Commissioning Team Leader (Preservation)
JACOBS ENGINEERING
Total years of experience :33 years, 3 Months
The OCP Phosphoric Acid Plant and sulphuric plant is designed to produce 450, 000 t/y of P2O5 and H2SO4 as 28 and 54% P2O5 phosphoric acid by the JESA Dihydrate process. The design instantaneous operating rate is 1500 t/d (62.5 t/h) of P2O5 as average 42% P2O5 phosphoric acid.
Having responsabilities in granulation train for the production of diammonium phosphate (DAP) or other ammonium phosphate based granular fertilizers. Specifically, the process and equipment have been designed and specified for the production of granular NP fertilizers, having nitrogen-P2O5-K2O compositions of 18-46-0 & 11-52-0. The design capacity when producing DAP is 135 ton per hour. Raw materials are phosphoric acid at concentrations of 28% and 54% P2O5, liquid anhydrous ammonia, 98.0% sulfuric acid and filler. The filler will be provided by feeding phosphoric acid reactor slurry to the preneutralizer. As a back-up a system for feeding phosphate rock to the granulator will be provided. Additional chemicals and utilities required are defoamer, coating oil, process water, fuel oi, steam, instrument and plant air and electrical power.
The process utilized is an updated version of the standard JESA slurry process including a pipe reactor and a dual-mole scrubbing system. Additional “state-of-the-art” features include a special JESA designed pre-neutralizer, and a tail gas scrubber ammonia vaporizer utilizing tail gas scrubber liquor as a heat source
Chuandongbei Project - entails the development of three related sour gas fields in the Sichuan province of China. Overall Development 1 (ODP-1) involves relocating an existing gas purification plant (Xuanhan), installation of a 60 km sour gas gathering system, the design and construction of gathering stations for gas dehydration and well construction. This plant and system capacity is ~ 318 mmscf/day/ and a 1200 tonnes of sulfur.
Lead systems/subsystem punchlist planning, walk-downs, documentation, and close-out as required to systems are completed per project specifications and regulatory requirements.
Responsible for maintaining documented records of daily activities and reporting daily status to Lead.
• Communicates changes of resource and scope of work requirements to Lead Process Engineer.
• Liaise with other disciplines, departments, project personnel, vendor and contractors. Works with CDB Ops Advisor/Team Lead to ensure ops coverage is supplied as needed to support commissioning and/or system operation.
• Serve as technical specialist in all matters relating to commissioning completion and start up of all instrumented systems. Works with Lead Engineer to ensure completion, closeout and handover of system with required signoff of PSSR and handover documentation.
• Provide technical support in the resolution of technical issues during commissioning and initial start up.
• Support in the Handover of all assets to the OTT team at Final Handover in accordance with the Completions and Handover Procedure.
• Support the implementation of safety in design (SID) in the execution of construction activities.
• Work in a cross functional Commissioning Group to perform Commissioning and Start Up activities in the Sulfur Plant.
• Pre commissioning and commissioning activities such as system walk downs, punch list prioritization, PTW, LOTO.
• Reading, interpreting, & editing (Red-lining): P&IDs, PFDs, piping, mechanical, electrical, & control drawings.
• The creation and review of Commissioning Procedures (FTPs, SATs, ) of Sulfur Forming and related Auxiliary Systems such as Fresh Water, WWT, Cooling Water, Air/N2 etc.
• Conducts PTW Audits, manage system interfaces, isolations, incident reporting and documentation.
• Develop dynamic commissioning procedures needed to execute Project Systems Completion Activities
• Endorse MC & SC Checksheet and Dynamic Commissioning Procedure
• Review Vendor commissioning procedure
• Support to preapre System Completion Schedule
• Support to populate CMS Engineering Data and provide all Design or Field Change updates to CMS Data Base Engineer
• Support to prepare TCP (Turnover and Completion Package)
• To perform system completion activities
• Verify Punch List items completion and update the CMS Data Base
• Coordinates Systems Completion activities within the discipline and ensures that all works are carried out with high quality
• Ensures materials, special services, and resources to successfully execute scope of work are available
• Assists Systems Completion Leads in working with the Start-up Team to achieve successful Turnover and acceptance and ACCEPTANCE to MCL Operations
• Completion verification of all work detailed within the process discipline sections of the Commissioning / integration plan and provides commissioning assistance to the commissioning engineers during the facility commissioning.
• Provide the start-up assistance to the Company as necessary.
-Coordinating commissioning activities for ‘’Installation of Low Sulphur Fuel Oil (LSFO), Fuel Gas and Fuel Oil of 48 inches pipelines from Mina-Al Ahmadi Refinery to Sabiya and Doha Power Stations’’ in northern part of Kuwait.
• Coordinating SAT completion and FAT procedures for FMC fiscal metering skids at MAA and power stations and BS-180 checking ultrasonically sound for each transducer of each flow element on flowing streams.
•Elaborating, checking and revising Site Mechanical Running & Performance Test ( SMR & PT ) for compressors, methanol injection system, biocide injection system, oil drain systems and other equipments.
