Hussain Fardan, Process Control Engineer- Major Projects Details

Hussain Fardan

Process Control Engineer- Major Projects Details

Bahrain Petroleum Company

Location
Bahrain - Manama
Education
Bachelor's degree, BSc. in Chemical Engineering
Experience
25 years, 5 months

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Work Experience

Total years of experience :25 years, 5 months

Process Control Engineer- Major Projects Details at Bahrain Petroleum Company
  • Bahrain - Manama
  • My current job since August 2001

1- Adavance Process Contorl System for HCU:
The project aimed at developing an APC system for the Hydrocracking Unit (HCU). It involved identifying the control objectives of the unit, Evaluation of the instrument and operation reliability and tight tuning of control loops. Furthermore, Built the DCS interface for the DMC System. Also, developing inferential models for product properties such as top product RVP, Flash-point, Freeze-Point and side product 95% ASTM Temperature. Furthermore, carrying out step-test for two reactors and the fractionators variables. Configuring Process Controllers and validating the model. Finally, writing the documentation and auditing the system profitability as well as identifying the KPI’s.
2- Adavance Process Contorl System for FCCU:
The project aimed at evaluating and improving the existing APC system of FCCU after a major modification to the feed rate, feed quality and equipment. It involved identifying the control objectives of the unit, Evaluation of the instrument and operation reliability and tight tuning of control loops. Also, developing inferential models for product properties such as top product RVP and side product 95% ASTM Temperature. Furthermore, carrying out step-test for reactor and fractionator variables. Configuring Process Controllers and validating the model. Finally, writing the documentation.

Process Control Engineer at Bahrain Petroleum Company
  • Bahrain - Manama
  • My current job since June 2008

I support different complexes in the refinery i.e. Distillation, Low Sulpher Diesel Production, Fluid Catalytic Cracking, Power and Utilities. This involves supporting all the regulatory control and the advance process control systems in refinery units. Also, responsible for handling all aspects of Management of Change (MOC) projects for implementing control applications. Besides, I am responsible for identifying opportunities for improvement in the process control applications. Thus, I have been involved in revamping and implemented critical changes to the control applications and processes both on regulatory control and advance control layers. I have a intensive understanding and experience of both processes and control systems such as Yokogawa DCS and aspentech DMCplus APC system. I am the control engineer responsible for commissioning the newly built Lube Base Oil Unit. This includes developing, reviewing and implementing the regulatory control schemes to meet the operation and profitability objectives of the plant as per international standards and codes. Also, it included tuning the control loops on the startup of the plant and developing NIR analyzers models and resolving problems with instrumentations. Currently, I am involved in preparing a feasibility study for implementing APC.
The main on-the-job accomplishments were developing APC System for both The Hydrocracking Unit (HCU) and the Fluid Catalytic Cracking Unit (FCCU) (Reference: Major Projects Details, page 4). Also, was involved in developing APC system for optimizing refinery heaters operations by rationalizing fuel gas consumption and minimizing CO/CO2 emissions. I support APC systems to maintain product qualities, maximization of process yields, reducing off specification products to slop, maintain optimum operating conditions and maximizing heat integration. I have developed robust inferential models for product qualities meeting challenging tight targets.

Technical Training Specialist at Bahrain Petroleum Company
  • Bahrain - Manama
  • August 2004 to June 2008

The main on-the-job accomplishment was training senior operators in the Oil Processing Department on the use of the Distributed Control System (DCS) as part of the Instrument Modernization Project (IMP). This involved, assessing operator performance capabilities and developing and implementing targeted solutions for individual performance gaps. Also, involved training Refinery Operation personnel on YOKAGAWA DCS Human Interface Station (HIS) for different Refinery units, such as LSFO and FCCU units; in the process of migration the refinery control system from the obsolete pneumatic system to a computer based control system. This involved designing the course, developing the course materials, training the trainers and designing an evaluation system that ensures high competency level of trainees to operate critical refinery units.
Furthermore, I was involved in training Operators working in BAPCO’s projects of Low Sulfur Diesel Production (LSDP). LSDP complex consists of Hydro-cracking Unit, Hydrogen Plant, Sulfur Recovery Unit and Tail Gas Treatment Unit. I was involved in the jobs of process control and DCS, plant mechanical commissioning jobs as well as Start up activities.
Besides, I am a TÜV certified internal quality assurance auditor. I am extensively involved in auditing all refinery processes and operations as well as financial, legal and medical systems.

