Process Control System & Pre Commissioning Manager
SPECO Shandong Electric Power Construction Corporation
Total des années d'expérience :22 years, 5 Mois
Company Profile: SEPCO Shandong Electric Power Construction Corporation is a global engineering, procurement and construction EPC that specializes in the engineering and construction of various types of power plants, including thermal, nuclear, gas, hydro, wind, transformer substation, biomass, photovoltaic, solar energy and sea water desalination.
Key Responsibilities:
• Prepare detailed plan of PCSs and all pre commissioning activities along with time schedules and resource requirements of all activities to commission the plants.
• Explain the activities and the schedule of commissioning to the entire project team to have a uniform and clear understanding amongst team-members and provide technical clarifications when required.
• Finalize the technical scope of work with Invensys that include software, automation and energy control, negotiate price service delivery terms and conditions.
• Develop complete project schedule with Invensys representatives, defining project milestones, test and review plan and contingency back-up to complete the project as per schedule.
• Review progress of the project along with the project team leads and Invensys representatives, resolve technical issues to ensure that all the quality standards defined as a part of project plan are achieved.
• Coordinate pre-commissioning activities of other disciplines such as mechanical, electrical, instrumentation and control, and piping as per the project schedule.
• Develop and execute the sub-contracting plan - finalize activities to be subcontracted, select competent subcontractors, define scope of work, hold negotiations and award contracts.
• Monitor the progress of work assigned to each subcontractor, check the quality of work, provide technical clarifications, de-bottleneck constraints and solve coordination issues to ensure completion of work as per schedule.
Company Profile: Saudi Aramco is the state-owned oil company of the Kingdom of Saudi Arabia and a fully integrated, global petroleum and chemicals enterprise.
Designation Chronology & Location:
• Jan 2015 - Oct 2015: Senior Project Engineer, Project Management Team, Project Management Support Services Department, Operational Excellence Division, Dhahran, Saudi Arabia
• Apr 2013 - Jan 2015: Senior Project Engineer & Pre-commissioning Manager, Project Management Team, Sadara Petrochemical Program, Jubail, Saudi Arabia; Houston, USA; Bangalore, India; Reading, UK.
• Mar 2012 - Mar 2013: Lead Project Engineer, Project Management Team, Wasit Program, Co-gen package, Dhahran, Saudi Arabia
• Feb 2011 - Feb 2012: Lead Project Engineer, Project Management Team, Wasit Program, Co-gen package, Seoul, South Korea.
• Aug 2010 - Jan 2011: Project Engineer, Project Management Team, Wasit Program, Early Work & Site Preparation, Jubail, Saudi Arabia.
• Nov 2009 - Aug 2010: Control & Instrumentation Engineer, Process and Control System Department, Engineering Services, Dhahran, Saudi Arabia
• Apr 2006 - Nov 2009: Sr. Project Engineer & Project Engineer, PMT-Khurais Program (USD 11 billion)
• Sep 2005 - Apr 2006: Control and Instrumentation Engineer - Process and Control System Department, Engineering Services
• Jan 2002 - Aug 2005: Control and Instrumentation Engineer, Operation and Maintenance, Abqaiq Plants
• Aug 2001 - Jan 2002: Control and Instrumentation Engineer, Process and Control System Department, Engineering Services
Key Projects to Credit:
Jan 2015 - Oct 2015:
• Accelerated Transformation Program - Designated Team Member for “Operational Excellence Team” in Saudi Aramco
• Contributed to the Saudization of workforce participation in project management team.
Apr 2013 - Jan 2015
Sadara Petrochemical Program worth $ 20 billion
Aug 2010 - Mar 2013:
Wasit Program (At various Locations) worth $ 6 billion
• Mar 2012 - Mar 2013: Dhahran Technovalley - Cogen Package
• Feb 2011 - Feb 2012: Seoul, South Korea - Cogen Package
• Aug 2010 - Jan 2011: Jubail - Early Work & Site Preparation
Apr 2006 - Nov 2009
Khurais Program worth $ 11 billion
Jan 2002 - Aug 2005:
Abqaiq Plants, Operation and Maintenance: Projects include the following:
• Wastewater Environmental Protection Project BI-3753. Participated in the installation, setup, and commissioning of Fieldbus instrumentation on BI-3753.
• NKCP Fieldbus Project BI-3156. Heavily involved in the Fieldbus FAT, Commissioning and startup of BI-3156 pump station.
• Maintain Gas Compression Capacity Project BI-3751. Had primary responsibility for the Fieldbus SAT, commissioning and startup of Maintain Gas Compression Capacity Project BI-3751.