•Checking and revising SAT and FAT, according vendor suggestions, procedures and datasheets
•Supporting the project control team for turnover and completion package
•Verify punch list items for the equipment on site and adapt on MRT according commissioning procedures
•Performing writing and reviewing Procedure documents related to Pre-Commissioning and Commissioning activities, Instrumentation Function test, create and implement Inspection test report for Pre-commissioning and Commissioning activities, etc.
•Maintaining record and update the Instrument Index Instrumentation SPI data base.
•Corrective action implemented in project design, solutions and report updated to engineering department involved .
•Site Inspection on Mina-Al Ahmadi refinery of the KOC Project for Module inspection and Preservation scope.
•Prepare document related to Commissioning phase as per procedure, documenting inspection, Construction Pre-commissioning Application, managing completion process and acceptance of systems, monitoring and controlling loop checking process, C&E testing, function dynamic testing and commissioning, managing pre-commissioning processes and acceptance of pre-commissioned systems
•Coordination of process simulation illustrating thermo-dynamical changes that occurred during flow for Compressor Anti Surge Control valve with IN 24 inch OUT 30 inch according PRO II software
•PFD, UFD & P&ID Development for projects at Basic engineering as well as at Detailed engineering stage for various EPC projects. Also participated in project kick-off and P&ID review meetings.
•Design & adequacy check of Shell & Tube Heat Exchangers using HTRI.
•Sizing of equipment like Vessels, Tanks, Tray towers, etc.
•Single & Two phase hydraulic system design including Pumps, Compressors, Control valves and Flow elements.
•Relief system design i.e. Scenario development, Relief load calculations, Safety valve selection & sizing, inlet line and Flare header sizing as per API standard.
•Venting, Breathing and emergency venting calculations for atmospheric and low pressure tanks as per API 2000.
•Development of Heat & Material Balance. (Process Simulation using Aspen HYSYS and PRO-II.)
•Preparation of Material Selection Diagram (MSD), Design Pressure & Design Temperature (DPDT) Map, and Utility Distribution Diagrams.
•Settle out pressure calculations to set design pressure of compressor suction system
1) PERIOD: August 2007 - May 2012
COMPANY: Messer Group -Bucharest -Romania
POSITION: Process Operations and Completion Start-Up Engineer
PROFESSIONAL
ACTIVITY: Messer Romania Gas is the branch in Romania of German company Messer Group GmbH
I have coordinated all operations necessary for built-up air separation factories for different customers in Romania.
The main responsabilities consists in: -Making the design plans for proper placement inside the factories of different liquified gases needed for industrial purposes like cooling, medicinal purpose, especially in hospitals and welding activities.
The design plans was consists in made calculation of capacity of the tanks with different types of liquified gas, choose the proper tank, calculation of diameter of the pipelines according with the debit of the fluid, necessary for the customers, establishing of what type of bib-cock, coupling cock, pressure valve, check-stop valve, etc..is necessary.
-Supervise and checking on site the operations of built-up according the project and internal procedures.
-Coordination and checking the operations of delivery liquified gas to the customers when the plant is ready.
Air Separation Plant automation system maintenance and enhancement;
Prepare and review Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs)
Reviewing Basic Engineering Design Data / Package, Front End Engineering Package, Process Design Package
Pressure drop and Utility load calculations
Preparing guarantee test procedures.
Preparing of Instrumentation, Piping components, Special Part, Equipment List.
Preparing Equipment and Instrument Process Data Sheets. Safety Valve sizing (Relieving Capacity, Sizing of Valve, Inlet & Outlet Piping, Rated Capacity)
Preparing Control Valve process data.
Preparing Line List (Line Schedule)
Pump calculations (NPSH), Hydraulic Calculations, Line sizing
Preparing Operating manual, Pre-commissioning and commissioning manual, RAMI analysis, Operation and Control manual.
Coordination with Construction, Mechanical & Instrumentation groups.
Coordination, supervision and check out the operations consists in built up of gas station.I coordinate directly the construction of 3 filling station in 2006 such as:Agip Timisoara, Agip Pitesti and Agip Braila .
-Lead various projects in the field of construction works and to assist the management to introduce modern projects coordination techniques.
Sets up and coordinates the implementation of new investment and maintenance projects.
- Controls and coordinates the activity of subcontractors.
-Supervising activity of technical maintenance made for good function of pumps, car-wash, refrigerating plant, different electrical machine, and other equipments.
The main responsibilities consists in:
-Coordination of existance in the field of technological project signed by the designer and follow up to keep in order of bench mark from layout and put in practice in the field.
Involved in solving daily technical problems on following equipment:
- PLC Allen - Bradley (Basic Software : Windows NT) within the Automatic filling station
In charge of start-up, repairs, maintenance and operating of the control loops of flow, temperature, level and pressure. Checking and start-up measuring and control loops interlocking system. Checking transmitters, recorders, controllers and control valve how they are working in field and how are sent from the field to central control room. Troubleshooting of computer and auxiliary network equipment, control file and signal conditioning cards for DCS. Knowledge in assembling and disassembling the equipment according to specifications. Extensive knowledge of workshop practices and facilities. Extensive knowledge of protective system, start-up logic, vibrations and governing system reciprocating centrifugal machines. Knowledge in repairing and maintenance of intelligent transmitters, recorders and controllers such as Foxboro, Yokogawa, Barber-Coleman, Bentley-Nevada,
Inspection of general condition of the means of transport including tightnes and/or cleanliness test, supervision at loading/unloading&monitoring of distribution of oil products.Coordination of sampling, preparation of average composite samples, inspection of tests/analysis in accredited fuly-owned laboratories, running and accuracy tests .
