Lead Commissioning Process Engineer
NPCC
Total years of experience :27 years, 2 Months
Current Project: Umm Shaif Supercomplex (USSC) Offshore Brownfield modification (AGFA) Project.
Client: Abu Dhabi Marine Operating Company (ADMA OPCO)
Supporting Project: Managing offshore Commissioning sites of Zakum Development Company (ZADCO), Abudhabi - UZ 750 Project’s EPC-1 work scope.
Leading and Managing Accomplishments:
Home Office- Inputs during FEED and Detail Engineering, Inputs for bidding and sub-contracting.
Preparing Project Commissioning Deliverables in accordance with the Project execution strategy.
Coordinate with PMT and PMC for commissioning documents approval and verifying compliance with agreed procedures.
To bring to the Management’s notice, potential problems or delays and recommends solutions.
Involvement with Engineering Contractor in design phase for Reviewing Engineering documents for commissionability.
Development of Limit of System Sub-system Handover (LOSH) drawings.
Coordinate with Construction Manager for completion activity by systems sequence in order to ensure efficient and economical pre-commissioning starting condition of systems.
Manage and coordinate availability of all documentation necessary for precommissioning/commissioning and handover activities for completeness of each system dossier and its consistency with agreed procedures.
Manage and organize daily activities and quality system application by site staff.
Coordinate with Head Office for arrival of personnel, Vendors and Licensors as necessary.
Coordinating for the ICAPS database population by inputting the check sheets, FTR (Functional Test Record) sheets and OTP (Operational Test Procedure), Commissioning Test Procedure (CTP).
Provide assistance to the Commissioning Mechanical, Electrical & Instrument /Control groups to ensure that the all Mechanical Pre-Commissioning activities and dynamic Commissioning activity are completed in a safe manner.
Leading the Mechanical Completion (MC) walk-down, compiling and issuing the punch list for clearance and sign-off.
Leading the Ready For Start-Up (RFSU) walk-down, compiling and issuing the punch list for clearance and sign-off.
Monitoring execution Schedules, plans, milestones, Reporting and monitoring pre-commissioning, commissioning progress in the ICAPS database.
Preparation for review / acceptance of the relevant N2-He leak test-packs required for the onshore & offshore N2-He programmes within the onshore / offshore commissioning phases.
Projects Executed: Qatar Gas- Jetty Boil-off Gas (JBOG) Recovery EPCM Project with ODD and PMT, Qatar Gas (Qatar Gas- Conocophilips- Shell joint venture- 2 LNG Trains) -“Purge Reduction EPCM Project”.
Leading and Managing Accomplishments:
Provide proposal preparation/technical support for new projects.
Defining Project Mechanical Completion, Turnover and Handover Strategy.
Preparing Project Commissioning Deliverables, Plans, Procedures and Sequence.
Preparing Database for monitoring and progress reporting of Mechanical Completion, Pre-commissioning, Commissioning and Handover to Asset Operations.
To bring to the Management’s notice, the potential problems or delays and recommends solutions.
Defining the System, Sub-system limits for the sequential commissioning and handover.
Preparing Inspection and Testing Plan (ITP) with responsibility matrix for execution of Commissioning.
Preparing Check sheets and Functional Test sheets “A”, “B” and “C” for construction completion, static precommissioning and dynamic commissioning execution.
Developing Operation and Maintenance Manual.
Coordinating with the construction team for mechanical Completion and Certification Process to minimize the punch list items. Review of PC&C spares requirement.
Conducting Pre-MCC walk-downs and clearing punch list to achieve Discipline Completion Certificate (DCC), System Mechanical Completion Certificate (SMCC).
Leading the Preparation for review / acceptance of the relevant N2-He sensitive leak test-packs required for the commissioning phases.
Leading the walk-downs for Ready for Commissioning (RFC), Ready for Start-up (RFSU) Certifications.
Leading the walk-downs for Pre-Start-up Safety Review (PSSR) and Operational Readiness Review (ORR) in the CSU process.
Ensuring OR&A process in the completion to achieve RFC and RFSU in the CSU process and handover to Asset Operations. Assisting operations team during start-up.
Preparing the Procedure and Conducting Performance Testing of the facilities.
Achieving the Provisional Acceptance Certificate (PAC).
Sep, 2005 to Jan, 2013
Company : Indian Oil Corporation Ltd, India (REFINING OPERATING COMPANY)
Positions : Operation Engineer, Commissioning Engineer
Mar, 2002 to Aug, 2005
Working Companies: Technip Italy, Daelim Industrial Company, PDIL, Punj Lioyd
Client Company: Indian Oil Corporation Ltd, India (REFINING OPERATING COMPANY)
Positions: Operation Engineer, Commissioning Engineer, Commissioning Supervisor
Working Plants:
• Commissioning and Operation of EPC of SRU Project (ATU, ARU, SWSU, TGTU) with Sulphur Granulation and Palletization Facility - 60 TPD - Project Cost $ 87.5 million.
• Commissioning and Operation of EPC of Flare/ flare gas recovery project- 60000/900 Nm3/hr- Project Cost $ 150.0 million.
• Commissioning and Operation of EPC of Instrument Air/ Air Separation/ Cryogenic Nitrogen Generation Unit- 4000 Nm3/hr.