Achievements:
• Planned, executed and completed three mega projects (Program): Khurais, Wasit and Sadara within budgets and defined timeframes.
• Successfully executed three other projects within time and budget at Abqaiq Plant; commended by the management for providing reliable support for keeping the plants running without any disruptions to meet government and customer demand.
• Achieved connectivity of Khurais Network with Aramco network ahead of schedule including redesign of the entire network as per Aramco’s engineering standards.
• Successfully managed pre-commissioning of Khurais Program including loop checking within specified milestones.
• Successfully handled trouble shooting and investigation of plant trips and instrumentation failures and considerably reduced plant trips Abqaiq plant.
• Investigated repetitive failures of ZV at Riyadh Refinery, identified root causes of failure and took corrective steps thereby considerably reducing repetitive failures.
• Credited with developing the Operational Excellence (OE) systems, and customizing, evaluating and implementing the systems across PMT departments.
• Associated with Saudi Aramco Engineering Services and provided advisory services to improve plant operations, supported ongoing projects and updated engineering standards.
• Successfully managed, as a single point of contact, all the activities of Saudi Armco Engineering Services departments including P & CSD, inspection, loss prevention and EDMU (Engineering Drawing Management Unit).
• Saved additional cost of USD 3, 20, 000 in Khurais Site Project by using a special cable in GA/PA.
• Saved additional cost of USD 1, 50, 000 in Khurais Site Project by using Fisher Valve Link Software.
• Saved additional cost of USD 1, 35, 000 by completing shipment of system cabinet in advance from Yokogawa YME office in Baharain, by clearing and closing all the punches related to PCS FAT/IFAT.
• Nominated as a member of Fieldbus Panel Discussion at Process Automation Technical Exchange Meeting in 2006 in Dhahran.
Key Responsibilities as Senior Project Engineer, Project Management Team, Project Management Support Services Department, Operational Excellence Division:
• Spearheaded operational excellence activities in the project management support team and implemented project improvement initiatives as a part of Accelerated Transformation Program (ATP).
• Developed process structure and deployed systems for improving project execution by project departments across the organization.
• Customized the OE system to meet the requirement of various project management teams and ensured that OE system was deployed by all departments.
• Assessed the performance of all project departments within the organization, prepared report, shared feedback with the respective project department and made recommendations for improvement; kept the management updated.
• Carried out gap analysis to identify the gaps in implementing operational excellence structure and system, prepared action plan with clearly defined deadlines to bridge the gaps.
• Carried out internal assessment of project management administration area to identify shortfalls and recommend improvements.
• As part of a team study to assess and enhance the percentage of Saudi nationals in the project management team, and amended the contract accordingly to enforce implementation by engineering, procurement, construction contractor.
Key Responsibilities as Senior Project Engineer, Project Management Team, Sadara Petrochemical Program (USD 20 Billion):
• Provided leadership to the team in execution of process control system projects with process control system vendors, ABB and Yokogawa with SDL department with input/output counts exceeding 10, 000.
• Recruited and assigned manpower as per the requirements of the project, organized suitable training programs and allocated them to the respective areas as per approved manpower strength.
• Defined the scope of work of the instrumentation subcontractors like ABB, negotiated and finalized contracts defining both technical and commercial terms and conditions.
• Evaluated and finalized scope documents of instrumentation projects from design to loop checks for tank farm, packaging centre, off site pipelines and port.
• Reviewed actual progress of project with the team on periodic basis to sort out coordination, technical and resource issues and initiate necessary actions to ensure adherence to project schedule.
• Coordinated with inspection department to resolve quality assurance and quality control issues and initiated appropriate measures for meeting quality norms.
• Participated in project cost review meetings to analyze variances in actual cost versus the budget and recommended measures to control costs.
• Identified risks associated with the project, as a member of the risk management team and developed risk mitigation strategies and action plans.
• Additionally, handled tasks as Pre-com Manager for the Tank Farm; tasks handled included preparation of pre-commissioning scope, planning, allocating resources, prioritizing activities and execution.
• Prepared complete plan of pre-commission of tank farm project activities with exhaustive list of activities involved, internal and external resource requirements, time targets and costs involved; installed electrical, mechanical, piping and control / instrumentation.
Key Responsibilities as Lead Project Engineer, Project Management Team, Wasit Program (USD 6 Billion) - Co-gen Package (Dhahran, Saudi Arabia)
• Evaluated the scope of work of PCS vendor (Honeywell) covering technical as well as commercial aspects, moderated the same in consultation with internal team as well as the vendor for finalization.
