Sr. Engineer - Turnaround Planning & Execution
OQ
Total years of experience :17 years, 11 Months
Coordinate with stakeholders throughout all Turnarounds / Shutdowns life cycle: Initiation, Scoping, Challenge Session, Planning, Pre-TA, Execution, Post-TA & Close-out as per industry best practice. • Preparation of TA charters, planning strategy, identification of long lead spares & preparation of Budget estimates at different phases of turnaround to track budget requirements. • Facilitate scope challenge session with all stakeholders to optimize Turnaround scope. • PR creation for long lead items & contract services in planning stage to minimize impact of cost & schedule. • Responsible for the Technical Evaluation of spares for RFCC / CDU / VDU / DCU Static equipment’s and capital spares. • Perform job site visits to confirm existing field conditions and engagement with field execution & customer. • Scope development / Writing and detailed planning for TA jobs, making an arrangement and ensuring the availability of resources ( Manpower, Materials, specialized vendor services & tools to meet the shutdown requirements. • Reviewing of TA integrated Primavera (P6) schedule with contractors & stake holders for Critical & sub-critical task and resource availability as per agreed TA Window. Also reviewing the resource levelling for resolving the schedule conflicts. • Preparation of work packages as per finalized work-list in Pre-TA phase with required drawing, Spare parts MTO, Method Statement, Execution Plan, Critical lifting, Specialized Vendor or OEM Service & Tools, for smooth turnaround. • Regular contact with Turnaround Contractor and Sub-Contractors, call-of contract vendors, OEM and suppliers. • Ensuring and follow up for the SAP Notification & WO availability for TA jobs, material reservation in SAP against work orders / PTW in E-Vision and attending the JSA meeting with stake holders for critical and sub critical tasks. • Ensuring the Refurbishment of capital spares Post TA after the evaluation of repair methodology and keeping ready for next opportunity. • Progress Monitoring to update the Management and controlling during following phase of Turnaround execution; o Pre-TA: Site establishment, Fabrication, Scaffolding, Insulation removal, Tagging, Hot bolting, Vendor mobilization, Decontamination activity, identifying the interface, Turnaround Risks Assessments & readiness audits (TARA), defining waste methodology, Equipment handing over / taking over sequence with OPS for smooth Turnaround. o TA (Mechanical Window): Site Progress, HSE compliance, Site Co-ordination among stake holders, follow up for additional jobs, PSSR point clearance as per system or loop handover. o Post TA: To Ensure no leak during Start-up, verifying job completion, Material reconciliation, site clearance with proper Housekeeping, SAP Work order TECO with history updates, Sharing the lessons learned for the improvement of next TA.
• Preparation of detailed project programs using Primavera-P6 with resource / Cost and Quantity loaded schedule as per Scope from Level 1 to Detailed Level (L-4) schedule
• Establish the Work Breakdown Structure (WBS) and Cost Breakdown Structure (CBS) which to be performed as defined by the contract and ensuring their congruency.
• Follow-up with PAC (Project Assurance & Control) and VAR (Value Assurance Review) for Schedule Approval.
• Progress analysis for from Initiation to project execution (PDP, CDP, FEED, EPC, Pre-Comm. /Comm., Project Closeout)
• Participating in Kick off Meeting, Weekly / Monthly Progress review meeting with Contractors & Sub-Contractor and Vendors, Bid clarification & Audit for Contractor in FEED & EPC stage
• To prepare and review of Progress Reports (Daily / Weekly / Monthly) in order to compare the Planed & Actual Progress Status with Resource Histogram and S-curve as per physical progress at site.
• Issue and Review the 2 or 3 weeks look ahead schedule and slippage report.
• Monitoring the Procurement Schedule in-order to place the PO, fabrication, FAT / SAT Schedule, Delivery & Installation of Long Lead Items.
• Project coordination from FEED to EPC contractor to Operating Companies, Sub Contractor & Vendor Management for Project Deliverables.
• Liaise with Materials planners and Service Planners to ensure availability of required materials, appointment of contractors, vendor’s specialist etc., as applicable.
• Assist in Schedule risk analysis (Quantitative & Qualitative) prior to FEED & EPC project and assist to identify the risk and prepare the Risk Mitigation plan with disciplines.
• Prepare the presentation or slides for management review and updates.
• Review & approve Schedule, Progress measurement for any new project before FEED stage and EPC stage and to make sure for the compliance of project execution as per procedure.
• Ensuring all contractors, sub-contractors for the supply of material, equipment & laborer are in compliance with the approved project plan.
• Prepare and Review of contractor VOWD / EOT / Delay Analysis as per approved progress measurement system and scope of work.
• Establishing and maintaining the E&V Planning, Scheduling and Progress monitoring procedures and guidelines with the Project Cost estimate and Manpower forecast that serve as the project baseline for original sanctioned budget.
• Creating and retaining the hierarchy of plans and schedules in conjunction with the Project Management Team.
• Prepare the cost estimate during Tendering/FEED/Execution for management review and approval and liaise with discipline engineers to raise the AFE for management approval.
• Providing the forecast budget cost phasing information to cost department.
• Formulating the project calendar and project execution road map for the project as per (iPMS) Integrated Project Management Systems.
