Lead Project Engineer
Saudi Aramco Shell Refining - SASREF
Total years of experience :23 years, 7 Months
Coordinating /Maintaining liaison and engaging project stakeholders (Operations, Inspection, Maintenance, Technical Support, Safety, Security & Contractors) for project engineering coordination and technical interface during Screening and prioritization of new projects, Scouting, Concept optimization studies, FEED & Detailed Engineering, Procurement, Construction, Pre-commissioning, Commissioning and Handover phases in accordance with project requirements and company guidelines.
Developing and managing Project Execution plan/ strategies, Project Management KPIs, Procurement plan for long lead items, Risk Management Matrix, Stakeholder Management plan, Change Management plan, construction, pre-commissioning and commissioning strategies, for all projects.
Coordinating and participating in Risk Assessment, HAZOP, SIL review, Multi-disciplinary Design Reviews, Desk Safety Reviews, 3D Model (30%, 60% & 90%) reviews, Pre-Start up Safety Reviews (PSSR), Punch listing walkdowns, FAT, SAT, Post Mortem Review, and follow up for closeout of action items.
Preparing Budget proposals (CAPEX & OPEX), CBI (Capital Budget Item), AFE (Authority for Expenditure), Cost breakdown structure, cost performance baseline, engineer’s cost estimates, trends and forecast remaining cost/ resource requirements.
Presenting project proposals in Technical GM Meeting to get approval for project Development and Implementation. Presenting the TC requests to Tender Committee members to get approval for invitation, negotiation and award.
Developing schedule network diagrams, Baseline, What-if, & Recovery schedules, Earned Value reports, WBS, coding structure, S-curves, activity resource requirements, activity duration, logic & cost estimates, and requirements traceability matrix to create and issue integrated schedule to monitor and control project performance.
Maintaining Stakeholder register and Risk register, Issue logs and Change requests, assessing impact of change and develop contingency plans.
Developing scope of work, project specifications, tender documents, Technical & Tender Committee Requests, conducting pre-qualification/ evaluation of contractors/ vendors, technical bid evaluation and contract award while ensuring that all technical objectives, safety & quality requirements, budget and schedule constraints are addressed.
Monitoring, controlling and reporting overall projects progress and performance with respect to Cost, Resource, Schedule, Quality & Safety and perform variance analysis to ensure alignment with project milestones, identify areas of risk, figure out issues and take corrective actions to implement recovery plan.
Conducting periodic progress meetings and two weeks look ahead with the Design & Construction teams.
Developing project control procedures to ensure monitoring of all construction & commissioning activities.
Working collaboratively with Contractors’ to review their plans & progress measurement to ensure alignment of Planning and Cost control reporting requirements.
Conducting Safety Audits, Job Safety Analysis, Tool Box Meeting, Risk Assessments to ensure high level HSE performance and Safe Work Practices are followed at site to maintain and attain HSE target of ZERO LTI through effective HSE programs.
Preparing project closeout report and providing cost breakdown to Finance department for financial closeout.
Completing all project Acceptances of Work & Handover requirements (spare parts, as-built drawings and operating manuals) as per Project closeout checklist required for timely project closure.
Successfully commissioned the SADARA project (HFO & CFN) within schedule that enabled SADARA to start steam generation facility and main production units.
Key Result Areas:
Managed, coordinated and facilitated the project interface activities towards the compliance of the project objectives set by both SASREF and SADARA stakeholders.
Provided a single focal point technical coordination/ support for the SADARA project related matters to ensure compliance with SASREF standards.
Managed engineering phase, procurement and overall field execution, mechanical completion, pre-commissioning, commissioning, system turn over and flawless startup of project.
Managed and coordinated execution of 21 multi discipline (Piping, Instrument, Electrical & Civil) tie ins between multiple assets across the project. Worked closely with OEMs for equipment FAT & SAT and commissioning activities.
Coordinated with contractors regarding all permit requests, job safety analysis, risk assessment and site safety audit to ensure compliance of HSE procedure and guideline are adhered.
