Instrumentation Engineer
Emirates Steel
Total years of experience :19 years, 8 Months
Responsibilities
Plan, Manage & coordinate Electrical & instrumentation maintenance activities & ensure availability & reliability of equipments. Technical inputs/reviews on current plant revamping projects to increase plant availability in coordination with continuous improvement team.
Involved in HAZOP study for current plant revamping project.
For revamping project attended FAT TEST for new controller at Ternium, Mexico.
Coordinate with various service departments & Operation department for carrying out emergency maintenance jobs & resolve in minimum down time.
Coordinate with other dept. for maintenance activities related to Valves, Motors, Boilers, Air & Process gas compressors, elevators etc.
Supervise critical Field Maintenance activities of the equipment & provide technical solution to the sub ordinates. Also ensure that PTW procedures are followed
Ensure that subordinates follow the HSE norms set by the company and carry out toolbox talks.
Monitor & Inspect the Preventive Maintenance Schedule
carried out by technician as per procedures & record the same for audit purpose.
Coordinate & maintain inventory of spare & consumables in liaison with Purchase Department/ External vendors.
Monitor repair of equipments & calibration at workshops
Develop & manage contracts for specialized services for Valves, motors, etc
Carry out technical evaluation of offers from various parties.
Coordinate & supervise work of external contractors.
Supervise & ensure planned/scheduled jobs are executed with good workmanship.
Prepare Capex / Opex budget for the department & Implementation of the same.
Identify repetitive problems /issues, and develop a plan to eliminate & increase reliability of the equipments
Responsible for looking after automation related queries and carry out modification to increase the availability of plant.
Carry out modification in present control loops, graphical changes in HMI, review & changing of interlocks in Yokogawa DCS, Prosafe System (ESD) & PLC as per operation requirement.
Calibration, maintenance & Troubleshooting of Foundation Fieldbus Instruments, Hart Instruments, CH4, Co2 & O2 Analyzer (Emerson Make), Specific gravity.
Stroke check, Calibration, maintenance & Troubleshooting of Fieldbus control Valve
( Make :- FISHER fieldvue, Samsung, Flow Serve).
Replacement & configuration of new Foundation fieldbus devices.
Creating backup for CS3000 DCS, Siemens PLC, Prosafe PLC ESD System, PRM and Updating of antivirus for the system.
Troubleshooting of Siemens Simocode Motor Control.
Scheduling of Manpower for normal shifts and in shutdowns/breakdowns.
Total No of reporting Persons =15 no’s, out of which Engineers: - 9, Sr. Technicians: - 4nos, Technicians: - 2nos.
a) Project Activities
Actively involved in successful commissioning of Natural Gas based Direct Reduced Plant ( Zero Reformer Unit ), HYL Technology.
Actively involved in erection, installation & communication of Foundation Fieldbus instruments such as Transmitters, Control Valve, and Thermocouples etc with Yokogawa DCS.
Actively coordinated between the HYL Persons for establishing communication between Yokogawa DCS CS3000 and Foundation Fieldbus instruments, Profibus equipment, Siemens Simocode motor control, Weigh Feeders etc.
Independently handled the mapping of signals between DCS and Siemens PLC
Independently carried out modification in PLC logic as per operation requirement.
Troubleshooting of Profibus Loops, Foundation Fieldbus Loops
Monitored cable laying of Profibus and Foundation Fieldbus equipments.
Digital & analog I/O (DCS) checking with HYL Persons
To make availability of Instruments spares.
Procurement of material.
Monitoring of Project activities and Job Planning
Monitoring of site activities including installation, commissioning & testing of instrumentation equipments, cable laying, loop checking DCS/PLC installation.
Having great ability to understand & review P & IDs, Loop Drawing, Block and functional Diagrams, Electrical Drawings.
Actively involved in commissioning of Motors, Motor Feeders, Weigh feeders, Conveyors etc.
Ensured compliance to safety requirements while carrying out jobs at site.
Coordinate with OEMs for any problems arising during erection, installation & commissioning at site and resolving the same within stipulated time.
Made availability of construction power at site as per contractor’s requirement.
Total No of reporting Persons =7 no’s, out of which Technicians were: - 4nos, Helpers: - 3nos.
Project Activities
Involved in successful commissioning of 198Sqmtr Sinter Plant. The total Plant has come up with Chinese collaboration, M/s MECC & M/s CFMCC.
M/s MECC was responsible for whole design of sinter plant & M/s CFMCC was responsible for the erection & commissioning.
Actively involved in commissioning of ESPs, Proportioning House (Belt Weighers, Round disc Feeders), Conveyors, Screens, Motors & Main suction Fan with synchronous motor of rating 6600KW (with German Persons).
Supervision of Erection and commissioning of Electrical & Instrumentation system which include Cable Engineering, Panel Erection, testing, loop checking, termination, installation of Field Instruments etc.
Installation & Commissioning of Pressure, Temperature, Flow Transmitter.
Making Technical specifications, comparative statements, Interaction with Project consultants.
Estimation of Project materials for Procurement.
Material Management (SAP) and Follow up of Procurement Material.
Preparation of spares list of whole plant.
Manpower scheduling & Distribution to respective areas.
All bill Processing & handling of Cash Purchase.
Monitoring of Project activities and Job Planning.
Inspection of LT Power & Control Cable, Cable Tray.
Distribution of Power supply for construction activity.
Proper documentation of drawing.