control systems engineer
Yanpet
Total years of experience :20 years, 5 Months
• Technical Support to Operation and Maintenance (Run and Maintain) team issues related to Instrument and Control System.
• Work on Area of Improvement Instrument and Control Systems.
• Up gradation projects executions for DCS and ESD.
• Involvement with E&PM team for expansion projects from Engineering to Execution.
• Spare part management and Vendor relations for Control System.
• Control Systems:
o DCS: Honeywell TDC2000/HPM/C300
o ESD/BMS/FGS: Triconex, ICS Triplex, Hima
o Rockwell Logix 5000 Controllers
o Woodward Controllers
o ALMS, OPC Servers
o VMS/CMS: Bentley Nevada
Role:
• Reviewing the project P&IDs, installation drawings, datasheets and specifications
• Furnishing assistance in the development of project schedules and manpower requirements
• Rendering support for sourcing and specifying instrumentation & control systems
• Performing the inspection of field instruments installation as per standards
• Accomplishing SAT for DCS, ESD and all other control systems in domain based control system
• Conducting the functional verifications of DCS and ESD logics as per procedure for various areas in refinery
• Driving the logic corrections in DCS and ESD during function test
• Liaising with package PLCs vendors and ensuring that the systems are functional, tested and commissioned as per requirement
• Tracking the configuration and troubleshooting of Fieldbus Devices using DCS & PRM
• Control Systems:
o DCS: Yokogawa Centum VP
o ESD / BMS / FGS: Yokogawa Prosafe RS
o CCS: CCC; AMS (PRM), ALMS, DAHS, ExaOPC Servers, SOE OPC Servers, APC & AMB
o CCTV and Wireless Network
o VMS/CMS: Bentley Nevada
• Field Instruments:
o ESD Valves, Control Valves: Flowserve; Pressure, Flow and Level Transmitters - Yokogawa & Emerson
o Smart Positioners: Flowserve, Fisher DVC - 6000
o Guided Wave Radar Level Transmitters: Emerson
Role:
• Supervised the maintenance and troubleshooting of:
o ESD, SSLS and BMS System PLCs (ELOP-II)
o Man Turbo Make Process Gas Compressor (CRU) having Duplex/7, Duplex Smart and TMR Systems (Gebhardt Automation-Germany); Man Turbo CRU System and CMS/TMS System (Bently Nevada) \[Man Turbo CRU Capacity: 12 MMSCFD\]
o Cooper Bessemer Make Process Gas Compressor (CRU) Engine (Reciprocating); Capacity: 9 MMSCFD
o Condition Monitoring System - CMS ( Bently Nevada-3500)
• Executed the logic and graphics modifications in DCS
• Managed AMS & FDM for configuration, calibration and troubleshooting of Smart Field Instruments
• Delivered the corrective and preventive maintenance jobs
• Control Systems:
o DCS: Honeywell Experion PKS (C-200) and TDC-3000 with OPC Servers
o HIMA PLCs for ESD, SSLS and BMS
o Condensate Recovery Unit (CRU): Man Turbo and Cooper Bessemer
o PHD, AMS and FDM Systems
• Field Instruments:
o ESD Valves, Control Valves: Masoneilan & Fisher
o Pressure, Flow and Level Transmitters - Emerson, Honeywell & ABB
o Level Transmitter - Masoneilan - Displacer Type
o Smart Positioners: ABB, Fisher DVC-6000
A)Project :
Capacity/Technology: 600 TPD/DuPont
PMC : Chemtex Global
Project cost : 450 Cr INR
Control Systems :
DCS-Yokogawa CS3000.
Bertram Heater-HTF (Germany) using Siemens PLC S7-300
PTA conveying system (Coperion) using Siemens PLC S7-300.
CHIPPER system (Reiter-Germany) using Siemens PLC S7-300.
Bagging Machine (ChronosRechardson).
Chips conveying system using Siemens PLC S7-200.
Role:
• Analyzed the project documents and developed the scope of work for contractors
• Created the cable, cable tray & junction box schedule
• Formulated the bill of materials and monitored erection of cable tray, junction box, field instruments & control panels
• Supervised the installation and commissioning of DCS System having 2000 I/Os
• Performed process graphics and logic modification as per requirement
• Managed the configuration of process parameters and trends groups
• Executed the installation and commissioning of PLC System for Heater (HTF), PTA, Chippers, Bagging & Chips Conveyor System
• Accomplished the Transfer Line-3 Project using Yokogawa Make CS3000 DCS independently entailing DCS hardware installation, graphics building, loop configuration, interlock logic implementation, configuration of trends and alarms
• Worked on the programming, graphic modification and maintenance of DCS System
• Delivered the in-house projects and manage breakdown & shutdown jobs
Studying the process philosophy & preparation of control write up.
Preparation of I/O list & Bill of material.
Design & Engineering of control panels for Automation.
Design and construct MCC panels and VSD panels.
Prepare Control panel wiring diagrams (Using AutoCAD & EPLAN).
Software development of Siemens S7-300 systems using Simatic Manager.
HMI development using WinCC and Protool-pro.
Carryout FAT and SAT.
Installation & commissioning of PLC system at various sites.
Installation and Commissioning of Siemens make AC Drives (Micromacter Series-MM3/4, Master
drive Series-CUVC/CUMC) in various area of application like Synchronization,
regeneration & Energy saving.
Maintenance and troubleshooting of AC/DC Drives.
Developed Cops Servo Winder system using S7-200 PLC, AC Servo Drive.
Expert in establishing communication between PLC & Drives using Profibus & USS protocols.
A)Project :
Capacity: 6500 TPD
PMC : L&T
Project cost : 1500 Cr INR
Control Systems :
Modicon 984 PLC for Rawmill, Kiln-Cooler, Coalmill, Cement Mill
AB PLC for Raw mill and coal mill Hydraulic system
Modicon PLC for Stacker and Reclaimer
SDR SCADA system
Field Instruments:
Pressure, Temp & Flow Transmitters (Rosemount)
Pressure, Level & Temp Switches, Proximity Switch, Auma Actuator
Job Profile :
PLC logic implementation with PMC group using Modsoft.
Take part in Process Graphic design with PMC group.
Control system commissioning and Loop checking.
Commissioning of Bin weighing system (Philips) and Dossimate weigh feeder (PBL).
B)Maintenance :
Maintenance & Troubleshooting of various control panels for Raw mill, Kiln,
Cooler, Coal mill, cement mill, Stacker, Reclaimer & Hydraulic system having
PLCs (Modicon 984 / R84, AB).
Maintenance of UPS (Make : Aplab).
Program modification & online troubleshooting using Modicon PLC.
Maintenance and calibration of instruments.