• Develop & maintain the contract planning & scheduling and project schedule at different levels (Pre-FEED/FEED/Execution) and update the project schedule and make sure that the Project Master Schedule complies with company process and procedures.
• Review and evaluate the contractor Initial Planning Packages, Project Control documents and procedures.
• Responsible for Project Controls Functions including review, approval, formulating project budget, monitor project schedule& cost performance and forecast of contractor's project schedule.
• Reviewing contractor’s report - Daily, Weekly, Monthly reports (Histogram / S-curve) with respect to plan vs actual progress charts and analyzing the deviation from plan.
• Evaluate and ensure the contractor executed their progress reporting, cost report and value of work done (VOWD) process and analyze the KPI performance & productivity.
• Project progress monitoring & controlling by approved progress measurement procedures with various S-curves of EPC and project overall.
• Conducting regular site visit to observe the project health and evaluating the physical progress.
• Early identification and elevation of schedule risks and proposing mitigation plan for review.
• Reviewing of contingency, recovery schedule, revised schedule, change order and extension of time (EOT) claim with the help of float or critical path analysis (CPA).
• Preparation of monthly reports with areas of concern and corrective actions to meet contract schedule and highlight the variances against baseline schedule.
• Monitoring and Issuing the Monthly cost report of EPC contractor, PMT and owner cost for management information.
• Development of corrective action plans/schedules, Delay analysis and shareholder presentation when required.
• Ensuring compliance with safety standards
• Develops policies and procedures to improve the adequacy and efficiency of the planning and scheduling the activities.
• Analyzes the drawings, specifications and statement of work in the preparation of networks for project planning and scheduling, manpower loading, materials, equipment, installation and testing supports facilities and costs.
• To conduct the daily progress review meeting with discipline engineers & site managers and prepare the Daily Project or Work Report related to field activities and identified the direct or indirect resources which is required to execute the activities.
• Make the site visit on daily basis to monitor the actual progress of ongoing activities as per schedule.
• Having proper Coordination with site personnel for daily resources utilization/mobilization and demobilization at site
• To receive the daily site activity report from field supervisors or superintendents with respect to update the schedule and plan the next activity.
• To obtain the daily fabrication report from work shop supervisor and NDT report from QA/QC which is imperative to achieve the progress.
• Preparing the following Schedule (Design Engineering / Plant and equipment / Procurement / Construction & Installation / Commissioning activities.
• Obtaining and reviewing the updated schedule from sub contractors in order to maintain the construction schedule.
• Liaison with discipline engineer to coordinate the resource forecast and requirements and identify the overall project resource requirement.
• Preparing the weekly progress reports (with the help of daily report) and updating the progress percentage and progress of the work (graphical representation S-Curve) to be signed by Construction & Project Manager and submitted to the client and copied to Management as per agreed cut-off date.
• Establish and maintain a full working knowledge of the project or specified area scope of work.
• Preparation of critical path project programmes at a level of presentation, suitable for conveying an understanding of the project scope, targets and goals.
• Submit Daily Progress Report (DPR) & Weekly Progress Report (WPR) to the client as per agreed contract.
• Prepare the 3-week look ahead schedule and also make the micro plan with the coordination of Discipline Engineer.
• Technical specification review and approval of specification and drawings with co-ordination of discipline design engineer.
• Prepare the resources (Manpower and equipment) histograms.
• Prepare S-curve for progress, cash flow, and material status.
• Prepare the method statement of erection and vendor shop activities.
• Prepare, monitor, update project schedule and highlight project delays.
• Project Planning, scheduling & progress monitoring work at various sites and timely reporting of progress & bottleneck.
• Prepare project communication etiquette and intimate client so that effective communication is ensured.
• Keeping in view contractually agreed project schedule, plan a project schedule to level II & I and obtain concurrence from internal sections/departments. In case of slippage, take timely necessary actions to avoid delays and to deliver a project on or before time.
• Steer and ensure every activity is as per schedule & also ensure quality and budget margins.
• Manage all sub-contracting activities of a job and verify sub-contractor’s invoices before payment.
• Coordinate with commercial section for any changes.
• Work as a single point of contact for all concerned persons (client, internal coordination etc.) and the total ownership of a project.
• Attain a comprehensive familiarity on all commercial conditions and technical specifications and drawings of project.
• Conduct or attend meetings (Kick-off, in house, pre-inspection.etc) with client & vendor and prepare their minutes and ensure the action has to be taken on or before time.
• Preparation and submission of Project Schedule to client and ensured that programmes are specific, comprehensive, understandable and realistic.
• Create bill of material, detailed instructions for manufacturing process of new part, specification for packaging, external supplier specification to provide standard cost structure and instructions for manufacturing.
• Follow up contractors to submit work schedules, manpower/equipment/materials input plans, organization charts, key personnel lists, and other technical documents, and examine them to secure contractor’s readiness and compliance with technical requirements.
• Effectively communicate the requirements of the programme to project management, engineering, procurement and construction staff.
• Tracking, updating and monitoring the project schedule.
• Use ERP & PMS system for indenting & tracking of material.
• Estimate the additional requirements of the project and getting waiver from client.
• Prepare check list for project invoices and ensure release of all payments from client.
B.Tech in Mechanical Engineering
Diploma in Mechanical Engineering