• Scrutinized and reviewed preliminary and critical design documents with the project team and identify gaps, if any, in meeting the requirements, so that the design could be moderated.
• Undertook study of the process of conducting factory acceptance tests as well as integration test, test criterion for acceptance, modification and approval of the solution.
• Planned all activities starting with scope finalization, review and finalization of design, both functional as well as integration testing so that the shipment dates are met.
• Reviewed the work of the Process Control System vendor, Honeywell on daily basis to monitor progress as well as to intervene in case of any delay for timely completion of project.
Key Responsibilities as Lead Project Engineer, Project Management Team, Wasit Program (USD 6 Billion) - Co-gen Package (Seoul, South Korea)
• Coordinated with Samsung Engineering (EPC) and Honeywell (PCS vendor) for PCS scope design, procurement and carrying out tasks as per the defined scope, and monitored progress.
• Prepared the complete project plan and schedule of all the activities, with time duration, resources requirements, cost of resources and systems.
• Reviewed progress of work with the contactors and internal team to initiate action plans for controlling any delays and meeting schedules.
• Negotiated and finalized orders with the instrumentation vendors including design, monitored deliveries as per requirements of the project.
• Planned pre-commissioning activities with internal team as well as the vendors to prepare complete list of activities with target dates and responsibilities.
• Attended periodic review meetings to compare actual cost with budget for controlling costs within approved budgetary limits.
• Identified project risks, and in collaborations with the project manager developed and implemented a risk mitigation framework.
• Reviewed progress, updated stakeholders of status, ensured quality parameters were met, and project deliverables met expectations.
Key Responsibilities as Project Engineer, Project Management Team, Wasit Program - Early Work & Site Preparation
• Supervised daily work carried out at site, provided technical guidance to the contractors and internal team members and resolved problems affecting the progress of work for completion of work as per schedule.
• Organized inspection and testing of incoming project materials and equipments, testing of instruments, control panels, drives, to check conformation to quality.
• Conducted weekly project review meetings involving internal team members, vendors and contractors to assess actual progress of work with reference to schedule, expedited activities that were behind schedule.
• Finalized complete list of materials, equipments, systems to be procured with delivery schedule, negotiated prices, delivery schedules and commercial terms and approved purchase orders.
• Decided on the jobs to be subcontracted, defined the scope of work with quality specifications, floated enquiries to enlisted and competent contractors, negotiated prices, completion schedules, terms and conditions and approved release of contracts.
• Designed and finalized design parameters for the work on Wasit bridge and its access road, scrutinized and approved drawings.
Key Responsibilities as Control and Instrumentation Engineer (Process & Control System Department, Dhahran, KSA):
• Carried out review of Saudi Aramco engineering standards, verified maintenance of records to check whether latest standards are being followed or not and to update the records as per latest standards.
• Conducted assessment of health condition of all the distribution facilities in the western region to initiate necessary maintenance activities to restore their health conditions to normal.
• Advised Saudi Aramco Operating Plants on the system of instrumentation maintenance and controls to be followed, as and when called for consultation.
• Reviewed the progress of capital expenditure projects including actual expenditure vis a vis budget, identified and analyzed the delays and additional expenses, initiated corrective actions as and when required to control delays and additional expenses.
• Played active role, as a representative of instrumentation function in the Plant Integrity Assurance Framework, at Ras Tanura Plant to improve the reliability of the plant.
Key Responsibilities as Project Engineer Saudi Aramco-PMT-Khurais Program (Project Control and Instrumentation, Milan, Italy):
• Was responsible as a team member of the integrated project management team for execution of the projects from grass root stage to start up, including detailed design.
• Reviewed and verified the overall and deliverables scope of the contractors’ work to ensure that there are no gaps and to bridge the gaps, if any.
• Monitored the actual progress and cost incurred in the project with reference to schedule and budget and initiated proactive actions, including order amendments, release of communications to external and internal teams to ensure that the project is completed within the approved budget and on time.
• Developed a suitable system of project document control, including amendments at various stages with proper version control to improve traceability and retrieval.
• Reviewed technical specifications of the materials and services to be used in the project, modified the same in consultation with the others concerned to release purchase orders and contracts accordingly.
• Initiated preliminary and critical design reviews, setting up procedures for factory acceptance tests, integrated factory acceptance test requirements and documents and records to be maintained.
• Implemented foundation field bus control for all control and monitoring loops and monitor the proprietary technology by application of field bus.
