Instrumentation Engineer - Material Standardization (Review/Cataloguing)
Star Link Middle East (Client: Saudi Aramco)
Total years of experience :13 years, 5 Months
• Implementing Quality Assurance and Quality Control Processes of Material Standardization “Equipment and Spare parts” according to Saudi Aramco Engineering Standards. This includes classification, Hierarchy, provide full technical specification, documentation, and identifying required spares for each instrument.
• Reviewing and extracting the required technical data from Spare Parts Data Package (SPDP) received from EPC/LSTK by referring to PO, Data sheets / Specification sheets, Bill of Materials (BOM), Priced Spare Parts List (PSPL) / Spare Parts Interchangeability Record (SPIR), technical drawings, manufacturer’s catalogue, and Test certificates.
• Cataloguing of the operational spares in the SAP/MM (SAP/MDM) module as per Saudi Aramco Engineering Procedure (SAEP-3101) and UNSPSC cataloguing classification system.
• Dealt with SPDP’s of various field instruments such as control valves, safety relief valves, on-off valve, pressure regulating valves, analyzers, level, pressure, temperature and flow instruments. Identifying and ensure these Instruments have enough operational and capital spares for maintenance purposes.
• Handled SPDP’s for control and monitoring systems such as RTU, DCS, SCADA & ESD systems, marshalling cabinets, Fire Alarm System, Gas Detection System, Vibration and Monitoring System, Telecommunication system, Chemical Injection Skids and ensuring these systems have enough operational spares.
• Check and review equipment SPIR/PSPL includes communicating directly with LSTK, OEM / OCM in finalizing required spare parts list / any documents for new equipment.
• Installation, Commissioning, Maintenance and Loop Checking of field instruments (Flow, Pressure, Level & Temperature transmitters), Control Valves, On-Off Valves, Installation of Cable Trays, Impulse pipe lines and Junction Box, Cable terminations (Instrument, Junction Box and Panel side).
• Supervision of calibration for Transmitters, Switches, Gauges, Thermocouples and RTDs.
• Coordination with the vendors for activities under vendor scope to support and ensure the completion of the installations.
• Participating in work progress discussion meetings and engineering drawing review/revision meetings.
• Coordination with the construction team to give the technical information about the field instruments and ensure the completion of the installations.
• Coordination with the QC team to ensure the completion of punch lists.
• Leading and supervising of Installation, Commissioning, Maintenance, Loop Checking, Calibration and Troubleshooting of various Field Instrumentation & Control Systems to ensure minimum disruption to the online plant facilities.
• Maintenance, Loop Testing & Troubleshooting of SIEMENS S7 - 300 PLC, SIEMENS HMI’s, FIBRE OPTICS, FIELDBUS & PROFIBUS systems and Sensors for various applications.
• Installation, Maintenance & Troubleshooting of Siemens S7-300 PLC based Bulk material handling equipment’s (Reclaimer, Ship loading & Mobile Conveyors).
• Maintenance, Calibration and Troubleshooting of Weigh Bridge \[Avery\], Weighers & Weigh Feeders \[Schenck, MicroTech\].
• Assisting in Implementation of RCM and other Maintenance Improvement initiatives.
• Accepting work permit (PTW) and Supervision of Installation & Visual Inspection activities of Control Valves, Transmitters, Instrument Communication cables & other Instrument activities.
• Ensure that all work orders are closed out in CMMS by reviewing all WO feedbacks and updating the job history.
• Training the technicians, Technically & Safety-wise about maintenance activities to complete the task safely as per the guidelines of the Safety Maintenance Procedures.
• Coordinating with Contractors inspection activities and accepting QC inspection records in accordance with company / client specifications.
• Involved in Turn Around Maintenance \[TAM\] / Shutdown activities in Ammonia Plant
• Conducting Site safety inspection and supervision of instrument maintenance activities, Coordinating with Stores for emergency spares, Coordinating with Workshop for Servicing, Calibration and Inspection of field instruments and maintaining those records for auditing purpose.
• Documentation and Implementation of SHEM standards and maintaining departmental documentations for auditing purpose.
