support for two world-scale PET plants, followed by the support provided to the operating team to commission / initially operate these plants. My main achievements in this role included; • developed an innovative, conceptual PET chemical recycling process which was used by the business to benchmark all future recycling proposals, • successfully commissioning / operating two world-scale PET plants. • debottlenecked the cold end of a Paraxylene plant resulting in 50% increase in throughput with no impact upon product quality, • developed cleaner, more efficient, inherently safer TA Oxidation process (which was patented), • designing, installing, and commissioning of a modified control system on catalyst addition in a Petroleum Resins plant. This change produced an order of magnitude improvement in the accuracy of catalyst addition, resulting in significant Improvements to both product quality and plant operating margins. Cleveland Iron, British Steel Corporation, Teesside, UK Sep 1984 to Jun 1989 Blast Furnace Shift Foreman, Ironmaking Technologist This company manufactured Pig Iron and Ferromanganese on one of two Blast Furnaces, and had a short period of two years producing Basic Iron on both furnaces at maximum capacity, while a local modern large Blast Furnace was relined. Reporting to the Blast Furnace manager, I managed a shift of 22 operators responsible for operating both Blast Furnaces simultaneously. I later transferred to the Coke Ovens as Ironmaking Technologist, where part of my duties included ;
  • 4. • Monitoring the quality of process water being recycled back to the plant, • Maintaining the utility plant efficiencies (systems included seawater cooling, water cooling, compressed air, gas cleaning, storage and recycling, etc.) • Efficient operation and use of energy EDUCATION, EXPERTISE AND PROFESSIONAL QUALIFICATIONS Academic Qualifications BSc (Hons) Degree Chemical Engineering Newcastle University, UK Jul 1984 Professional Organizations Consultant Chemical Engineer: Saudi Council of Engineers (registration number 216980) – Mar 2015 Chartered Chemical Engineer: Institution of Chemical Engineers (member number 222275) - Mar 1993 Chartered Engineer: UK Engineering Council (registration number 448018) – May 1993 Software Proficiency Aspen Plus; HYSIS; Microsoft Office (Excel, Word, Powerpoint, Access, Visio and Project); Microsoft Dynamics; AutoCAD; Navisworks Professional Development Courses Process Safety Management Best Practice (ABB) Edinburgh Nov 2013 Full UK Driving Licence Full Saudi Arabia Driving Licence British Citizen Born : Sunderland, UK Date : 01 Oct 1960 REFERENCES AVAILABLE ON REQUEST
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