Lead Commissioning Engineer Instrumentation and Controls


Last Updated: 23rd January 2018 (over 4 years ago)

Address
India

E-mail
Locked

Phone Number
Locked

Gender
Male

Age Range
45 to 54

Qualification Level
Degree

Languages
English, Hindi, Urdu

Summary

I have more than 25 years of experience in Control System Engineering and project management of upstream oil and gas production and gas treating facilities, refineries, and petrochemical production worldwide. My levels of responsibility include hydrocarbon facility, production and gathering station, refinery, chemical plant, conceptual design, FEED front end engineering design, detail design, management of control system engineering disciplines, project management, and construction management of facilities.
I have extensive expertise in evaluating the technical and economic feasibility of projects and in the development of licensors, front-end engineering design (FEED), and engineering, procurement, and construction (EPC) packages. I am technically competent individual in control system, DCS, SCADA, and RTU, systems, SIS (safety instrumented system) ESD system, PIMS (plant information management system), control system security and Condition Monitoring systems Bently Nevada 3500.
PLC such a HIMA, Honeywell FSC, Modicon, Siemens, Field instruments such Yokogawa, Foxboro, Emerson, Fisher Rosemount, I have also been involved in commissioning of process plan rotating and static equipment such compressor, pump, turbine, tank, bulk separator, test separator, also been involved in the commissioning of MV/LV switchgear motor control centre.
Supervise FAT’s, review functional logic diagram & cause & effect resolving SQ’s, determining system boundaries, system punch lists, as built packs, supervise a pre commissioning and commissioning, start-up & handover of packages general systems and attending regular progress & problem meetings with client.

Education

Birsa Institute of Technology Sindri, India
Electrical Engineering

   Jun 1987
— Jul 1991

Bachelor of Engineer in Electrical

Experience

PB Power (WSP Group)
Senior Instrument & Controls Engineer

   Dec 2014
— Jul 2017

 As a PMC Instrument & Controls Engineer where I was responsible for Design, FAT (Factory acceptance Test), Construction, Quality, Pre-commissioning and Commissioning SAT (Site acceptance test) of Instrument and controls, Electrical Controls, F&G System and HVAC System.
 responsibility of review and approved Design document, Work procedure, for Construction, Commissioning, Quality submitted by EPC contractor are below
Instrumentation and F&G system:- P&ID, Instrumentation layout drawing, F&G layout plan, PMS (Power management system), LMS (Load shedding Management System), GMS (Generator Management System), ESM (Electrical switching and Monitoring System), TFR/FMS(Transient Fault Monitoring and recording System), PMS DCS Data exchange list, Modbus list , I/O list, Cause & Effect Matrix, panel general arrangement drawing Hook-up drawings, Cable tray layout, Cable schedule, Loop drawing, Wiring drawing, Method statement, ITP, DCS Graphic modification document, Loop test and function test procedure, Material submittal, Red Mark-up Drawings, As-Built drawings etc..
 Monitoring construction activity and report to PMT project engineer and project manager
 Verifying construction activity as participating Responsibility as a QC Inspector
 Commission the project as participating the commissioning engineer from ADGAS side for instrument and Electrical Controls where i responsible to attend all commissioning activity and approved once completed successfully.
 Attending meeting and sharing my observation of project to ADGAS team and Drafting letter to EPC contractor for betterment to improve contractor performance into the project.
 Giving feedback to ADGAS PMT and project manager where EPC and Sub contractor fail to get progress and sharing Ideas how they can improve the progress to achieve Mile stone.
 Supporting and providing my availability to Electrical and HVAC department of PMC/ADGAS when no electrical engineer are presence on site due to leave rotation in all level, Design document review, construction monitoring, work Inspection, Commissioning, Site visit, ETC..
 Attended FAT for all Electricals controls panels, Instrumentation System, F&G and HVAC Panels.
 Responsible for all SAT of Instrumentation, F&G HVAC System and Electricals controls.
 Experience and extensive knowledge of Loop checking, functional test and calibration.
 Knowledge of control system SCADA, IT and communication system including optical fiber.
 Knowledge of auxiliary equipment, HVAC, Firefighting system, Safety equipment, LV cubicles, Batteries + UPS, Generator, etc…
 Able to follow and control on site auxiliary equipment.