• Familiar with various Work Permit Systems - PTW (Safe, Hazardous & Confined Space) JSA, Tool Box talks and LOTO procedures.
• Involved in Start-Up activities of Ammonia Plant.
• Commissioning and Start-Up of PLC based Heavy Material Handling & Conveying equipment’s like Ammonia Ship Loader, Di-Ammonium Phosphate Reclaimer and Tripper.
• Installation, Commissioning, Loop checking, Maintenance (Preventive, Routine, Breakdown), Troubleshooting, Configuration & Calibration of Electronic, Pneumatic & Hydraulic field instruments including SMART Transmitters \[Flow, Pressure, Level, Temperature & Conductivity\], Analyzers, Control Valves, ON/OFF Valves, MOV’s used for process monitoring and controlling.
• Designing & Modifying of instrument Open and Closed loops, Point Configuration, Graphic Implementation, Trending & Historisation etc. in Honeywell’s TPS TDC 3000 x DCS.
• Installation, Maintenance & Troubleshooting of Allen Bradley - RS Logix 500 based Reciprocating compressors.
• Maintenance & Calibration of CO2 \[ADC\], O2 \[Yokogawa\], H2 \[Riken Keiki\] analyzers and Conductivity meters \[Yokogawa\], Turbidity Meter, pH Meters.
• Extensive knowledge in using various test and calibration equipment’s and field communicators (HART and BRAIN TERMINAL) for calibrating field instruments.
• Maintenance, Calibration and Troubleshooting of Weigh Bridge \[Avery\], Weighers & Weigh Feeders \[Transweigh\], Weighing Scales \[Essae Teraoka\] & Bagging Machines \[Chronos Richardson\].
• Coordination & Preparing engineering documentation for the Calibration of Test Instruments with International Standard Instruments \[FCRI\] and maintaining calibration reports for the same.
• Generating the Preventive & Breakdown maintenance schedule, Calibration schedule, TAM schedule through CMMS and executing these tasks as per the guidelines of the Maintenance Procedures.
• Understanding of P&ID’s / ILD’s and explaining to the technicians for the Safe execution of tasks.
• Trouble shooting instrument failures effectively and in time to reduce the instrument downtime and carrying out root cause analysis of those problems to come out with a permanent solution.
• Preparation of Data sheets and specifications for all process instruments and control valves according to the company standards.
• Knowledge in preparing P&ID’s, Instrument index, Instrument hook-up and wiring drawings, Loop diagrams, Instrument datasheets, Preparation of punch lists.
• Responsible for the planning activities like Optimal Manpower Planning & Material Utilization, Material Procurement, Maintaining Instrument history, Departmental Spares Maintenance, Maintaining/updating of job history, Contractor’s bill inspections by visiting worksite.
• Involved in TAM / Shutdown activities in Soda Ash & Ammonium Chloride plants.
• Reviewing work orders (Preventive & Breakdown) and ensures those tasks are completed and updating the work order status in CMMS and signed & filed for auditing purpose.
• Vendor selection & reviewing of vendor documents for final product selection and procurement.
• Coordination with EPC Contractors / Vendors during Commissioning, Modification, Upgradation activities.
• Coordination with HSE (Safety) Department and ensuring the safe working ambience at Site.
• Involved in Erection & Installation of complete Instrumentation Systems for the new Project “AMMONIUM BICARBONATE PLANT” and the project was successfully commissioned.
• Involved in Start-Up & Maintenance activities of AMMONIA PLANT (Refrigeration).
• Upgradation of Pneumatic to Electronic instruments and hook up with DCS of Sodium Carbonate & Bicarbonate, Ammonia Chloride & Utilities Plants (Boiler, Instrument Air Systems).
• Familiar with the documentation and implementation of ISO 9001, ISO 14001 and OHSAS 18001 International Standards and maintaining departmental documentations for auditing purpose.
• Familiar with usage of PPEs, Fire Extinguisher.
Bachelor's Degree (BE) in ELECTRONICS & INSTRUMENTATION ENGINEERING from Noorul Islam College of Engineering, Anna University, TamilNadu. (2006 to 2010).
