Control & Instrumentation Engineer
Last Updated: 28th February 2018 (over 4 years ago)
Leading the engineering efforts throughout the various phases of the project, including:
FEED, Detailed Design and Engineering, Testing (FIT, FAT, EFAT, & SIT), then Commissioning Support.
· Extensive experience in evaluating available technologies and system modules specifications to see whether fit for purpose/design. This covers sensors (including different types of flowmeters), PLCs, hardware modules, and software packages.
· More than 20 years developing and designing control systems and smart sensor networks for several applications, including topside facilities, onshore plants, subsea systems
· Extensive system engineering (integration and testing), DCS, HMI, & SCADA Design.
· Development of C&E charts, review of P&ID drawings for complicated systems, including ancillary equipment like HPU, EPU, CIU,..etc.
· In-depth knowledge with industry standard communication protocols (e.g. TCP/IP. CANBUS, MODBUS, ProfiBus, etc.) as well as several DCS development environments (Honeywell Experion, Emerson DeltaV, Yokogawa Centum VP).
· Attended several courses with major manufacturers (Honeywell control College, Emerson Institute, Siemens Training, TI Training, Motorola training, etc.)
· HAZOP, HAZID, Risk Mitigation and Lesson Learned in-depth experience
· Worked extensively in problem solving and existing (legacy) systems as part of the sustaining engineering effort in several areas.
· I was a member of the IWIS committee. I also extensively participated in the SIIS standard release.
· Extensive global network of technical contacts in the US, Canada, Europe, and the Middle East.
· I carry 5 patents and published 4 papers about smart sensor applications.
Thirteen years of experience in design and various roles of engineering of Subsea and Top Side Control Systems in several countries, including, the US, Canada, the UK, Angola, and the Far East. Eighteen years of experience in various aspects of the harsh environment sensors systems, including operation, technical support, research and development in the oil and gas industry. Instrumentation and Control System Engineering Experience for both Topside and Subsea, including multi-phase flow meters, oil metering, chemical injection systems, HIPPS, and distributed control systems (DCS), P&ID design. Preformed System Integration and Testing (SIT). Analytical and problem solving capabilities at various levels of complex systems in both electronics, electrical, and software. Good leadership and coaching skills, effective communicator and team player. Reacts well to high pressure situations. Embedded software experience, which involves the MC68332 uC, as well as HC12 (hi temp Motorola uC) and a Real Time Operating System. PLC experience with Siemens 1516, S7-315, Honeywell C300, C200, and Wago 750-880. Detailed knowledge of control system hardware and software, including communication protocols, including Modbus, Profibus, CAN, HART, Ethernet TCP/IP. Detailed knowledge of sensor system integration, both top side DCS and Subsea Control. Good track record of system engineering experience in both electrical and mechanical disciplines. Proven operation / tech-support experience acquired in several countries. Enjoy working in multi-cultural environments. Holder of five patents and recipient of three engineering awards.
DORIS ENGINEERING, INC. (July 2014 – Sept 2016)
Control System Engineering Lead – Pemex Lakach Project:
Instrumentation and Control Systems leading the development process of the topside control system and subsea, including the MCS, EPU, HPU, HIU, CIU, SCM, as well as other modules. Coordinate and interface with Pemex Engineering, OneSubsea Engineering, and other third party vendors (OneSubsea, Corrocean, Halliburton, and others) to finish the Lakach Subsea Production Control System (PCS) as well as interfacing it with the Distributed Control System (DCS) by Emerson. Represented the customer (Pemex) with various vendors (OneSubsea, Emerson, Halliburton, and others) throughout the project phases. Monitored the detailed engineering phase of the PCS and ensure compliance to the standards. That included reviews of design calculations, drawings and assemblies, procedures, and procurements data sheets. Provided technical expertise to the engineering organization to test (FAT/EFAT/SIT) and support the hookup and commissioning efforts in terms of planning and execution. Ensured that codes and standards are implemented throughout the various phases of the project. Participated in product kick off meetings. Reviewed and participated in the development of Scope of Work, and FDS documents. Participated HAZOP and HAZID activities throughout the project phases. Reviewed (approved) and marked up (edit) drawings (including P&ID), documents, Cause and Effect Charts. Worked with the Doris and Pemex Leadership Team to ensure that the project in finished according to schedule. Monitored HSSE and QA for the Control System throughout the project phases and activities. Mentor younger engineers.
DTC INTERNATIONAL (Jan 2014-July 2014)
• Control System Engineering Lead: Control system lead responsible for the design and overall engineering efforts of three Drilling Risers Control Systems and HPUs for Statoil and Transocean. Interfaced with the customer and the staff to meet the requirements and the project deadlines. Developed FAT procedures and FDS documents for both the hardware and the software being developed. Reviewed design calculations and spec out procured parts. Developed and supervise testing as well as troubleshooting procedures for electronic modules in order to pass manufacturing testing requiremnts (FAT, Screen, HALT & HASS testing). Lead the effort to perform HiL (Hardware in the Loop) Testing of the control systems prior to SIT and field deployments. Supported manufacturing throughout the testing and assembly procedures and ensure that the final product meets the API and DNV specifications. Planned and supported the SIT activities. Delegated tasks according to the project requirements. Established Industry Standards HSSE and QA throughout the project phases..
