Lead Electrical Engineer
QST PV chemical plant
Total years of experience :30 years, 0 Months
A green field project, First in Middle East, 8000MTPA Photo voltaic (PV) Silicon manufacturing plant
• Responsible to lead the team of 4 Engineers, 25 staff to Commissioning, Energization of 220kV main GIS SS and MV/LV SS. Provided technical support and advice on first Energization of the plant comprising
GIS Switchgear, 4x Power Transformers, 52x MV Motors, 6x MV 33kV/10kV Switchgears, 66 LV Switchgears, Numerical Protection relaying (SEL, Siemens, ABB, Alstom) & 700 Motors.
• Performed Protection relaying cross check for Relay coordination, TCC review, settings with ETAP.
• Performed Troubleshooting, RCA and resolution of complex problems in MV Switchgears, Transformers and LV Bus duct installation.
• Developed post startup Operation and Reliability Centered Maintenance (RCM) strategies, Procedures in order to support plant maintenance team by using predictive tools such as Partial discharge UltraTEV Plus2 measurement, Thermography, Vibration signatures, Power quality & Harmonic measurement, Oil test result Analysis.
• Developed SOP, SMP as per best Engineering practices, applicable international standards to ensure safe and fit to purpose asset maintenance, repair, testing and overhauling.
• Developed PM and Condition Maintenance schedule and frequency as per OEM recommendations / standards.
• Reviewed Mitigate Threats to Availability (MTA), Mean time between failure (MTBF) and taken control measures. Recent task was introducing 2x VFD to stop ACB failures for frequent on/off requirement of pump.
• Reviewed and updated Plant Energy demand with respect to supply agreement with Electricity authority.
• Developed and controlled budget, Spare parts planning with SAPIII, Inventory control, SLA with effective usage of plant surplus and redundancy to ensure 100% equipment availability.
• Liaison with Internal / external stakeholders, Supply chain, Finance and Vendors/Subcon.
• Provided in-house training and assigning competency (SAEP/AEP) to the staff from first Energization to post startup operations and maintenance.
• In addition, as Project Manager, led the 20x team towards Engineering, Construction, Commissioning, and operation of 1.5MW in-house Solar power farm. Looking after Yield, Import / Export power to Grid.
A green field project, Build and operate 8000MTPA Photo voltaic (PV) Silicon manufacturing plant
• Led 4 Engineers with 60 staff in construction as per approved Project specification and regulations.
• Monitor Project progress, Schedule milestones, removal of deficiencies, bottlenecks to achieve milestones.
• Developed TDCR, resolved Tech Queries and deviation requests to ensure project meeting the deadlines, adhering Company's QSHE policy and statutory requirement
• Performed direct supervision to critical item installation of MV cables, EHV/MV Switchgear main busbar.
• Carried out SAT, Commissioning of Gutor, Emerson AC, DC UPS with battery banks, meeting pre-requisites of first Energization.
• Reviewed/approved construction IFC documents / drawings with due interface of all internal stakeholders.
• Ensured in time requisition of material in line with schedule especially for the long lead items.
Under a short duration contract, performed successful Commissioning / Energization of 34.6kV/13.8kV Substation and Tie-in with Main Saudi Electricity substation by using Aramco standards and ICAP documents.
Led the 3 E&I Construction supervisors with 20 staff in Installation, testing, commissioning, functional checks, punch closures at 6 major oil/gas client plant sites.
• Installed and commissioned ESP MV VFD pump at QPD offshore, Installed Control valves / field Instruments for ORYXGTL, Carried out E&I installation at Melamine plant extension at QAFCO, HCL Plant expansion at QVC and DCS/Tri-conex Up-gradation at Qatar Gas. Installation / testing of Coriolis flow control valve, AC UPS, GE/Siemens Relay settings for Ras Gas Train-VI.
• Ensured that expenditure is within budget and projections are sufficiently supported, adhering Company / Client policies and procedures.
• Analyzed, evaluated, and validated new project scope and prepared execution plans, time and manpower resources required to accomplish the project.
• Executed 3years E&I O&M contracts successfully. Supported plant maintenance by Electrical motors rewinding, Control valve Overhauling, Repairs, Seat replacement, Facing, Metalizing, stroke test.
• Accomplished all assigned construction and testing activities of E&I asset in a month long plant shutdown and Achieved Safest Sub-con award.
• Performed Plant performance test with Mitsubishi for 0.25 million MTPA Copper smelter plant
• Completed Substation automation, PMS system commissioning along with updated protection settings.
• Associated in team of major task - Furnace transformer replacement which got burnt due to external factor.
• Resolved a complex problem of poor efficiency of Anode refinery.
• Conducted and documented monthly Electrical integrity Audit to maintain the reliability of the assets
• Responsible to provide input to senior management for budget, Spare parts planning to ensure 100% equipment availability.
• Liaison with Internal / external stakeholders, Supply chain, Finance and Vendors/Subcon.
• Supported 4 Maint. supervisors with 50 staff to maintain 132kV switchyard, 2x11MW DGs, 11kV Switchgear.
• Authorized for implementation of company electrical HSE policy and procedures for MV & LV electrical equipment LOTO Lockout-Tagout Isolation and de-isolation, work Permit procedure etc.
• Performed monthly Equipment Integrity audit to ascertain the equipment Reliability and Availability in continuous process plant.
• Supported area maintenance team by providing professional input according to the best engineering practices and approved condition monitoring Procedures maintaining safe working conditions to the staff.
• Developed Reliability Centered Maintenance (RCM) strategies by using predictive tools such as Thermography, Vibration signatures, Power quality & Harmonic measurement, Oil test result Analysis.
• Analyzed and reviewed the plant breakdowns, incident, and faults, determining their causes and applying corrective measures to avoid re-occurrence.
• Achieved PF improvement by adding capacitor banks and avoiding low PF penalty.
• Reviewed the Energy consumption and taken control measures such as optimising the voltage level by introducing new Isolation transformer.
• Developed and validated SMP and troubleshooting guide to control the failures of Emergency DG sets in case of power failure (Black out). Handled loss-free Emergency DG operation in 3 blackouts.
• Developed Preventive and Predictive Maintenance schedule and frequency in Maximo® according to OEM recommendations and applicable standards for the critical equipment impacting plant performance.
• Maintain the spare management by Procurement® software.
• In addition, as Project Manager, led the team to accomplish the project of Mirror plant expansion with Klopper Germany.
• Completed project Construction to setup MV Substation, relays, MV/LV motors, Transformers.
• Testing and commissioning of 2x15MW Siemens HT Synchronous motors, LV PCC, MCC, DC UPS.
• Engineering input to Post start up RCM, team member to conduct RCA of a 15MW Motor exciter failure.
• Cost saving in Energy billing for fiscal PT error identification and resolution with State Elect board
Besides routine maintenance activities, I was involved in the team to convert contactor control to fully automatic control by new PLC (Siemens S5) for the main vertical furnace operations.
Taken part in routine maintenance activities. Additionally, I was involved in the team to build/operate Coal stacker and Reclaimer new units for better coal handling directly from Rail wagons.
Achieved First Division. Major subjects : Electrical Machines, Power system, Utility
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