Completed the project with Zero incidents with full compliance to all Safety and Environmental regulations.
Assisted in the development of the project interface key documents like Project Interface Coordination Protocol Agreement (PICPA), Transfer of Ownership Agreements, Operations & Maintenance Agreement.
Served as member of cross functional project management team to support Refinery Upgradation Project while managing the Inspection section.
Achievements:
For Refinery Upgrade project, I conducted due diligence for acquisition of pre-owned Delayed Coker unit (20K BPD) and Hydrocracker Unit (24K BPD) at Paramount Petroleum, Bakersfield, California, USA that enabled company to take decision on acquisition of pre-owned units.
Developed and implemented Project Management Systems for Refinery Upgrade projects and provided Project Management guidance across all design, procurement, construction and commissioning activities.
Key Result Areas:
Led the efforts to coordinate with all stakeholders to collect information/ data related to Basic Design Engineering Package (BDEP) questionnaire for refinery upgrade project.
Technically evaluated offers, material specifications and other relevant documents as received from vendors for procurement of new stationary equipment, (for refinery upgrade project) to ensure strict compliance with standards.
To close the observations, related to Mechanical Integrity, raised during Process Safety Audit,
Developed Terms of Reference for In Line Inspection (Intelligent Pigging) of 20 kilometers Dia.12”, Dia.10” & Dia.8” transportation pipelines.
Prepared plan to carry out over due inspections of Storage Tanks (25 nos.) and developed work scopes.
Worked in close coordination with Process Safety Advisor to get guidelines on Mechanical Integrity and other elements of Process Safety Management.
Led the inspection department constituting of engineers, supervisors and NDT technicians in carrying out all inspection activities on static equipments as per relevant codes & standards to ensure safe and reliable plant operations.
Communicated with project Teams during daily tool box meetings to inculcate company’s HSE policy, procedures, objectives, regulations and target for ZERO accident. Ensure that all inspections activities are performed with safety.
Member of Management of Change Committee, Incident Investigation Team and Emergency Response Team.Led the efforts to coordinate with all stakeholders to collect information/ data related to Basic Design Engineering Package (BDEP) questionnaire for refinery upgrade project.
Technically evaluated offers, material specifications and other relevant documents as received from vendors for procurement of new stationary equipment, (for refinery upgrade project) to ensure strict compliance with standards.
To close the observations, related to Mechanical Integrity, raised during Process Safety Audit,
Developed Terms of Reference for In Line Inspection (Intelligent Pigging) of 20 kilometers Dia.12”, Dia.10” & Dia.8” transportation pipelines.
Prepared plan to carry out over due inspections of Storage Tanks (25 nos.) and developed work scopes.
Worked in close coordination with Process Safety Advisor to get guidelines on Mechanical Integrity and other elements of Process Safety Management.
Led the inspection department constituting of engineers, supervisors and NDT technicians in carrying out all inspection activities on static equipments as per relevant codes & standards to ensure safe and reliable plant operations.
Communicated with project Teams during daily tool box meetings to inculcate company’s HSE policy, procedures, objectives, regulations and target for ZERO accident. Ensure that all inspections activities are performed with safety.
Member of Management of Change Committee, Incident Investigation Team and Emergency Response Team.
Achievements
For Refinery Upgrade project I conducted Due Diligence regarding acquisition of pre-owned Isomerization unit (88K BPD) at Gulf Refining Company, UAE that helped company to decide on acquisition pre-owned units.
Successfully managed Refinery Turn Around inspection activities that led to on time and safe plant startup.
Developed Mechanical Integrity Manual that served as compilation of inspection procedures, plans, forms and static equipment database correlated with operating /design parameters and inspection intervals.
Received Spark Award for cost saving of USD 0.1 Million by evaluating the test results of foundation bolts that enabled company to take decision on using the old column foundation instead of constructing new foundation to install new column.
