WORK EXPERIENCE REPORT

PRESENTED TO

THE NIGERIAN SOCIETY OF ENGINEERS (NSE)

BY
xxxx
MSc Process Systems Engineering, BSc Chemical Engineering

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE ADMISSION

AS A CORPORATE MEMBER OF THE NIGERIAN SOCIETY OF ENGINEERS
(NSE)

APRIL, 2017
 ATTESTATION
I certify that the information contained in this report is, to the best of my
knowledge, the true practical experience of BENDER JOHN.

NAME .....
SIGNATURE......
DESIGNATION.....
DATE...

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 Contents
ATTESTATION ................................................................................................................................................... i
SUMMARY ....................................................................................................................................................... ii
1.0 PROFESSIONAL WORK EXPERIENCE .................................................................................................... 1
1.1 Experience with Nigerian National Petroleum Corporation (NNPC), Warri Refining and
Petrochemical Company (WRPC), Ltd, Ekpan Warri. (Sept 2012 Present) ............................... 1
1.2 Experience with Citytech (Subsidiary of Honeywell ACS) (Oct. 2011 July. 2012).. ...................... 4
1.3 Experience with Willsark Engineering Services, Yaba, Lagos (March 2008 Sept 2008) ............... 5
1.4 Experience with Delta Afrik Engineering Limited, Victoria Island, Lagos State (Aug. 2005 Jan.
2006) ............................................................................................................................................... 7
1.5 Experience with Sunplast Industry, Oshodi, Lagos State (September November, 2004). ........... 9
2.0 QUALIFICATIONS AND COURSES ATTENDED ...................................................................................... 8
2.1 Education with Qualifications Obtained ......................................................................................... 8
2.2 Courses Attended with Dates ......................................................................................................... 8
2.3 Professional Membership ............................................................................................................... 9
2.4 Projects and Publications ................................................................................................................ 9
2.5 Technology ...................................................................................................................................... 9
3.0 CONCLUSION ....................................................................................................................................... 9

SUMMARY
This is a work experience report that provides the required background and experience
information about me. Specifically, it highlights the various roles (with dates) I have

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played in all the positions I have taken since I graduated in 2006 and also during my
internship in school. It also gives the details of some of the important publications and or
projects I have done.

My six-month industrial training in DeltaAfrik Engineering Limited provided me with the

first opportunity to see the application of chemical engineering principles I learnt in the
class room to solving engineering problems. I was introduced to the application of Process
Engineering simulators such as Aspen HYSYS, Flarenet and Pipesys in process design.
After, my graduation from the University, I also worked in Nigerian National Petroleum
Corporation, Willsark Engineering Services Ltd, and City Technology to consolidate my
experience in the field of chemical engineering.

Presently, I am a trainee Process Engineer in Warri Refining and Petrochemical Company

Limited (WRPC, a subsidiary of Nigerian National Petroleum Corporation, NNPC),
Ekpan-Warri. Delta State. My professional development in WRPC has provided me with
experience in plant optimization, plant operation, process safety, plant and equipment
monitoring and plant preservation among several exposures.

In my eight years of practice in various engineering roles, I have gained experience in the
process model development, process simulation, process optimization, plastic/polymer
production technology, plant operation, and process safety.

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 1.0 PROFESSIONAL WORK EXPERIENCE
1.1 EMPLOYER;
Nigerian National Petroleum Corporation (NNPC), Warri Refining and
Petrochemical Company (WRPC), Ltd, Ekpan Warri.
Core business of the Company: NNPC is an integrated oil and gas company that is
tasked with the responsibility of harnessing Nigerias potential hydrocarbon resources for
the benefit of all Nigerians and other stakeholders.

Warri Refining & Petrochemical Company Limited (WRPC) is one of the strategic business
units of the NNPC that designed to process 125,000 barrels (de-bottlenecked capacity) of
crude oil per stream day. The processing units are Crude Distillation Unit (CDU), Vacuum
Distillation Unit (VDU), Fluid Catalytic Cracking Unit (FCCU), Catalytic Reforming Unit
(CRU), Kero Hydrotreating Unit (KHU), Gas plant, Naphtha Hydrotreating Unit (NHU),
Hydrofluoric Acid Alkylation Unit (HFAU), Carbon Black Plant (CB) and Polypropylene
Plant (PP).

