Rajesh Kumar

Installation and Commissioning

Position: Assistant General Manager, Instrumentation;
Plant: Dangote Cement & Power Plant, Ibese - Gas Turbines. Maintenance, Planning, Repair works, Team leader. Trouble shooting of DCS/PLC/Instruments.

Egis -Oman
Lead Instrumentation & Control Engineer- December 2020 to(Currently working).

Project: Salalah IWP, Sharqiyah IWP, Oman(R.O. Water Plant), Client: OPWP.
Job Nature: Client’s I&C Engineer/Consultant (For OPWP Oman Govt.)
Job Functions
Responsible for allSite acceptance tests/Startup tests inspection mainly focused in to the I&C activities at site. Inspected /Witnessed Reliability and Performance test and Report making. Make sure water quality and environmental emissions are within limit as per the IWP Project Contracts. Ensure Site EHS policies are implemented during commissioning and Operation phases before handover to Commercial Operation. Coordinate with Site 3rd party EHS auditing.Make sure site quality policies are implemented. Produce daily and weekly reports to Client. Everyday reporting to Egis Project manager. Meeting with Owner Company and EPC as Client’s representative. Inspection of Plant Control systems, Analyzers and Process function tests. Review Acceptance test documents and comment. Make sure there are no forced signals and the plant is running in full automatic mode. Make observation reports and email to Owner company to resolve site issues during commissioning and startup. Review Reliability test and Performance test records before COD.

Gulf Power International- Saudi Arabia
Lead Instrumentation & Control Engineer- October 2019 to February 2020.

Project: Shuaiba Power Plant, Saudi Arabia
Job Nature: Maintenance / Shut Down
Job Functions
Responsible for all I&C Shut down / Maintenance activities in Boiler and Turbine area. (Remove, Calibrate, Service/ Maintenance and re install all field instruments).Train and lead Supervisors and Foreman. Make daily work progress report. Responsible for MakingAnnual Maintenance Final Reports for I&C, Electrical and Mechanical jobs. Receive and distribute PTW. Site visit and inspection of work progress; advise workers. Ensure Safety and implement EHS policies during work.

Achievement: Construction/installation of FGD area completed without complications. Critical logic changes implemented according to client’s requirement and in compliance with GE standards. Field instrumentation design changes done accordng to site requirements and send changes to engineering team for producing revised drawings.

Responsible for I&C construction works and I&C Commissioning support in FGD area. Reporting to site Team Leader. Advising client for I&C Installation and resolving any installation issues. Verification of I&C logic and meeting with Client for Logic modification. Assisting client engineers to perform jobs as per technical procedure without compromising safety. Preparing as built hand sketches and send to head office for producing as built drawings. Identifying I&C design issues in site and do modification accordingly. Communicating with vendors for resolving material supply issues and installation issues. Communicating with head office design team for resolving current design issues. Attending EHA meeting and making weekly Site EHS reports.

Completed RCA for boiler over heating issues and Instrumentation related problems. Successfully implemented resolution according to RCA. Increased total monthly production of electricity from 4000MW to 5000 MW. Reduced cost of maintenance, Increased plant reliability and performance. Completed DCS SUPCON upgrade. PLC Trouble shooting, Instrumentation calibration and Maintenance. Completed Logic Modifications, Instrumentation Design modifications. Troubleshooting of Biogas

Owner's Engineer
SAT, Logic / Interlock test, NCR, Punch list, Conducting weekly meeting, Site I&C Construction and Commissioning inspection for Thermal Power Plant (Oil fired)

Parsons Brinckerhoff, Indonesia,
SUMSEL-5, 2 x 150 MW, Coal Fired Thermal Power Plant.
Instrument &Control Lead EngineerJuly 2014 to September 2014
Job Nature: I&C Construction/Installation.
Job Functions
Worked as Owners Engineer.SAT of DCS Panels. Completed Site Instrumentation & Control system Inspection. Engineering document review and comment. Pushing the contractor for speeding up the material delivery. Advising contractors for proper construction/Installation and Commissioning as per site.