Key Result Areas
Developed Turnaround Report 2011 featuring Internal Inspection Reports detailing all inspection observations, maintenance works and future recommendations for all Static Equipment of plant.
Developed technical work scope for all Stationary equipment and piping after detailed inspection and issued it to relevant sections for execution during Turn Around.
Evaluate and analyze inspection data gathered from field by inspection team through conventional NDT (UT, PT, RT, MT, flaw detection), advanced NDT (LRUT, MFL, IRIS, PMI) and destructive tests (hardness testing, tensile and bend testing).
Organized periodic and routine inspection of in-service and standby Stationary Equipment for deterioration such as corrosion, erosion, fatigue, creep, temper embrittlement, cracking, hydrogen attack and operational upsets.
Plan, schedule and manage on stream, internal and external inspection of all static equipment - Furnaces (07), Reactors (04), Heat Exchangers (40), Boilers (03), Pressure Vessels (30), Tanks (50) & Columns (05) and Plant Piping - (Crude, Hydro & Platformer units) as per inspection plans.
As Senior Engineer Projects and HSE focal point I managed and delivered medium size projects mainly related to Construction of new Storage Tanks, Construction of transportation pipelines, Major repairs & modification of storage tanks, Installation of new plant equipment including Civil, Electrical & Instrumentation Works. I worked in Projects Initiation, Planning, Execution, Controls and Closing phases including Estimation, Budgeting, Cost Control, Contract Management, Engineering, Procurement, Fabrication, Erection, Site Supervision & Commissioning of multiple-discipline projects.
Achievements
Selected for Talent Retention Scheme to stay with PRL till June 2012.
Received Spark Award on successful commissioning of Dia. 30 inch crude oil pipeline of 1Km.
Special Recognition Award for managing Construction section with 60% less staff & on time project completion.
Key Result Areas
Prepared project plans including budget (CAPEX & OPEX) and cash flow requirements.
Performed Risk Assessments: identified, quantified and analyzed project risks and developed mitigation strategies.
Prepared Construction Scope of Work for Invitation to Bidders. Managed tender documents and agreements. Reviewed and evaluated bidder’s documentations, conducted techno-commercial evaluation and negotiations for selection of competitive bidder. Prepared comparative statements.
Monitored Contractor’s cost/ schedule based progress (Actual vs Planned) by various indexes (CPI, SPI), resource deployment, invoicing plan, workmanship and safety. Forecasted the impacts on the cost & schedule.
Maintained change management logs of changes through MOC process. Worked out Schedule and Cost Impacts due to change, identified issues and recommended corrective actions.
Developed Stakeholder Management Plan to coordinate with and update all project stakeholders.
Prepared weekly & monthly progress/ status reports, trend analysis, & cash flow projections for management review.
As member of area HSEQ committee, conducted HSEQ Training for contractor workers to implement company’s HSE policies, procedure and standards.
Promoted team work and provided feedback on performance of project team members.
Prepared project close out report of projects and listing down lesson learned at post construction phase.
Key Result Areas:
Developed Project Master Schedule for projects. Involved in project initiation, contract administration, ordering & follow-up of materials, implementation of HSEQ programs and overall coordination of projects.
Completed all projects within allocated Time Frame and Budget in compliance with Health, Safety & Environment Regulations and relevant engineering codes & standards.
Prepared tender documents & BOQ/ Material take off, verified actual work quantities including contractor’s invoice processing & compiled periodical Project Reports.
Reviewed and monitored Contractor’s project plans, schedules, progress and resource utilization.
Analyzed the progress variances for cost and time and forecasted the trends.
Administrated submittals, transmittals and correspondence and reports and maintained all records and documents regarding contractual matters.
Supervised and monitored contractors’ workmanship, safety & site housekeeping during projects execution.
Prepared and maintained Hot Work, Cold Work, Confined Space Entry, Work at Height, Excavation & Isolation permits related to projects.
Implemented project QA/QC plan and Work Safety Procedures. Redesigned and implemented effective SOP/ manuals.
Trainee Engineer