Enerflex Limited
Lead Commissioning Engineer Instrument

   Jan 2014
— Aug 2014

 Lead Project handover of operable control, Fire and Gas detection and safety shutdown systems. Participate in development and implementation of a long term preservation and system readiness program to deploy instrumentation and control system for client objectives.
 Develop testing procedures and policies that are aligned with commissioning best practices and regulatory requirements to ensure safety, operability, and compliance
 Responsible for providing design input/review of all aspects of project process control and safety shutdown systems, topsides processing, and various required systems.
 Lead Project handover of operable control, Fire and Gas detection and safety shutdown systems. Participate in development and implementation of a long term preservation and system readiness program to deploy instrumentation and control system for client objectives.
 Develop testing procedures and policies that are aligned with commissioning best practices and regulatory requirements to ensure safety, operability, and compliance.
 Input to the commissioning preparation work monitoring preservation monitoring of mechanical completion and pre‐commissioning activities commissioning temporaries, etc
 Monitored commissioning activities and managed a team of technicians and commissioning engineers.
 Coordinated between commissioning activities and client, ensured all strategies were developed in accordance to their need.
 Developed commission programs, allocated necessary resources and oversaw their implementation.
 Conducted and coordinated with various departments and performed Factory and Site Acceptance Tests.
 Trained team members on need of client, contract obligations and commissioning activity that were required to be followed.
 Provided necessary support for commissioning activities in operational phase of project.
 Evaluated contractor and vendor documentation and ensured that test procedures were carried in accordance to same
 Evaluated Instrument Commissioning design packages and ensured that commissioning issues were taken into account
 Assisted in resolving all technical queries of customers
 Coordinated with Instrument Commissioning contractors and ensured that designs were followed to optimal level.
 Maintained records of work carried in facility
 Provided technical support to processes in facility.
 Recommended ways to make program more cost effective and scheduled project timeline.
 Monitor any changes or upgrades that affect the controls systems.
 Complies with the highest level of safety during all stages of project execution to avoid any type of incidents and or accidents. Taken reasonable care of own health and safety and that of others in the workplace
 Assist in the final reconciliation of work and material and clearing up of the site as part of project closure.

SEPAM Middle East
Manager E&I

   Jan 2002
— Dec 2013

 Heading the manpower for implementation of the project in accordance with the scope of work
 Preparing planning calculation and engineering drawing sketches and detailed
 Providing verbal instructions and preparing work plan for implementation of the Project from the survey sketches
 Supervising the location of instruments areas and all types of cable trays and Stub-up panels & junction boxes
 Overseeing installation of various types of Power Signal Control and instrument cable installation and termination as per
 Supervising installation of:
• Ground earth pit and AC / DC bus bar, Installation all kind of electrical equipment in side substation and field.
• Telecommunication, Instrument & Fire & Gas all kind of Marshalling cabinet & consol in side main control auxiliary room and instrument satellite room
• Instruments and all Kind of Instrument tubing as per hook up drawing Assists the manpower regarding quality assurance and motivate to complete the Job within time period and prepare all Progress report
 Handled the completion of Job visits to the Location and confirm the all work done as per project Specification
 Liaising with civil, mechanical, piping, electrical, scaffolding, engineering department and planning engineer

Pre-Commissioning
 Handled pre-commissioning activities start when the plant or system achieves mechanical completion. Frequently however pre-commissioning activities overlap mechanical completion activities and for this reason the plant should be separated into easily manageable system packages
 Each system package will be pre-commissioned as a whole and isolations at the boundaries of the system package will be maintained until the completion of pre-commissioning activities
 Pre-Commissioning activities include checking for design conformity, checking the status of electrical mechanical and instrument installations, running-in of equipment, Hushing and cleaning activities, drying and so on

