Sr Instrument & Process Control Engineer
ADNOC SOUR GAS
Total years of experience :33 years, 5 Months
ADNOC, Shah Gas Development Project ( Gas Processing Plant) is unique in nature of High H2S (25% ) and CO2 content with latest art of Technology and producing NGL, Sales Gas, Condensates, Sulfur with its full capacity. Feed rate is 1000 MMSCFD.
•Involve in Gas Plant Commissioning, start up and stabilization, full load capacity & Test run activity.
•Provide Instrumentation, Process Control & Automation System support, Safeguarding and ESD System, Turbine & Compressor Control System and FNG system to ensure all system are operating efficiently, Reliable and available.
•Provide Leadership and guidance for DCS (Honeywell Experian System)/PLC (Honeywell SM) / F&G system (Honeywell SM) /Turbo Machinery (3500 series Bently Nevada) & CCC Anti Surge Control Systems.
•Trouble shooting and validation of different types of Process Control system and configuration check in system, like PID Control, Cascade Control, Split Range Control, Override Control, Selective Control, Lead/Lag Control, Performance controller, Anti-Surge Controller etc.
•Analysis and Trouble Shooting of Turbine Compressor Control System problem and Anti Surge Control tuning.
•Tuning of different Process Control System like Cascade, 3-Element Control in Boiler, Lead-Lag Control System in Air/Fuel Control in Furnaces, Ratio Control, Burner Management System and Control.
•Failure Investigation and Root Cause Analysis of different process/safety related failure, study critical incident and recommendation for Safe Plant Operation.
•Preparation of Instrumentation, Control System and Fire & Gas system Job Scope and Scope of Work for plant debottlenecking and small projects as part of improvement and maximizing Product efficiency and availability.
•Review as Technical Authority for Plant Expansion and Max Production FEED, Project Engineering Document which involves DCS/ESD System, Fire & Gas system, Instrumentation, Package Items, Control and Automation system of the Sour Gas Processing Plant.
•Preparation and review of Scope of Work for different Plant Instrumentation, Control & Automation modification work as part of MOC, Modification, Minor projects, Major Projects.
•Working as Technical Authority & Advisor for Green Field Project, Hail & Ghashha Sour Gas Development project’s FEED, ADNOC Sour Gas Optimum Expansion Projects FEED.
•Technical Authority for reviewing/commenting/ evaluation of Instrument, Control & Automation related document for different Brown Field/Green Field FEED Projects.
•Standardization of Functional Design Specification for DCS, ESD, FNG, Package Systems etc as per IEC 61508 and IEC 61511.
•Review of PFD, P&ID, Design specification for Instrumentation, Automation and FNG system, Cause & Effect Diagram, Data sheet review, Control and shutdown philosophy, Adequacy study for the plant Expansion Pre FEED & FEED stage.
•Involve is HAZOP, Safety Integrity Level analysis and study for Expansion, Maximum Production and different Change Management Procedure to Optimize/Maximize the production.
•Design document review of Instrumentation, Automation & Process Control for Expansion Project, Max-Pro Project, Sulphur Pipe Line FEED and EPC Project, Dirty Sulphur Remelter Project, CO2 Project, Optimum Expansion Project and other major projects.
Experience with Shell, NCPOC Seconded to Agipkco, Kazakhstan Offshore platform- D Island, Start-up, Commissioning & Maintenance :
Kashagan is one of the Shell’s biggest ever EP joint ventures, a unique combination of Technical complexity and Environmental Challenges ( -40 to +40 Deg C Temperature, frozen Caspian Sea and High Concentration of 17% H2S environment).
•Review Projects Design Engineering documents for Process Control & Automation, Control Narratives, DCS Control System & ESD Safeguarding System and Complex Blow downs system & Philosophy, Fire & Gas System, Safety System Integrity and Control systems.
•Provide technical input to operation/Commissioning team in preparation of the initial commissioning, start-up and operating procedures including preservation and training requirements.
•Co-Ordinate team of ICSS Commissioning Engineers, Vendor Engineer, Operations in Commissioning and preparation for Start-up activities in Offshore plant.
•Co-Ordinating and performing PCS/ESD/F&G system function test, EP Contractor technical quarries and defect rectification works.