• Led the project team in identification of the requirements and laying down the specifications of all major control equipment including control valves, MOVs, PZV, ZV, In plant paging system networks and field instrumentation including installation plan and testing methodologies.
• Consolidated the requirements of main control room consoles and plant interface building layouts and developed the design and layout.
• Monitored the daily output of the design contractor to ensure that the work is carried out as per the terms and conditions of the contract and project schedule.
• Managed the interface of work of 9 design contractors, resolved technical and commercial problems and expedited the actual work in order to complete the work as per project schedule.
• Facilitated coordination as a single point of contact with Saudi Aramco engineering services departments including planning, control, systems development, inspection, loss prevention and engineering drawing management unit.
Key Responsibilities as Sr. Project Engineer (Construction & Pre-commissioning Stage), Khurais Program, Khurais Site, KSA:
• Was responsible as a senior project engineer for exercising control for smooth execution of instrumentation work for the project work.
• Planned and oversaw ongoing construction activities for smooth execution of start-up of Khurais involving all functions.
• Was assigned a special project in Yokogawa-YME office at Bahrain, to close and clear all the punches related to PCS FAT/IFAT in order to ensure cabinet’s shipment to site on time.
• Led pre-commissioning activities including loop checking and achieving the specified millstones by coordinating with all concerned/
• Planned and ensured proper startup of all air compressors, HRSGs, boiler, CGTs, RO and other utilities systems as a team member.
• Provided connectivity between Khurais with Aramco network ahead of schedule including redesigning the entire network to meet Saudi Aramco Engineering Standards.
• Finalized the details and signed 13 instrumentation project management control and closure systems with the respective vendors.
• Played the role of a lead engineer to the electrical team as a part of the close out activities in addition to the normal duties.
Key Responsibilities as Control & Instrumentation Engineer with PID (Process & Control System Department) and Abqaiq Plants:
• Led the development, testing and approval of Metso ND9000 Field bus positioner with Yokogawa Centum DCS and took part in Field bus panel discussion at the process automation technical exchange meeting 2006 in Dhahran.
• Provided consultation services for Saudi Aramco operation plants and projects and presented Saudi Aramco experience with Fieldlbus at FFEUCME - Multaqa 2005 meeting in Bahrain.
• Carried out maintenance and configuration with the help of field instruments as instrumentation and control Engineer to support Fieldbus projects at Abqaiq Plants.
• Installed, set up, and commissioned Field bus instrumentation of Wastewater Environmental Protection Project BI-3753. Participated in commissioning, started up and maintained Gas Compression Capacity Project BI-3751 and Field bus SAT.
• Worked in multiple Field bus instrumentation projects in NKCP project BI-3156, field bus FAT, field bus SAT, and Delta DCS configuration program, commissioning and start up of Bi-3156 pump station.
• Was responsible as a Plant Operation Engineer for performance evaluation of matrix vibration transmitters and eclipse magnetrol GWR for level measurement,
• Developed performance evaluation of matrix vibration transmitters and GWR (Eclipse-Magnetrol) for level measurement.
• Reviewed relative engineering packages and drawings and provided necessary advice on corrections, wherever required.
• Attended to trouble shooting and investigation by undertaking plants trips and studying and analyzing instrumentation failures.
• Commissioned the corrosion inhibitors- Micro Motion flow meters in the NGL plants to prevent corrosion in time.
• Carried out flare performance tests and cleared the exceptional items and also conducted performance tests for the back up full gas supply.
• Conducted performance tests for the back-up full gas supply project BI-3171 and performance evaluation of point type and open path IR gas detectors and issued technical reports.
• Received request letters from vendor for waiver of penalty charges due to delayed projects or non fulfillment of contractual terms and conditions to decide on waiver based on merit of each case.
• Reviewed Saudi Aramco Engineering standards from time to time and carried out necessary modifications based on actual requirements.
• Investigated ZV repetitive failures at Riyadh Refinery, determined the root causes of repetitive failures and recommended appropriate corrective actions.
TRAININGS AND WORKSHOPS • PMT 202 Effective Project Controls • PMT 215 Project Management Fundamentals Training Program • Organizational Excellence Assessor Training & Certification • Supervisor Level Assessment Centre • PMT 105 Construction Management • Leadership Preview Program • Project Management Essentials • Leadership Challenges • PMT 102 Introduction to Estimating • GEMARK VI Turbine Controls Overview • DELTA V FF Configuration and Maintenance • PCI 102 Introduction to Process Control • PCI 210 Relief Valve Sizing Systems Analysis • PCI 206 ESD Systems • PCI 103 Size & Selection of Control Valves – P1