Coordination and inspection of draft survey, ullage and volumetric measurement for our importants clients such as: SNP-PETROM, LUKOIL DOWNSTREAM, GLENCORE INTERNATIONAL, VITOL SA, COTECNA Gmbh and more others.
Conduct site measures as required, and take-offs from drawings leading to the preparation of bill of quantities.
Responsible for Steel Structure, Piping, Electrical & Instrumentation quantity surveying deliverables being prepared correctly as required by the contract and internal requirements.
Check & Approved Subcontract Claims & Issued Invoices.
Controlling/ Monitoring/Updating Daily, Weekly, Monthly Progress.
Interfacing with the client quantity-surveying representative with regards to agreements to measured quantities and associated estimated values of work completed.
Experience in progress measurement, tracking installed quantities, interpreting construction drawings, and invoicing based on unit rates as a constructing job site
I was responsible with the unloading of L.P.G. from barge tank, tanks and storage them in pressure reservoirs.I have 5 reservoirs for propan of 200m3 each, and 5 reservoirs for butan of 200m3 each.I supervise the distribution of L.P.G. from reservoirs to autotanks and gas cylinder by pipe-line.Also I supervise and check the good function of the compressors, centrifugal pumps in the warehouse.All the equipment is automatized and he was installed by CRISPLANT-Denmark.
Corelation with the density of the gas to established technical caracteristics making after technical safety data of combustible gases and vapours.Carring out controllers fine tuning skilled diagnosis and defect repair for equipment in accordance with the maintenance plan or response to failure of equipment Checks the equipment to locate the fault, decides on appropiate method of repair and carrying out the job.
In the same period I work with my team in infield (6 manifold for recived the propane and butane from tanks by railway ) .
Responsability : instaling and conection of cables\[ as per drawing\], for all type of instrumental and electrical cables;electrical and instrumentation junction boxes,
instaling and connection \[includind glanding and cables termination \]installation and connection of varrios traductors type as:
Level transmitter (LT), level indicator (LI), pressure transmitter(PT), pressure indicator(PI)
Flow Indicator(FT), temperature indicator (TI), flow indicator(FI), level transmitter(LT), solenoid valves, level gauge indicator & heat detectors, smoke detectors, flame detectors -installing and conection electrical equipment, like : distribution board, panel installing, termination loop cheching;
Have also activities to conect the earthing cable, and heating cable.
All task and responsabilities for a instrument foreman
Work with Fire&Gas and Fire Fighting device, and put all this in function . ...
Working in comissioning, and precomisioning activities in intrumental department
6) PERIOD: August 1989 - February 2002
COMPANY: S.C. CONPET - Ploiesti
POSITION: Senior Process Operations, Commissioning & Start-Up Engineer
PROFESSIONAL ACTIVITY
Coordination of pumping and storage activities of crude oil by main pipe lines of 10", 12' and 14" between the production oil wells and the oil refineries (Ploiesti, Pitesti, Constanta)
Responsible team member for finalization of "Romanian national crude oil transport rehabilitation project"; Assist Factory Acceptance Tests for instruments and for the sub-systems: Solarton Factory for Densitometers and Jiskoot Factory for Automatic Samplers in UK,
Site Commissioning with the General Contractor (ABB Germany): documentation completeness, loop checks, DCS configuration, functional tests, metrological verification, authorities interface.
Conduct the proving team operating Mobile Bi-directional prover for calibration and maintenance works on the Crude-oil metering skids - PD-meter base or TM-meter base; Coordinating the supply with instruments and materials for project works; Organise, set-up and deliver training for the operators; Maintain the functionality of local area network.
Coordinating the pre-commissioning and commissioning activities, which consist of: Water Flushing, Air Blowing, Chemical Cleaning, Vacuum Drying, Chemical loading, Oil Flushing, Motor Run In, Pumps Run in, Blowers And Vacuum Pumps Run In, Air coolers Run In, Compressors Run In, Tightness Test, Leak Test, Service Test, Water run, Systems Inertization With Nitrogen.
Organizing the checking of Chemical Iso Containers nozzles connection and preparation for Chemicals Loading
Overseeing the Inspection activities for witness inspection for Hydrostatic Test, Pneumatic Test, for Final line check/ Reinstatement check
Coordinating the checking Piping Test Block Status (TB) and participating in Air Blowing activities
Blending & Storage
Preparing normal start-up, normal operation, normal SD procedures.
Training and assessment of shift supervisors and field operators.
Coordinating of all blending operations for petroleum products, loading, unloading of crude oil.
HIGHER EDUCATION: 1984 - 1989 (PROFESSIONAL Institute of Oil and Gases-day courses