•Review of Control Narratives and Control Systems Configuration check & simulation in DCS system for correct Controls system functionality before plant start-up and operation.
•Review of Cause & Effect diagram for ESD Safeguard system, Turbo Machinery Controls, HIPPS and FNG system.
•Different types of Control system’s configuration check, like PID Control, Cascade Control, Split Range Control, Override Control, Selective Control, Lead/Lag Control, Performance controller, Anti-Surge Controller etc. before plant start-up and in operation.
•Alarm Rationalization activity and implementation of the same across the offshore platform considering Safety, Priority, and Criticality.
•Responsible for Dynamic Commissioning loop testing and tuning during production start-up and Operations support interface of activities to offshore platforms and onshore groups.
•Conducting High Level ESD, ESD Safety Integrity, Hardware Degradation dynamic test, TUV shutdown, Safety system Communication system Degradation test, ESD & FNG Inter-trip and Safety System interlocks, HIPPS system checks for Offshore Platform, before plant start-up.
•Conduct walk down, site verification and punch points on various system in D -Island like, R &R Power generators, EDG, Fire water Pump, Instrument air system, N2 system, Utilities, Oil Trains, Flash Gas Compressor, Fire & Gas System, Well Head and Production platform etc.
•Review, Acceptance and Witness site acceptance Test of Foxboro DCS system and Control System, Triconex ESD & Fire and Gas System, Vendor packages including R &R Power Generators, EDG, Fire water Pump, Instrument air system, N2 system, Utilities, Oil Trains, Flash Gas Compressor
•Witnessing the Dynamic Test conducted on different Control system, Interlock & Shutdown system, Fire & Gas System, Package units Control & Shutdown system.
•Involve in the commissioning of CCC Anti Surge Control System (Vane Guard).
•Trouble shooting and Root Cause Analysis of Critical Compressor operation during plant start-up.
•Inspect, verify and review of all Control & Automation system, Fire & Gas System whether installed is as per Projects specification and followed standard Design Engineering Practices.
•Troubleshooting and Conduct Root Cause Analysis for failure of different Control & Automation system in offshore Oil & Gas Exploration and Production Platform.
•Involve in Corrective, Trouble shooting and Maintenance activity along with Operation during plant start up.
•Raise the Technical quarry and Partial Change Note for safe Plant Operation.
•Train the local Kazakh national while doing the job.
Experience with Shell, Brunei offshore Complex Maintenance:
Brunei Shell Champion 07 Complex, Offshore platform and its Associated Complex is producing Oil ( 175 Kbbl/d) & Gas ( 16 Mm3/d) and exporting to onshore.
•Provide Instrumentation, Process Control & Automation support to Operation including Process Control & Automation System, Safeguarding and ESD System, Turbine & Compressor Control System and Operation, FNG system to ensure all system are operating efficiently and available.
•Ensure Technical Integrity of Instrument & Control System Design & Maintenance by Implementing HSE and Quality system and Procedures and ensuring appropriate quality surveillance is carried out.
•Ensure Control & Instrument maintenance is appropriate and practical by preparing, reviewing and approving drawings, specifications, job instructions, material selection notes etc.
•Ensure Technical Integrity in change control, maintenance and commissioning of Instrumentation & Control system, IPS, DCS F&G and local PLC software and safeguarding by issuing Change Initiative Notes (CIN), Standing Instructions (SI), Technical Queries (TQ) and Non Conformance Reports (NCR). Ensure that appropriate approval to changes has been given prior to implementation.
•Provide Leadership and guidance for Control & Automation team, DCS (Foxboro)/PLC (Triconex TMR & Honeywell FSC) / F&G system (Triconex TMR) /Turbo Machinery Systems, Directs Engineering consultants, Vendor and Construction contractors in Design and Installation of Instrument equipment in EAST Asset.
•Trouble shooting of different types of Process Control system and configuration check in system, like PID Control, Cascade Control, Split Range Control, Override Control, Selective Control, Lead/Lag Control, Performance controller, Anti-Surge Controller etc.