Commissioning
 Managing commissioning phase in a project when design process fluids are introduced in to the process. Commissioning activities normally consist of activities associated with running or operating the plant and include operating adjustments necessary for the satisfactory operation of the plant
 Carrying out "functional checks" which are methods used to prove that an item of mechanical equipment or control system functions correctly
 The home office phase, which we did, includes the preparation of the tools for measuring and reporting of pre-commissioning and commissioning activities progress, project details and operation plan, and the preparation of detailed procedures

• (Pre-) commissioning engineering
• System/subsystem definition.
• Marked-up P&ID by system.
• Detailed pre-commissioning / commissioning
• Organization chart
• Operations plan per activity
• Generic Method Statement
• Commissioning plan and critical path network
• Activities to be performed by the system
• Organization roles and responsibilities
• Punch listing method statement
• Commissioning spare parts & consumables
• Testing schedule
• Equipment data

System/subsystem definition
 Facilitating a smooth transition from construction to commissioning it is required to complete construction work in small packages, known as systems
 Ensuring pre-commissioning work to progress from an earlier point in the schedule, thus reducing the final pre-commissioning peak workload substantially
 Preparing system summary sheets which list the system content by line and equipment numbers

Detailed Pre-Commissioning / Commissioning Execution Plan
 Charting out plan that identifies all of the major pre-commissioning activities by system
 Identifying "system ready for pre-commissioning" milestones
 Commencement of system turnover from construction to commissioning should ideally commence at approximately 70% erection completion. From this point handover of systems should be made on a regular basis
 A method of pre-commissioning progress monitoring will be developed to allow progress to be monitored by:
• Overall pre-commissioning completion for the whole project
• Pre-commissioning completion by process unit
• Pre-commissioning completion by system
• Discipline completion by system
• Vendor Schedule

Generic Method Statements
 Generic method statements are developed for each activity type (cleaning, leak test, inserting)
 Each statement will form the basis for the development of safe and efficient detailed procedures
 The method statements will contain information on the methodology, acceptance criteria, and IISE implications
 Commissioning organization consisted of an integrated team, PMC and EPC team
 Changed as commissioning progresses from design, through pre-commissioning and start-up activities
 Managed through regular reviews of the relevance of the commissioning organization structure to that stage of progress

Punch-Listing Method Statement
 A system will be developed to identify record and correct damaged, incomplete and incorrect installation and/ or fabrication. Items which are inaccessible or unsafe will be incorporated into this system. The system will be able to allow categorization of punch-list items as follows:
• Category A: Items that must be cleared prior to start of pre-commissioning.
• Category B: Items that can he cleared during pre-commissioning.
• Category C: Commissioning Items the system will be able to track outstanding items by system, Category and discipline.

