Lead Instrument Control Engineer
Ma’aden Gold And Base Metals Company - Mgbm
Total years of experience :11 years, 6 Months
Key Deliverables:
• Managing the Operations of a 450 km water pipeline by team of Instrumentation engineers and technicians, bringing treated wastewater from Taif City in Makkah Province in Saudi Arabia to 3 major gold mine sites. This environmentally sustainable solution is the first instance of the large-scale use of treated waste water for industrial purposes in Saudi Arabia.
• Proven ability to design, deploy, and maintain 450 km fiber optic network by linking remote locations to Internet connectivity, remote surveillance and SCADA system.
• Maintenance and troubleshooting of 400 cameras, access control system, microwave detection system and fence detection system for Ad-Duwayhi gold mine.
• Accountable for optimizing readiness of all plant and equipment, underpinning the security of production understanding that the direction of all routine maintenance complies with company operating policies and procedures and ensure adherence with safety, legislative, environmental and certifying authority requirements.
• Direct the activities of instrument staff to a high standard in accordance with safety regulations and procedures, in order to limit the risk of personal injury, environmental damage, and asset damage. This has resulted in elimination of large back log & quality PM’s being executed.
• Managed teams to implement productive Root Cause Analysis.
• Execute a robust review of Preventative Maintenance procedures to ensure alignment with performance standards, whilst assessing and enhancing maintenance routines in conjunction with other operational personnel and base support staff. Greater equipment uptime & efficiency are readily evident by this approach.
• Provide day to day instrument support & guidance on maintenance issue to assure that the integrity and reliability of the instrumentation, control, safeguard, condition monitoring, and analysis systems are maintained and fully functional.
• Identify areas of instrument, control & safeguard deficiencies, develop options and specifications for replacement to address obsolescence and instrument vulnerabilities
• Reduced equipment failure, identify the requirements to perform root cause failure analysis and lead / participate in analysis to prevent repeated failures.
• Identify and provide recommendations regarding new techniques, equipment and materials, which benefit the company financially through an increase in reliability and longevity of equipment.
• Identify long term and short-term system upgrade projects, assisted with budgetary cost estimates for fund approval, develop work packs & plans for the execution liaising with the operation and planning teams for the development of schedules .
• Lead continuous improvement initiatives within the automation and instrumentation function and coach team through the identification and improvement of plant performance issues.
• Initiating and reviewing (proposed) PM amendments and implementing them to improve the specific maintenance plans and maintenance strategies
Key Accomplishment / Success
• During 5years of service in Ma’aden Gold I have received 3 years 1st place in Performance rating and 2 years 2nd Place in Performance rating.
• Previously all stations monitor manually Since coming onboard I have online the SCADA system for remotely monitoring and controlling.
• Enhancing data connectivity of 150Mbps to remotely Ad-Duwayhi mine by utilizing 450 Km fiber optic cable as being done in-house. This has translated into a major cost saving of around 2, 000, 000 SAR and 3, 000, 000 yearly.
Controls & Instrumentation Design Engineer with approx. 5 years’ of experience, working as Design, Construction & Commissioning Engineer and across various industrial sectors (Gold, water, power, chemical & cement) with proven technical and management abilities.
• Experience in design and development of process instrumentation for across various industrial sectors. Process instruments including pressure, temperature, flow and levelling instruments, control and shutdown valves.
• Experience in design and detailed engineering of Front End Engineering Design (FEED), Floating Production Storage Offloading (FPSO) modules. Also experience in design and development of electrical systems including distributed control systems (DCS) and supervisory control and data acquisition (SCADA).
• Experience in developing engineering documents including piping & instrumentation diagrams which define key system parameters such as Set Points, Control Sequences, Flows, Pressures and Temperatures, instrument index sheets, instrument data sheets, junction box layouts, instrument loop diagrams, hook-up drawings, panel wiring diagrams, and PLC specifications.
• Experience in Low Voltage Signal I/O (PLC's, 4-20mA sensors and 24VDC actuators/switches/relays), High Voltage Switching Control, Intrinsically Safe Systems and Customer Networking Interface to Safety Instrumentation Systems, Distributed Control Systems and Motor Control Centers.
• Experience in design for all Engineering Change Requests and Orders.
• Experience in making As-build drawing and Redline markup in various field.
• Responsible for managing vendor selection and qualification activities.
• Responsible for managing designers and drafters to complete project deliverables.
• Responsible for working with cross functions to improve manufacturability and implementation.
Responsible for the calibration of instruments, erection, commissioning of 2 x 300 MW Power plant And Preparing P&I diagrams and process flow sheets for GMR EMCO Energy Ltd, Warora, Maharashtra.
Shut-down Experience
I have been involved along with a team of engineers for 27 days shutdown R&D work of one of the 7x210 MW power plant units at Wanakbori Thermal Power Plant which was commissioned in 1982 by Gujarat State Electricity Corporation Limited (GSECL), This is one of the biggest Thermal power plants in Gujarat, and having 1270 MW installed capacity.
300 DCS Detailed Commissioning and programming.
Generation of Distributed control system feedback control functions, operator station display function, sequence control & functions and graph panels using DCS.
On site training about Turbines 1 x 110 MW Francis turbines and 7 x 100.8 MW reversible Francis turbines and the Installed capacity is 816 MW
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