• Inspection of I&C commissioning activities in the conversion of Single cycle to Combined cycle power plant
• SAT (Site Acceptance Test) for DCS, PLCs
• Supervising / Leading junior Engineers
• Logic, Interlock and function tests inspection for HRSG, STG, GT, BOP/Aux area
• Raising Punch lists, NCRs, Surveillance reports
• Monitoring and advising the main contractor
• Verification of ECC and CCC Turnover Packages
• Reporting to Lead Engineer and Department Head
• Commissioning of GE mark VIe controllers and related I/O cabinets

•Erection/Installation and Pre- Commissioning of Instrumentation & Control system - ESP and FGD (Flue Gas Desulphurization) Unit. & BOP
•Leading the I&C Supervisors and technicians for the time and target oriented works with awareness of safety and quality
•Developing Conducting training / awareness program on FGD operation and field instrumentation for administration people
•Preparation / Modification of field design whenever necessary and co-ordination with Client / Consultant for FDC
•Co-Ordination with Construction Manager, Commissioning manager, Attending Daily meeting, Weekly Meeting
•Preparation of Weekly, Monthly progress reports
•Supervision of PLC, Control valves, Transmitters, LV Motors, Analyzers, On/Off valves, Motor Operated Valves etc.
•Supervision of Instrument Calibration with DRUK, HART Communicator
•Preparation of work permits
•Conducting Client witnessing program for I&C Section
•Electronic Data Logging for GRP Pressure test

The Duty is to Supervise the I&C Commissioning team in the 600MW each unit, Boiler side and BOP, Maintenance jobs for guarantee period for total three units. The detailed duties are as follows


•Participated in the Initial activities of commissioning like planning, scheduling, recruitment of junior engineers etc.
•Pre commissioning of boiler area and training the I&C Supervisors / Technicians for the same using HART Communicator and other tools
•Supervising the calibration of SMART Electronic Instruments Using DRUK calibrator, SFC and HART Communicator and related tools and equipments. Calibration and function test of Positioners, I/P Converters, Control Valves, Mass flow meters and Ventury flow meters, Pneumatic Actuators, Control Dampers, Calibration and Trouble Shooting of Motor Operated Valves, O2 LAND Analysers,
•Attending daily meeting and Reporting
•Optimization of Pneumatic controllers
•Checking of control Logic implemented in Air& Gas, Water & Steam and BMS systems
using Siemens DCS
•Cold /Hot Commissioning of BMS, BPS and Checking of logics FD, ID and GR fans etc including vibration and temperature sensors.
•Commissioning of Allen Bradley PLC Systems
•Commissioning of Security Camera Systems TELEA, SANYO,
•Commissioning of Soot Blower system/PLC
•Meggering / Insulation test for MV Motors
•Document Preparation and Client / Consultant Witness Procedures

The Duty is to supervise the Commissioning team of Instrument and Electrical section including Loop check, Energisation, Function Test, Calibration of All systems in the Steam Boiler in Stage I and stage II. The major responsibilities are listed as follows.

 Supervision of a commissioning team including Instrument and Electrical section
 Calibration of Electro Pneumatic Instruments Like Positioners, I/P Converters, Control Valves in Power plants, Pneumatic controllers, Calibration of SMART Electronic Instruments Using DRUK, SFC and HART Communicator.
 Commissioning and Function test of Mass flow meters and Ventury flow meters
 Loop checking and Pre-commissioning using SFC
 Commissioning of Rotary Equipments such as Draft Fans, Motors, etc
 Commissioning of Pneumatic Actuators, Control Dampers and Commissioning/ Stroke Check of Motor Operated Valves
 Commissioning, Calibration of O2-ABB, Co & Co2 Analysers. SICK/MAIHAK Germany
 Commissioning of Allen Bradley PLC Systems
 Commissioning of Security Camera Systems TELEA/SANYO
 Handheld Ultrasound Flow measurement for testing purpose
 Commissioning of Sooth Blower system
 Turnover document Preparation and Preparation of Documents for field activities
 Performance of Client / Consultant Witness

To Supervise the Calibration and Installation of all of the Instruments in Ammonia and Caprolactam Plant (Chemical and Petrochemical)