PERIOD OF EMPLOYMENT; Sept 2012 Present

POSITION HELD; Process/Chemical Engineer (on-the-job training)
RESPONSIBILITY;

Supervised the preparation of process equipment such as process line draining,

steaming out and valve isolation for maintenance jobs.
Carried out blending operations to achieve the desired product specifications for
market
Prepared daily and monthly plant activities report for PP, CB and oil movement
pump-houses.
Involved and participated in the commissioning of recycle gas compressor in CRU.
Monitored running sets of equipment for abnormal noise & overheating, ensuring all
are properly and duly lubricated.
Supervised & involved in the commissioning of heaters (lighting of pilot/main
burners).

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 Ensured good housekeeping in the plant and compliance to HSE
procedures/regulations.
Involved in elimination of product leakage from process equipment e.g. flanges etc
Supervised the elimination, insulation and cladding of heat exchanger in NHU.
Commissioned low-pressure & medium-pressure steam and other utilities to the
units.
Supervised gas leak tests to detect leaks and subsequent elimination of such, if
detected, in the process plant.
Participated in valve stroking to ensure that pneumatic valves are functioning
properly.
Supervised most maintenance work carried out in the Area 100 of the Polypropylene
plant.
Participated in routine preservation activities carried out in the polypropylene plants.
Involved and participated in truck loading of polypropylene rich feed in PP.
Involved in propylene receipt in to bullets in PP.
Participated in the plant study of PP.
Participated in various fire prevention activities such as servicing and recycling of
fire extinguishers, routine check on various hydrant pillars in operating areas etc.
Carried out routine ambient monitoring of particulate, noise level, and toxic gases in
production areas.
Carried out the lighting of the flare (Y930), after lining up the main and pilot line of
Propylene from the storage tank (D110) to the flare stack.
Carried out leak or/and pressure tests on different process equipment upon
completion of maintenance work by the Maintenance department.
Carried out routine checks around tank farm for possible leakages or process failures
around tanks or pipelines and suggested how such anomalies can be corrected.
Was involved in the bi-hourly monitoring of storage tanks during inter-tank
transfers or during truck loading to ensure the target levels are not exceeded.
Complied with HSE rules, regulations, procedures and practices in-house and in
process monitoring activities

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MAJOR CHALLENGES ON THE JOB AND SOLUTION PROFERRED;
Failure of pumps to discharge. Strainers of such were cleaned of any
entrainments/clogs.
Steam failure. Emergency shut-down of the plant was carried out.
Power surge. All electric motors were quickly switched off and switched back on.
Low quality steam. Condensate was drained from the steam until steam became
dried.
Vibration of electric motor of pump. Motor casing dislodged to check that bearings
are in place. Damaged bearings were replaced, while displaced ones were adjusted.
Cavitation of pumps. Ensured that liquid being pumped was not at or close to its
boiling point. Pumps got properly primed and put back in service.
Inability of Medium Pressure (MP) steam to get to the top of C102A/B,
troubleshooting helped to discover that there was a blind in one of the pipes which
wasnt removed after a maintenance job was completed.
EXPERIENCE GAINED;
Operation and troubleshooting of different process equipment such as Heat
exchangers, distillation columns, compressors, reactors etc.
Knowledge of the start-up and shutdown procedures of some critical process
equipment in the Fluid Catalytic cracking Unit (FCCU) and Polypropylene
Plant.

1.2 EMPLOYER;
City Technology (Subsidiary of Honeywell Technology), Portsmouth, UK
Core business of the Institution: City Technology was founded in 1977 by four City
scientists, John Finbow, Brian Hobbs, Tony Tantrum and Robert Chan Henry whose work
focused on exploitation of novel oxygen sensing technology developed by City's Wolfson
Institute for Electrochemical Technology.
The young company developed the galvanic oxygen sensor, the technology that can be
used in industry to monitor potentially dangerous conditions arising from oxygen
deficiency or excess.
City Technology now leads the global market in the development, design and manufacture
of innovative gas sensors and sensing technology employed in safety critical gas detection
equipment.

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.
With a range of more than 300 products detecting 28 different gases and a growing
number of facilities in Europe, the USA and Asia Pacific, City Technology is the number
one choice for sensing technology.

