SENIOR INSTRUMENT PROJECT ENGINEER
SHELL MIDDLE DISTILLATE SYNTHESIS (SMDS)
Total years of experience :16 years, 2 Months
o Project Manager for Machinery Protection System (MPS) Rejuvenation Project Phase I - delivered project on time and budget within timeframe of Plant Turnaround (PTA).
- The scope of the project is to rejuvenate machine monitoring system and introduction of condition based monitoring system, governor control system upgrade, introduction of electronic overspeed protection, and migration of “black box” anti- surge control and trip function to Shell Compressor Anti-Surge Control (CASC) algorithm. This is the novel brownfield project approach in Shell.
- Successful completion of MPS Rejuvenation pilot Project for compressor K-3201 in a very challenging timescale; 6 months including design, procurements, and execution with an exceptional number of interfaces both internally and externally.
- Successfully completed on schedule and under budget for Phase 1 of MPS Rejuvenation Project during PTA. This required managing a number of challenges including a late change in direction regarding implementation of a key technologies for the compressors, delivery of materials but with a cost saving around 700k USD as a result of prudent strategy implementation.
o Project Manager for SMDS Gas Chromatograph (GC) Upgrade Project Phase II - delivered project on time and budget within planned timeline.
- The GC Upgrade Project intends to improve reliability and availability of the 17 GCs by upgrading all relevant obsolete and aging components. Siemens MAXUM II GC is selected as the replacement model. The project was executed online/on stream.
o Manage Instrument Projects section delivering the following:
- Plant modifications (Plant Changes)
• Detail Design Engineering
o Initiate HAZOP/IPF Review
o Design the required modifications with specification and selection of systems, transmitters / detectors / valves, and fit for purpose technology as per Shell Design Engineering Practice standard requirements.
o Technical review of functional and detailed design documents.
o Develop instrument scope of work with cost estimates +/-10%
• Procurement
o Develop/initiate contracting and procurement strategy for the site execution.
o Employ to Shell RtP process on the procurement stage.
• Installation, Test, and Commissioning
o Technical review of functional and detailed design documents, participation and acceptance of FAT and SAT, installation and commissioning of systems.
• Documentation Update
o INTOOLS/SPI documentation update for instrumentation loops and datasheet.
o Pressure Swing Adsorber (PSA) PLC Upgrade Project - flawless site execution.
- The PSA PLC Upgrade Project intends to improve reliability and availability of the PSA system by upgrading obsolete and aging Modicon 984 Series PLC to Siemens S7 400 Series PLC. The project executed during plant turn around, within schedule, cost, and as per outlined quality.
o SMDS Instrumented Protective Function (IPF) Site Focal Point
- Developed IPF Lifecycle Management procedure for SMDS, “cradle to grave” strategy/approach.
- Developed SMDS integrated Hazard Effects Management Process (HEMP) and IPF 10 Year Masterplan.
- SMDS IPF Facilitator for the IPF review/classifications.
- SMDS IPF engineering designer.
- Optimization of the IPF testing intervals to eliminate
o Subject Matter Expert on Yokogawa DCS system; Yokogawa Centum CS, Yokogawa Centum CS3000, Plant Resource Manager (PRM), and Yokogawa CCTV System ADPRO.
o Subject Matter Expert on Honeywell Fail Safe Controller (FSC) system.
o Subject Matter Expert on Siemens PCS7, and Siemens S7.
o Subject Matter Expert on Machine Monitoring System; Bently Nevada System.
o Subject Matter Expert on Machinery Speed Control System; Woodward 505E, Woodward Micronet Plus, and Woodward 501.
o Subject Matter Expert on Overspeed Protection System; Woodward Protech TPS, and Woodward Protech 203.
o Develop and execute maintenance strategies to ensure the reliability and integrity of the control systems hardware, software, and applications.
o Develop and execute strategies to maintain control systems IT security and integrity.
o Ensure sufficient and suitable resources and equipment are available to correctly and safely execute maintenance and engineering activities on the control systems.
o Initiate and develop specific procedures, work instructions, work plans, inspection and testing schedules for control systems, including control system IT security.
o Ensure documents, i.e. control system architecture, drawings and software backups are maintained and updated.
o Review the control system content of plant modifications and instrument trip/alarm settings change to ensure that plant integrity is not compromised and that design objectives and regulatory standards are met.
o Act as Contract Holder for selected contracts. In this role, be responsible for the initiation, award, execution and completion of the contracts for which you have been appointed Contract Holder.
o Responsible for the development of the Instrument Systems team as well as individual’s competencies, necessary to achieve the business needs
o Technical Authority (TA) for the control and safeguarding system.
o Design and implementation of Auto-MOS scheme on the safeguarding system which has contributed to real bottom line savings in preventing shutdowns due to nuisance single trip initiators.
o Demonstrated a keen commercial mindset by identifying how unused software license could be used for the implementation of a high resolution data logging facility thereby saving EUR150k and realizing a superior solution to the expensive alternative. A “Gold Awards” been awarded for this work under “Shell Bright Ideas” work stream.
o Extension of Plant Resource Manager (PRM) coverage to all the accessible field devices which facilitates the transition from reactive to proactive maintenance culture with less technician intervention, lower probability of trips and better planning of maintenance effort. A “Gold Awards” been awarded for this work under “Shell Bright Ideas” work stream.
o Process Control Access Domain (PCAD) implementation recognized by the PCAD project management as being the best in class for the execution.
o Developed tools for operations and technologists for post trip analysis and for promoting own team's productivity. The tool eliminates the need for manual data analysis from the safeguarding and DCS system which resulted in quick fault finding - key on managing the risk to “As Low As Practicable (ALARP)”
o Completion of the control systems' training unit and development of a long term strategy for the evolution of the DCS in face of future obsolescence of key components and software.
o Developed a scheme for the instrument system daily proactive maintenance reporting. This scheme is a paradigm shift from weekly proactive maintenance to daily proactive maintenance with half of the time of weekly maintenance - this has significantly improved the maintenance coverage on the health of control system. A “Bronze Awards” been awarded for this work under “Shell Bright Ideas” work stream.
o Commissioning Lead Engineer for SMDS Safeguarding System Rejuvenation Project
- This project was on the critical path during plant turn around 2011.
- Ensure the flawless execution of the project.
Ensure the rejuvenation project is executed as per Shell Standards.
o Ensure Safe Production (ESP) Project Implementation
- Successfully deployed the ESP project in SMDS with the role as the technical subject matter expert, and the main driver for the entire project.
- Designed and developed the alarm management and mapping scheme on the Yokogawa DCS system for the ESP implementation in SMDS.
o Instrument system focal personnel for the Gas Global Asset Management Excellence (GAME) implementation in SMDS.
o Commissioning and start up instrument system focal point for SGP Prefurn project and the research plant HPS Demo.
o Focal point to build foundation fieldbus knowledge in the instrument department.
o Instrument System focal point for the SMDS plant shutdown exercise.
o Focal point for the DCS Alarm management.
Purdue University, West Lafayette, Indiana, USA (Full Scholarship by Malaysian Government) Major: Electrical Engineering Minor: Communication Overall GPA: 3.59 January 2000 to December 2003