On Development Assignment in Refinery Operations at Bahrain Petroleum Company
  • Bahrain - Manama
  • August 2001 to August 2004

I underwent an extensive training program in all departments in the refining division in BAPCO such as Oil Processing, Power and Utilities, Oil Storage and Export, and Technical Services. The training program had two main objectives. First, was to gain knowledge and experience of the refinery units including units’ function, operations, troubleshooting and emergencies. I gained wide knowledge about operating and troubleshooting many equipments such as furnaces, boilers, reactors, distillation columns, pumps, steam and gas turbines, compressors, heat-exchangers, instruments and control systems…etc. I developed many dynamic simulation programs in the course of studying these equipments and their performance using different software such as MS-Excel, PI Process-book. Second, was to identify different operators’ roles and responsibilities.

Systems Analyst at Sarwani Systems W.L.L.
  • Bahrain - Manama
  • October 1998 to July 2001

Worked in the business of system-integrators, which provides cost effective industrial solution and delivers customers value by developing sophisticated software and hardware applications to streamline processes and improve performance. The main on-the-job accomplishments were leading and engineering projects to develop and commission Supervisory Control and Data Acquisition (SCADA) systems; Human machine interfaces (HMI) as well as Plant Information (PI) applications (Reference: Major Projects Details).
Also, developed many PLC programs and Tank gauging programs based on Saab Tank Master and Fuel Manager Applications.
Furthermore, I participated in several projects to provide on-line services and on-the -job training as well as providing technical support and consultancy services. Have extensive experience in networking, Microsoft Win NT and UNIX operating systems. Also, have experience in programming using Visual Basic (VB6 & .Net), Visual C++, Java, database applications as well as web designing.
I developed and participated in many projects for different reputable corporations such as ARAMCO and Petroleum Development Oman (PDO) in different countries like Bahrain, Saudi Arabia, UAE, Oman and USA.

Systems Analyst - Major Projects Details at Sarwani Systems
  • Bahrain - Manama
  • October 1998 to July 2001

1- Central Access Domain (CAD):
Worked with Petroleum Development Oman (PDO), as a member in a team, to migrate control system network from UNIX to Windows. The responsibilities were to provide on-site services and training. Project was to interface different control systems equipment such as DCS, PLC’s and RTU’s to central iFIX Database on Windows NT server. Also, developing SCADA system to provide an interface to other programs such as PI servers, FieldWare and SAP.

2- Batch Reporting System:
Project leader of Batch Reporting System for Saab Tank Control aimed at automating the sales of petroleum products in order to improve performance and reduce measurement losses. I was completely responsible for managing the project team responsibilities, designing, engineering and commissioning the project. Project was to interface Saab TankMaster with iFIX HMI using OLE for process control (OPC) driver for two redundant nodes. Project included developing highly sophisticated automation functions for redundancy, auto-reporting system, auto-archiving system and auto-backup system.
3- Medina Hydrill
Developing Radio Communication Medina Hydrill OPC Server Driver for CAC RTU based on Intellution OPC server Toolkit using Visual C++ V6 for Petroleum Development Oman (PDO).

4- Furnace Shutdown System
Responsible for developing and commissioning a system based on FIX32 V6.15 under Windows NT to interface 2 GE Series 6 PLC’s used to control annealing furnaces to an Oracle database for Gulf Aluminium Rolling Mills Company (GARMCO) in Bahrain. The project aimed at automating the flow of data from the plant-operations to the management applications. The project involved preparing database, developing graphics, writing scripts and setting up interface to PLCs as well as to the database using ODBC and SQL to communicate with Oracle Database.

Education

Bachelor's degree, BSc. in Chemical Engineering
  • at University of Bahrain
  • February 1998
Diploma, Diploma in Chemical Engineering
  • at University of Bahrain
  • February 1995

Specialties & Skills

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