City Technology has won a host of prestigious prizes, including the coveted Queens
Awards for Technological Achievement, Technology and Export Achievement.

PERIOD OF EMPLOYMENT; Jan. 2011 July 2012

POSITION HELD; Process Devices Designer and Assembler
RESPONSIBILITY;

Involved in the production of sensors that monitor oxygen in anaesthesia gas within
ventilators and incubators, carbon monoxide levels in lung function tests and
smoking cessation programmes.
Was involved in the testing and calibrating of parts and mechanisms to meet
tolerances and product specifications and identify units that fail tests or tolerance
levels and do the repairs as necessary.
MAJOR CHALLENGES ON THE JOB AND SOLUTION PROFERRED;
Tough competition from other companies in the same line of business, producing
their sensors based on demand instead of mass production to avoid losses
EXPERIENCE GAINED;
Gas sensors design and assemblage.
Health and Safety laws and guidelines as pertain to the electronic manufacturing
industry.

1.3 EMPLOYER;
Willsark Engineering Services, Lagos
Core business of the company: The firm was founded in 2005 and it was established to
train Design Engineers in the Oil and gas industry the use of different engineering
softwares such as Caesar II for stress analysis, SACS for civil engineers, PDMS, PDS,
HYSYS, OLGA etc.

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PERIOD OF EMPLOYMENT; March Sept. 2008
POSITION HELD; Process Engineer and Design Software trainer
RESPONSIBILITY;

I was involved in the training of staffs of different companies in the use

Engineering Design softwares like HYSYS and other Aspen Engineering suites
etc. and also giving support and assistance to such companies on different projects
pertaining to simulation and modelling.
I was involved in the Business Development arm of the company by giving
presentations to clients in order to convince them to take up the company's services.
I was also involved in the preparation of the training schedule to fit the clients
specification and trained in the use of PRO II and Aspen Engineering suites such as
Flarenet, and Flaresim by softbits.
MAJOR CHALLENGES ON THE JOB AND SOLUTION PROFERRED;
The inability of some universities to incorporate the study of Design softwares into
their curriculum
High cost of purchasing Engineering Design software licenses, the company had to
go into partnership with some foreign companies as technical partners and share
licenses.

EXPERIENCE GAINED;
Business Development and marketing
Process Design
Process Simulation and modeling using HYSYS, and other Aspen engineering
suites.

1.4 EMPLOYER ;
Deltaafrik Engineering Limited, Victoria Island
Core business of the company: DeltaAfrik Engineering Limited is a world-class
Engineering Company with vast experience in the Oil & Gas, Power and Infrastructure
sectors. The company was incorporated in August 2003 under the laws of the Federal

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Republic of Nigeria and it is jointly owned by DeltaTek Engineering Limited (100%
Nigerian Engineering Company) and WorleyParsons (the foreign technical partner).

Their services include but are not limited to the following listed items:

Engineering Studies
Front Engineering Design (FEED)
Detailed Engineering
Procurement
Construction Management
Project Management
These services are for the following facilities; LNG Facilities; Offshore production
facilities; Deepwater production facilities; Onshore production facilities; Gas gathering
systems; GTL facilities; Floating production facilities; LPG facilities, NGL facilities
and Power.

PERIOD OF EMPLOYMENT; Aug. 2005 -Jan. 2006

POSITION HELD; Intern (on Student Industrial Work Experience Scheme)

RESPONSIBILITY;

Was involved documents control and preparation of deliverables for the Project
management department.
I was also involved in the review and modification of PFDs and P and IDS using
AutoCAD for the Process Engineering Department on the Chevron Wash Tank
Project.
I also learned how to use process simulators like HYSYS, Pipesim, Flarenet and
Microsoft suites for oil and gas facilities design and sizing.
I also gained working experience in the use of various API and ASME standards in
the design of oil and gas facilities

MAJOR CHALLENGES ON THE JOB AND SOLUTION PROFERRED;

The use of Expatriates as Leads of Departments and Projects, but the Local Content
laws changed this trend making it easy for Nigerians to understudy the Expatriates
and then lead projects.

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 Lack of adequate manpower for projects, the company had to jointly bid for
projects with other companies as partners.