•Maintenance & Troubleshooting of Gas Generator, Turbine & Compressor (Ruston, Avon, GE1600 Gas Turbine with Kawasaki, Borsig Compressor), Control and interlock is implemented in Triconex, GE Alstom Mark II and Ruston Gas Generator for power generation, control & Interlock implemented in Triconex TMR.
•Trouble shooting and diagnostics of Turbine & Compressor start-up logic.
•Trouble shooting & Maintenance of Triconex TMR PLC for Plant ESD and IPS, Fire & Gas Detection system.
•Troubleshooting of Honeywell FSC System for IPS and Plant interlock.
•Maintenance and troubleshooting of Sieger Point type, Light of sight type Gas Detecter, Flame Detector and smoke & heat detector in F&G System and Analyzers.
•Responsible for any Plant safety critical Instrument overrides, Conducting Risk Analysis Matrix assessment and raise deviation for Technical Authorities approval.
•Maintenance and troubleshooting of Bently Nevada 3300 and 3500 series Machine Monitoring system.
•Maintenance and troubleshooting of CCC Series 3 plus Anti-Surge controller.
•Commissioning, start up and Maintenance of 5.5 MW Torus Solar Power Gas Turbine Generator.
•Review of Process Control system and interlocks, Troubleshooting and tuning of control parameter to operate within Safety limits.
•Liaise with Operation regarding process related problem, recommendation for better and reliable operation.
•Lead in conducting RCA on Critical Equipment failure, plant shutdown and on bad actors effecting Production reliability and availability.
•Improve the reliability of the equipment by conducting RCM on the equipment.
•Custodian of Process Control Access domain in Offshore Platform and member of PCAD Audit team.
•Conducting HSE inspection, Emergency Critical role as
Experience with Petronas Gas Processing Plant Maintenance & Engineering Dept
Petronas Gas Processing Plant ( GPP 5 & 6- Complex -B) is the largest Gas processing Plant in Malaysia and having two Gas plants of production Capacity 2 x 500 MMSCFD Sales Gas ( C1 ) Production, and C2 ( Ethane ), C3 ( Propane ), C4 ( Butane) and Condensate products and utilities for the entire complex. The Plant feed is Natural Gas & Liquid from off-shore.
•Provide DCS (Foxboro) and PLC (August TMR & AB PLC) related Technical, Engineering and Troubleshooting support to the concerned Department in order to ensure high reliability and availability of Gas Processing Plant 5 & 6. Also provides in-house training as required.
•Liaises with Operation division personnel in order to ensure understanding of Problems and Solutions to the DCS and PLC Associated Instrument & Control Systems.
•Planning and execution of Regular, Preventive Field Instrumentation maintenance job, troubleshooting of different types of Instrument (Different type of Flow Measurement Instrument, Level, temperature, Control Valve, On-off valve, Sequence valve etc) used in Gas Processing Plant 5 & 6 and DPCU.
•Trouble shooting of process Control/ Instrument related recurring problems.
•Investigation and Analysis of Trip or Failure, Root Cause Analysis and recommendation for corrective action.
•Investigation of Process & Instrument related problems and recommendation for corrective action.
•Preparation of Change of Design (COD) and implementation of the same in a safe and effective manner.
•Preventive maintenance of Allen-Bradly PLC used for Package & Utility systems (Furnace, Compressor, Turbines, Dryer package, Sequencing etc).
•Preventive Maintenance of August TMR PLC used for Plant Safe Guarding System and Shutdown system, Heater/Furnace, Incinerator, Compressor, Turbine package.
•Preventive Maintenance of Bently Nevada (Series 3300) Machine Monitoring System used in pump, compressor and Turbine and Data Manager 2000 for the entire complex.
•Modification, Review and Improvement in the Control & Interlock scheme to improve the plant operation.
•Preventive Maintenance and Troubleshooting of Burner Management System used in Heater/Furnace.
•Maintenance of Sieger Gas Detector as a part of Fire &Gas System.
•Involved in the Shutdown/Turn around activities of Gas Processing Plant (DPCU and GPP#5 ).
•Preparation of Training schedule and train the Local technical staff by proper structural Training programme.