• Chevron Lianzi Project – Offshore Angola Control System Lead Engineer: Instrumentation and Control Systems leading the development process of the topside control system. Coordinate and interface with Chevron Engineering, KBR Engineering, and other third party vendors (Yokogawa, Emerson, MPM, and others) to finish the Lianzi Distributed Control System (DCS). Represented the customer (Chevron) with various vendors (Yokogawa, Emerson, and KBR) throughout the project phases. Monitored the detailed engineering phase of the DCS and ensure compliance to the standards. That included SIL and Zone analysis. Review Technical Documentation including P&ID Drawings and C&E Charts. Provided technical expertise to the commissioning group to test (FAT/EFAT/SIT) and support the hookup and commissioning efforts in terms of planning and execution. Ensured that codes and standards are implemented throughout the various phases of the project. Reviewed design calculations and procurements data sheets. Reviewed and participated in the development of Scope of Work, and FDS documents. Participated HAZOP and HAZID activities throughout the project phases. Reviewed (approved) and marked up (edit) drawings (including P&ID), documents, Cause and Effect Charts. Worked with the Subsea7 Leadership Team to ensure that the project in finished according to schedule. Monitored HSSE and QA for the Control System throughout the project phases and activities.
• Lead Systems Controls Engineer: ExxonMobil Julia HIPPS FEED – Subsea Controls System Engineer responsible for the preparation and review of the BOD documentation, Cause and Effect Charts, and P&ID drawings and developed System FDS and Scope of Work.
Control System Principal Engineer: Responsible for distributed Control Systems (DCS) & SACADA Design and Configuration– Topside Controls. Worked with various teams (in-house and at customer sites) to develop design, integration, and test plans for topside systems. Utilized the Experion & C-300 in system design. Reviewed, maintained, and developed relevant documentation, which included FDS and Scope of Work. Configured Servers and Engineering Work Stations for offshore operations. Developed configurations based on the C&E charts and P&ID Diagrams. Create system Database and tag lists. Delegated assignments to team members. Attend HAZOP/HAZID workshops with the customer (BP).
CAMERON, DPS (2008-2011)
• Chevron Jack & St. Malo Project and Husky North Amethyst Project: System Integration and Testing (SIT) System Lead Engineer responsible for development of design concepts and functional requirements for various parts of Subsea Systems, including Control Systems and production plants. Performed System Integration and Testing (SIT) duties on and off location, including site support, procedures development, and interfacing between R&D centers in Celle, Leeds, and St. Johns to execute pre-commissioning tests of all system modules. Developed Test Procedures, review (mark up) Drawings (including P&ID) and Cause and Effect Charts. Participated and reviewed FDS and Scope of Work as well as Work Philosophy for the SIT. Provided the Scope of Supply information to ensure that all the SIT activities are covered. Monitored HSSE and QA for the Control System throughout the project phases and activities. Participated in HAZOP/HAZID and Risk Metigation workshops and activities. Performed /Support / Witness FAT and EFATs for various system modules, including Trees, Manifolds, SCM’s, MCS, and other Ancillary Equipment (e.g. multi-phase flowmeters/DHPT gauges). Worked with the various disciplines to ensure that the tasks are done on time. Ensure that all the work done conforms to the HSSE and QA requirements. Monitor compliance. Technical support of ALL SIT related engineering activities.
• BP Kaskida Project (GoM): System Lead Engineer responsible for performing a HIPPS technical study for BP GoM Strategic Performance Unit for the Kaskida Field. The objective was to develop the Kaskida Sub-Salt discovery in Keathley Canyon, which involved evaluation of the readiness of the subsea valve systems to handle the additional pressure requirements desired by BP. Provided detailed description of the proposed control system (proposed FDS). Ensured that both the plan & the FDS implemented the API 17D & the API 17O specifications. Developed logic description and implementation. Developed system modules technical specs, including logic solver control valves, and pressure sensors. Developed scope of supply of system parts. Prepared project schedule and cost estimate. Presented the proposed system to BP.
DRIL-QUIP, INC. (2004-2008)
• Section Head, Control System Engineering: Supervised the design of subsea control systems, including development and custom building of Subsea Electronic Modules (SEMs), Master Control Station (MCS), as well as system integration with the topside. Developed FDS, Testing, and Scope of work plans and documents. Interviewed, hired, trained, and mentored younger engineers. Set R&D and business plans with the upper management to remain competitive in the market. Supported the manufacturing department with all activities to meet schedules and project plans. Implement the HSSE and QA Industry Standards and monitor compliance withing DQ and within the various vendors’ organizations.