EXPERIENCE GAINED;
Process Design such as line sizing, valve sizing, equipment sizing (separator sizing)
etc.
Process Simulation and modeling using OLGA for flow assurance simulation,
HYSYS for steady state process simulation, Flarenet for designing and rating flare
systems.
1.5 EMPLOYER;
Sunplast Industries Limited, Oshodi, Lagos State
Core business of the company: Sunplast Industries Limited, established in 2002, is the
flagship plastics manufacturing company of the Sun Group is situated in Isolo, Lagos. The
company is into manufacturing, mouldings etc. of various plastic production items and is
equipped with top-of-the-line injection moulding machines from Ferromatic. The plastic
products manufactured at Sunplast Industries Ltd consist broadly of house-hold and
furniture items.

PERIOD OF EMPLOYMENT; Sept 2004 November, 2004

POSITION HELD; Intern (on Student Industrial Work Experience Scheme)

RESPONSIBILITY;

Carried out mixing of resins for the production of plastic chairs in multicavity
injection mould tools within a plastic injection moulding plant.
Carried out process validation to ensure process consistency that the plastic
products produced are of the specified quality.
Devised different process improvement techniques such as developing continuous
improvement (kaizen) ideas and lean manufacturing methods to help improve
production.

MAJOR CHALLENGES ON THE JOB AND SOLUTION PROFERRED;

Power outage with emergency shutdown of the plant.

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 Production of scraps during machine malfunctioning or power outage which are
usually discarded. As a solution, the company had to purchase a machine that
breaks the scraps into resins.

EXPERIENCE GAINED

2.0 QUALIFICATIONS AND COURSES ATTENDED

2.1 Educational Qualifications with institutions attended-

Imperial College London, United Kingdom. Master of Science (MSc, Merit) in

Advanced Chemical Engineering with Process Systems Engineering. November,
2009.
Obafemi Awolowo University, Ile-ife, Osun State of Nigeria. Bachelor of
Science (BSc, Second Class Upper) in Chemical Engineering, December 2006.
Air Force Secondary School, Ikeja. Lagos State of Nigeria. Senior Secondary
School Certificate Examination (SSCE), June 1999.

2.2 Courses Attended with Dates

DATE TITLE OF PROGRAMME AND

VENUE
29th August- 9th September 2005 Steady state and Dynamic simulations using
HYSYS in- House by Worley Parsons, Lagos
15th -17thSeptember, 2009 Flow Assurance with OLGA by SPT Group,
Surrey, UK.
22nd -26th February, 2010 CFD with Multiphase Flows and Combustion by
Cranfield University, Bedford, UK.
24th-26th May, 2010 Introduction to CFD and Turbulence modelling
by Cranfield University, Bedford, UK.
14th-16th June 2010 Emergency First Aid in the Work Place by
Thanet College, Margate, Kent, UK.

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10th September 2012- 20th May 2013 NNPC Foundation Skill Training Programme for
Engineers. Warri, Delta state.
15th May 12th June, 2015 MOOC Oil and gas from exploration to
distribution by IFP School in France (online)
5th 9th December, 2016 Refinery Energy Management by Matwims
Consult, Sapele, Delta State.

2.3 Professional Membership

Affiliate Member- Institute of Chemical Engineers-IChemE (Chartered Membership in

view)

Graduate Member- Society of Petroleum Engineers (SPE)

2.4 Projects and Publications

Optimization of productivity of antibody-secreting mammalian cell cultures (MSc
Project).

Plant wide Simulation and Control using HYSYS and AspenPlus and Dynamics
(BSc Project).

2.5 Professional Skills using Technology

Microsoft Office (Word, Excel, Power Point, Visio, Project, Outlook)

Process Simulation Software (gPROMS, Flarenet, PVTSim OLGA, Pipesim AspenPlus,

HYSYS and other Aspen Engineering Simulation Packages)

Others (MATLAB, GAMS)

3.0 CONCLUSION

My work experience has been successfully highlighted in this report. The report also
shows that I am currently on an on-the-job training as a process engineer in Warri
Refining and Petrochemical Company Limited, a subsidiary of Nigerian National
Petroleum Corporation. I strongly believe that my skills and abilities will contribute
immensely to the growth of the organization and the field of chemical engineering in as a

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whole. I hope my application as a corporate member of the Nigerian Society of Engineers
(NSE) will be granted.

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