Experience with Haldia Petrochemicals Ltd.,
•Worked as Sr. Project Engr- Instrumentation for Naphtha Cracker Ethylene plant (470 KTA), Licensed by ABB Lummus, USA and LSTK Contractor is Toyo Engineering Corporation, Japan & Project Management Team (PMT) is M/s. Bechtel International Inc. USA.
•Co-Ordination with Licensor, LSTK, PMT, PMC and with different vendors for different project related issues.
•Co-Ordination, Correspondence and review of Engineering documents (Control system, Marshalling Philosophy for DCS & TMR PLC, Honeywell DCS, TRICONEX TMR PLC, Design of Safe Guarding System and Emergency Shut down system as per IEC 51608, Fire & Gas System, Machine Monitoring system, Woodward Governor System, Antisurge Control System, Compressor Package, PSA package, , Analyzer & Shelter, Field Instruments etc.
•Review of Tender documents, Technical bid analysis and Selection of DCS, TMR PLC, Package items, F&G System for the Ethylene Plant.
DCS (HONEYWELL TDC 3000 DCS) & PLC (TRICONEX TMR)
•Review of Honeywell DCS (TDC-3000 with GUS & HPM) Graphics philosophy & approval of system & Marshalling Panel drawing and wiring philosophy, I/O database distribution philosophy for DCS& ESD TMR PLC.
•Review, implementation & troubleshooting of different Process Controls like Auto Control, Cascade Control, Ratio Control, Feed forward Control, Split range Control, Boiler 3 Element Control, Furnace Temperature Control, Override or Selection Control in Naphtha Cracker (Ethylene) unit - Implemented in Honeywell DCS which consists critical process application like Naphtha\ LPG Cracking Heater, Compressor, Cold & Hot section and other packages.
•Review and approval of Interlock and Shutdown System Logic Diagram for Ethylene plant (consists of Furnace logic, Compressor & Turbine Logic, Flare Load Management System, Pump Auto Start/Stop logic, Different Columns safety logic). Implementation of new concepts of using double Solenoid valve in the Interlock logic philosophy ( On line Solenoid Valve Checking Procedure through Interlock ).
•Commissioning, Troubleshooting, Regular, Periodic & Preventive Maintenance of Honeywell TDC 3000 DCS and TRICONEX TMR PLC.
•FAT and SAT of Honeywell TDC 3000 DCS, Triconex TMR PLC &Analyzer Shed and Analyzers.
Engineering Document Review, Implementation, Commissioning & Maintenance of (a) 3500 series Bently Nevada Machine Monitoring System for Compressors in Ethylene plant and Data Manager 2000 (b) Anti Surge Control System- APPECs Controller supplied by Moore, USA for CGC, C2R & C3R Compressor and (c) Woodward Governor Micronet TMR Controller for Compressors Turbine Speed and Extraction control purpose.
F&G:- (a) Tender, Bid Evaluation, Selection, F&G System Philosophy, Engineering document review and approval of the entire Fire & Gas System in the HPL Complex (b) Commissioning, Maintenance and Troubleshooting of Fire &Gas System, which is implemented in Trusted ICS TMR Processor ( Dragger Make IR Gas Detector and Thorn Make Fire Detector). (c) Commissioning & Maintenance of CO2 Flooding system for fire protection.
Field Instrumentation: - (a) Monitoring & Supervision of LSTK Contractors Instrumentation job at site and involved in the field activities like Instrument calibration (Honeywell Smart Transmitter, Rosemount smart & Analog Transmitter, Level troll, Purge type level measurement, Pressure switch, Draft gauge etc.), Calibration, Installation, Loop Checking, Trouble shooting etc. ( b) Commissioning, Troubleshooting and Maintenance of Motor Operated Valve ( MOV), Rotork. ( c) (c) Daily Instrument Maintenance Job, Modification job, Job planning & Execution, Shutdown planning & Execution, Manpower Planning, Co-Ordination with other Dept. (d) Use of SAP R/3 in Plant Maintenance and Material Management (e) Document review and commissioning of Analyser House with all accessories, Field analyzer, IR, O2 Analyser, Viscosity, GC etc
Naphtha Cracker ETHYLENE PLANT IN RELIANCE ( May 1996 to Nov 1997)
Pre-Commissioning, Commissioning, Start-up & Maintenance Experience in Ethylene Plant :-
•In-charge of the Commissioning and Maintenance of Emergency Shut Down (ESD) System ( Modicon PLC ) and Fire & Gas System ( Sieger).