• Commissioning and Operation of EPC of Operation of Hydrogen Generation (Production) Unit and Diesel Hydrotreating Unit (DHDT).
• Operation of Hydrocracker Unit (HCU).
• Commissioning and Operation of EPC of DHDT/MS Quality Upgradation Project Cost - $ 500 million.
• Commissioning and Operation of EPC of Refinery Expansion Project Cost - $ 850.0 million.
• Commissioning and Operation of EPC of Visbreaker Unit (VBU) 20000 BPSD Project.
• Commissioning and Operation of EPC of Fluidized Catalytic Cracking Unit (FCCU) - 20000 BPSD, Project Cost - $ 225.0 million.
Major equipments commissioning in the above projects are as below.
• Fixed bed Catalytic Reactors, Fluidized bed Catalytic Reactors operating at high pressure and temp.
• Natural draft Furnaces, Balanced draft furnaces (Reformers), Naphtha Crackers, Gas Crackers.
• High Pressure Centrifugal Pumps (multistage), Reciprocating Pumps, Slurry Pumps.
• High Pressure Centrifugal Compressors, Reciprocating Compressors with auxiliaries.
• Pressure Swing Adsorption (PSA) Purification Units.
• Atmospheric and Vacuum Distillation Columns. Fractionators, Separators, Storage Tanks.
Leading and Team Sharing Accomplishments:
Reviewing contractor’s commissioning plans, sequence, procedures, methods, and System/ Sub-system mark-up P&ID.
To bring to Management’s notice potential problems or delays and recommends solutions.
Leading the Mechanical Completion walk-downs, compiling and issue the punch list to the contractor.
Leading and witnessing the pre-commissioning execution activities (water flushing, air/steam blowing, leak testing and inerting) and dynamic commissioning (rotating equipments running-in testing, Lube oil flushing and Seal oil Flushing)
Leading and witnessing the Pre-start-up activities (Catalyst Loading, inerting, shutdown/trip logics verification).
Preparing DCS for operation, checking control valve stroking, and shutdown valve functioning.
Providing technical support and training to the operations and maintenance department in the commissioning and start- up of new plants.
Leading the plant start-up (Alkali boil-out/degreasing, refractory dry out, catalyst activation, adsorbent regeneration).
Managing Plant start-up, operation and conducting Performance Guarantee Test Run (PGTR).
Conducting relevant work audits e.g. commissioning audit, RFC audits, HAZOP, HAZAN, RA.
During plant operation, identified multiple cracks on transfer line of reformer, prevented multi-million damage to the plant and company reputation.
During plant operation, identified the hot spots on the Process Gas Boiler, prevented the property damage.
During plant operation, corrected the cause of fire balls form flare stack.
Working Plants:
Commissioning and Operation of EPC of LPG/NGL recovery and Gas distribution Project- $ 116.5 million:
LPG/NGL Plant (recovery by cryogenic process Similar to LNG) - 210 MMSCFD: Including Gas inlet facility, Gas Gathering Station (GGS), Gas Metering Station, gas dehydration plant for dew point control, LPG /NGL storage bullets.
Compressor Stations- including booster compressors for exporting the lean gas to consumers.
Gas distribution pipelines- Including flooding, swabbing, drying and PIGGING inspection operations.
Utility Plants- Raw Water Treatment Plant, Waste Water Treatment Plant, Cooling Tower, LP steam generating boiler, Plant air, Instrument Air and Nitrogen generation Plant, Flare, Fire Water.
Operation of LPG/Propane/NGL recovery Plant and Gas Compression and Distribution Plant:
LPG/NGL/ Propane Plant (recovery by cryogenic process Similar to LNG) - 300 MMSCFD (9 MMSCMD) X 2 trains: with enhanced recovery of liquids by using Propane Refrigeration Unit (PRU)
Compressor Stations- including booster compressors for exporting the lean gas to consumers.
Gas distribution pipelines- PIGGING inspection and gauging operations.
Utility Plants- Raw Water Treatment Plant, Waste Water Treatment Plant, Cooling Tower, LP steam generating boiler, Plant air, Instrument Air and Nitrogen generation Plant, Flare, Fire water.
Accountable for the team sharing responsibilities of commissioning execution and plant operation as below.
Supervising and solving the problems in the execution of pre-commissioning, commissioning and advancing to start-up as per plan and schedule in a safe and effective manner, within budget, on time and fulfilling the applicable Company Procedures and Technical Specifications.
Deputing the site commissioning team in carrying out water flushing, air/steam blowing, inerting, purging, conformity checks as per drawings, static and dynamic tests.
Verifying the LO flushing, Seal Oil Flushing for the Centrifugal Compressors and Gas Turbines.
Managing all necessary commissioning preparation work (monitoring preservation, mechanical completion, pre-commissioning activities, develop fabrication drawings for commissioning temporaries, arranging necessary materials, special tools, consumables etc).
Preparation of daily, weekly and monthly reports as required, attending daily progress review meetings, addressing and solving the hurdles.
Managing Mechanical completion Check sheets, pre-commissioning and commissioning database, signing off certificates, conducting walk-downs, managing punch list, Preparation of final closeout report related to pre-commissioning, commissioning and start-up.