Badar Al mulla & Brothers WLL
QA QC Inspector Instrument

   Feb 1998
— Oct 2001

 In-charge of field instrumentation construction activity like installation of cable tray,impulse line,air line
 Junction box, local panel, marshalling cabinets cable glanding and termination etc
 Recording and endorsing reports of inspection & tests; witnessing and compiling scope files to identify inspection status
 Reporting on defective work and non-conformities, root causes of problems and ensure timely resolution of reported problems.
 Provide onsite quality training and awareness to supervisors and artisans
 Assisting in preparing report required by the QA/QC department, project and location
 Supervising Site Foreman and responsible for implementation of standard & procedures for the entire construction phase of the project.
 Prepare and interpret construction drawings including the preparation of field design changes or as-built drawings to be utilized as the reference in construction execution.
 Recommending measures to correct any deviations; checking technical specifications of materials used for Electrical / Instrumentations for field installations and acceptance of materials
 Reviewing vendor documents, drawings, preparing & reviewing instrument & control cable schedule, cable laying and terminations, etc.
 Supervising and inspection for field installations of Electrical / Instrumentation equipments, like Transmitters Gauges Switches, Junction box’s, Panels and Cables
 Assisting client for testing & commissioning of Electrical & Instrument cable and equipments
 Caring witness inspection for instrument calibration lake transmitters, control valves, Gauges and Switches for prior to installation
 Preparing & reviewing quality plan job procedure, work instruction, inspection and plan for field work, progress monitoring and conducting meetings
 Monitor the effective implementation of procedures in accordance with quality assurance manual and quality test plan.
 Involved in inspection of instrumentation site work activities for fabrications and installations
 Checking and receiving all incoming materials for possible damages and non-conformance to project standard and quality specifications
 Submitting reports to QA/QC Manager pertaining to inspection acceptance progress
 Supervising instrument and control cables glands and terminations for JBs, panels and transmitters side, cable insulation resistance testing and continuity checking

IMECO
Instrument Technician maintenance

   Feb 1996
— Nov 1997

 Responsible for Instrumentation and controls maintenance in DCS, PLC, F&G System & Field Instrument, preventive & corrective maintenance for the oil & gas field, refinery and platforms.
 Provide technical support for Start-up within the ICAT
 Participating in and assisting with the co-ordination of the Project’s performance test(s)
 Following and controlling the testing and commissioning of new/modified equipment system, machinery instrumentation
 Had well experience in supporting the Engineering and improvement Projects for plants control loop schematics for DCS, ESD, F&G, CMS and Machine control.
 Well exp. in Preparation of I/O List, Instrument Index, Plan layout, Control room & Control Equipment layout, Cable schedule and Interconnection diagrams, Instrument Installation drawings, Process flow diagrams, P&IDs and etc.
 Loop checking, commissioning, and instrument calibration.
 Assisting with new Up-Grading projects People
 Testing various types of transmitters, switches, control valves, commissioning & start-up.
 Calibration and commissioning of various type of Electronics and Pneumatic Instruments.{Temperature, Pressure , Level , Flow & Control Valves

Blue Star Limited
Instrument engineer

   Oct 1994
— Aug 1995

 Monitoring projects with respect to Cost, Resource Deployment, Time over-runs and Quality Compliance to ensure execution of projects within the time & cost parameters.
 Provide project cost estimates and material procurements, material take off (MTO). Preparation of daily, weekly and monthly progress reports for onward submission to consultant, employer and head office.
 Preparation of monthly interim payment certificate as per contract value. Preparation of rate analysis of extra items carryout the quantity calculations in order to finalize the B.O.Q items and correspondence for discrepancies of BOQ clarifications with consultants.
 Managing various activities pertaining to testing and commissioning of a wide range of machinery, systems and equipments.
 Conducting inspection and tests to ensure the effectiveness of various machines and equipments keeping in view the performance, safety & quality standards.
 Implementing and monitoring effective procurement schedules along with finalizing the specifications of the spare parts and establishing the quality & quantity limits.
 Coordinating with vendors for ensuring on-time supply of equipments.
 Effectively allocating the resources optimizing the available time for enhancing profitability.

Process Controls and Technology
Junior Instrument Engineer

   May 1992
— Jul 1994

 Provide project cost estimates and material procurements, material take off (MTO). Preparation of daily, weekly and monthly progress reports for onward submission to consultant, employer and head office.
 Implementing and monitoring effective procurement schedules along with finalizing the specifications of the spare parts and establishing the quality & quantity limits.
 Coordinating with vendors for ensuring on-time supply of equipments.
 Effectively allocating the resources optimizing the available time for enhancing profitability.
 Managing various activities pertaining to testing and commissioning of a wide range of machinery, systems and equipments.
 Conducting inspection and tests to ensure the effectiveness of various machines and equipments keeping in view the performance, safety & quality standards

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