•Installation, Calibration of field Instruments ( Rosemount Smart & Analog Transmitter, Fisher Control Valve, On/Off Valves- Neles, Rotork MOV Actuator etc.).
•Commissioning and Maintenance of ABB Advent DCS System.
•Commissioning & Maintenance of ESD system ( Modicon 984-785E, 984-685E) for Ethylene & Aromatis.
•Commissioning & Maintenance of F & G system supplied by Sieger for Cracker & Aromatics Plant.
•Involved in the Commissioning of Bently Nevada 3300 series Vibration Monitoring system.
•Involved in the commissioning of Antisurge Control System Series 3 Plus supplied by CCC.
•Involved in the commissioning of Woodward Governor S509 Model for three Compressors.
•Simulation and Dynamic checking of logic for the Ethylene & Aromatics plant .
•Modifications of Logic ( In ESD PLC) for better operation and plant safety.
•Design, Detail Engineering of NGL/Naphtha Cracker Plant 700 KTA Expansion EDS Logic and implementation of the same in Modicon PLC Online.
•Preparation of shutdown schedule and supervision of shutdown jobs in Ethylene plant.
•Train and develop training programme on Plant PLC and shutdown system for Engineer and Technician .
Design & Engineering Experience in Larsen & Toubro Ltd. :
• Estimation, Design & Detail Engineering of Uranium Corporation of India Ltd., Jaduguda, Bihar- ADU Filtration, Drying & Packing Plant.
• Preparation of Instrument Index, Annunciation Schedule, Cable schedule, Instrument Hook-Up drawing, Instrument Installation diagram, Instrument Location diagram, Instrument data sheet for UCIL-ADU Filtration, Drying & Packing Plant.
• Standardization of different Instrumentation items and drawings.
• Technical Evaluation of different types of Instrument used at our various project.
• Selection of PLC and Design & Detailing of PLC Logic Input & Output.
• Site support to Rayalsheema Ash Handling Plant of APSEB’s Thermal Power Plant of 2 x 210 MW capacity.
VCM & MEG PLANT EXPERIENCE IN RELIANCE ( July 1990 to Dec 1993)
Project, Pre-commissioning, Commissioning, Start-up, Maintenance of VCM, MEG Plant & Offshore Project:-
•Reviewed Instrumentation documents like P&ID, Instrument Index, Field Junction Box wiring diagram details, Cable schedule, Shut down Logic wiring diagram, Electrical Installation Detail diagram, Instrument Hook-up drawing, loop schematics etc. for VCM Plant.
•Checking of Control philosophy, Plant overview, graphics etc. in ABB MOD300 DCS for VCM Plant.
•Factory Acceptance Test & SAT of DCS system ( ABB MOD 300 system) at Faridabad, India.
•Calibration, Installation and loop checking of different Pneumatic and Electronic Instruments, Control valves.
•Simulation and checking of PLC based Emergency shut down Logic Signals in VCM plant.
•Commissioning and Maintenance of Modicon PLC ( Model 984A, 984-680) for VCM plant shutdown and Incinerator unit supplied by Mc Gill.
•Commissioning and Maintenance of Incinerator unit supplied by Mc GILL-USA ( In Modicon PLC) and Burner Management System ( BMS) in Incinerator unit.
•Commissioning, Troubleshooting & Maintenance of MOD 300, Fire & Gas Detection System supplied by Detection Instrument.
•Modification, Review and Improvement in the Control & Interlock scheme to improve the plant operation, Preparation of site modification scheme and implementation of the same in a safe and effective manner.
•Troubleshooting, Preventive & Regular Maintenance of field Instrument used in VCM Plant.
•Preparation of shutdown schedule and supervision of shutdown job in VCM Plant.
•Worked in the Offshore job in REL GAS VIKRAM EDC Storage Project (Document review, Calibration, Installation, Loop Checking, Commissioning and Troubleshooting of Different Instrument used.)
Instrumentation Electronics Control system Engineering
Physic Honours Mathematics Chemistry Bachelor Degree