• TOTAL Jura PCS and HIPPS – North Sea: Responsible for leading the design effort for the mechanical design of the SEM, including the wiring and back plane, as well as integration of the subsea FO modem & power supply. Ensure that the SEM design conforms to the IWIS and SIIS specifications. Reviewed and verified the C&E chart and tested both the MCS and the Subsea Controls. Designed the environmental screen test procedures (ESS) and personally performed the testing at PTI Labs in Austin and South West Labs in San Antonio. Designed and assembled the test fixture to perform EFAT prior to shipping to the SIT location in the North Sea. Provided technical support to the SIT. Participated in the reliability analysis studies for the system. Trained the customer on the use of various types of Control Systems.
• Cirrus M1-A PCS and HIPPS – North Sea: Lead controls engineer responsible for the interface with the supplier (HIMA) and the customer (Cirrus) to implement all the requirements in the design. Generated the FDS for the system and hardware/software scope of supply. Ensure that the FDS conforms to the API 17O and the IWIS Specifications. Reviewed and verified the C&E chart & tested the logic solver. Designed the environmental screen test procedures (HALT & HASS) and personally performed the testing at PTI Labs in Austin and South West Labs in San Antonio. Designed and assembled the test fixture to perform EFAT prior to shipping to the SIT location in the North Sea. Provided technical support to the SIT. Participated in the reliability analysis studies for the system. Trained the engineers on the use of the logic solver.
PATHFINDER ENERGY SERVICES (2003-2004)
• Sr. Electrical Engineer: Support and sustaining engineering work.
WEATHERFORD INTERNATIONAL, INC (2000-2003)
• Lead Electrical Engineer for all downhole and surface TrendSet MWD/LWD systems: Embedded Software in ANSI C and C++, hardware joint development effort with different vendors. Gained experience with Top Side Systems, and established vendor interface.
BAKER HUGHES INTEQ (1995-2000)
• Software Engineer, The Hercules Team, MWD Engineering: Embedded: System Integration using ANSI C. Desktop: Design of a Directional, Pressure, Gamma Simulators. Hardware System Engineer, Advanced Development. Evaluation of new sensors. MWD Field Engineer
SPERRY-SUN DRILLING SERVICES (1986-1994)
• Regional R&M Services Coordinator: Established the third biggest R&M center within Sperry-sun to support the following systems worldwide. Trained and coached technicians to perform various maintenance tasks. Development of special projects like: At Bit inclinometer (ABI), Pressure While Drilling (PWD) Module. Modified the SRO design to boost its reliability by 500% and reduce the cost from $100 per gyro per run to $2 per gyro per run. Electronic design of the first Pressure While Drilling module (PWM) used by Sperry-Sun on under-balance MWD jobs.
• Maintenance Engineer: Same as above. Only regional support.
• Instrumentation Engineer: Same as above. Ran Survey and production test jobs at various locations in the Middle East.
SCHLUMBERGER WIRELINE (1985)
• Field Engineer: Ran Wireline logs on cased hole wells. Performed various wireline services. (e.g. packer setting and perforation).
MILITARY TECHNICAL ACADEMY IN CAIRO (1983-1985)
• Research Assistant: Developed algorithms and software for signal processing and simulation in BASIC and HPL languages. Simulation design for noise analysis and system optimization.
PROFESSIONAL TRAINING & SKILLS
FIVE CLASSES TRAINING ON SCADA CONFIGURATION, EXPERION, AND C-300 CONTROLLERS.- HONEYWELL
LEAN SIX-SIGMA TRAINING. CERTIFIED GREEN BELT TRAINING. CURRENTLY WORKING ON MY ADVANCED DEGREE IN SUBSEA CONTROLS.
ETHERNET NETWORKS & LINUX OS
TOPSIDE MCS HARDWARE AND SOFTWARE.
DELTA-V SYSTEM TRAINING.- EMERSON
BASIC SUPERVISOR TRAINING
MDW (MANAGER DEVELOPMENT WORKSHOP)
EDUCATION & REGISTRATIONS
B.S. ELECTRICAL ENGINEERING
U OF B - EGYPT 1983
FULL MEMBER, IEEE
PUBLICATIONS & PATENTS
• PATENT # 6,097, 310. AUGUST 1ST, 2000: METHOD AND APPARATUS FOR MUD PULSE TELEMETRY IN UNDERBALANCED DRILLING SYSTEMS
• PATENT # 6,212,476 APRIL 3RD, 2001: APPARATUS TO MEASURE THE EARTH’S LOCAL GRAVITY AND MAGNETIC FIELD IN CONJUNCTION WITH GLOBAL POSITIONING ATTITUDE DETERMINATION
• PATENT # PCT/US2001/049036 DECEMBER 18, 2001: METHOD FOR DETERMINING MAGNETOMETER ERRORS DURING WELLBORE SURVEYING
• PATENT # CA 2475153, AUGUST 3, 2004: AUTOMATED WELLBORE APPARATUS AND METHOD BASED ON A CENTRALIZED BUS NETWORK
• SPE PAPER # 52142: IMPLEMENTATION OF THE MODULAR MAGNETIC TOOL IN AIR DRILLING SYSTEMS
• SPE PAPER # 56701: A NEW PLATFORM FOR ATTITUDE DETERMINATION AND DECLINATION CORRECTION
ENGLISH, FRENCH, ARABIC