EDUCATION
2003-2007 University of Engineering and Technology, Lahore, Pakistan
BSc (Honours) in Mechatronics and Control Engineering 77.55 % Marks
Faculty of Mechanical Engineering
PROFESSIONAL SUMMARY
Jubail United Petrochemical Company (SABIC), Jubail, KSA
Feb 2012 till date – Instrument Engineer
Agritech Limited (Formerly Pak-American Fertilizers Ltd.), Mianwali, Pakistan
Mar 2011 to Jan 2012 – Area Engineer (Instrument) – UREA Plant
Dec 2010 to Feb 2011 – Project Commissioning Engineer – UREA Plant
Aug 2007 to Nov 2010 – Instrument Engineer – Utilities Plant
PROFESSIONAL SKILLS
• Field instrumentation maintenance & trouble shooting including transmitters, switches, control valve & analyzers.
• Procurement of field instruments, control valve, analyzers & control system.
• Project co-ordination, execution and management.
• Expertise in installation & troubleshooting of Pneumatic, Electronic & PLC (GEFanuc, Siemens S7, S5, HIMA) based control systems.
• Expertise in orifice plate sizing and Firstvue fisher control valve sizing and its selection.
• Technical review of basic and detail engineering documents including general specification for instruments, P&IDs, instrument datasheets, hook-ups, material to order, isometrics & DCS/PLC I/O list.
• Good working experience of SAP Maintenance Module.
• Conversant with international standards & engineering practices related to instrumentation and control .i.e. API, ISA, IEC, NFPA.
PROFESSIONAL EXPERIENCE
Jubail United Petrochemical Company (UNITED) – SABIC, Jubail, Saudi Arabia
Jubail United Petrochemical Company is a fully owned company by SABIC. UNITED produces ethylene, ethylene glycol, polyethylene and linear alpha olefins.
Instrument Engineer Feb 2012 – Present
Responsibilities
• Preparation, improvement & implementation of Preventive and Pro-Active Maintenance of Plant Equipment.
• Provide technical support and problem solving backup to operation department as and when required.
• Team member fully responsible for planning and execution of Turnaround and Shutdown Jobs.
• Procurement and management of critical & non-critical spares.
• Technical Support to Control System Team.
• Logging & Recording of equipment maintenance history for improvements in PM schedules.
• Development of an approach to maintenance incorporating modern principles, programs, and strategies for personnel and equipment improvement.
• Review and execute Preventive Maintenance Schedule in SAP.
• Clarification about scope of work and make the execution plan for jobs.
• Understanding, analysing and solving execution problems of Engineering.
• Review P & ID’s, Loop Drawings and Data Sheets for all kind of Instruments.
• System integration testing, system checkouts, site acceptance testing, loop function checks DCS/PLC configuration verification, loop tuning, boiler management systems, machine monitoring and protection systems.
• Supervise and control all the activities regarding installation, termination, calibration, testing and commissioning of field instrument, DCS and MCC along with cable tray and conduit installation and cabling work at project site.
• Responsible for the development of training material & tests in “TRACCESS” system for on job trainee technicians.
Agritech Limited (Formerly Pak-American Fertilizers Ltd.), Mianwali, Pakistan
Agritech Limited (Formerly Pak-American Fertilizers Ltd. (ISO-9001:2008, 14001:2004 and OHSAS 18001:2007 certified) is a fully owned company of Azgard9 Limited. Agritech Limited is a state of the art Ammonia & Urea complex.
Area Engineer (Instrument) – UREA Plant Mar 2011 – Jan 2012
Responsibilities
• Responsible for implementation of planned and pro-active maintenance approaches to reduce breakdowns and to enhance plant availability and reliability.
• Hands-on experience of control valves & transmitters (pressure, flow, level, conductivity, ph etc) maintenance/calibration.
• Critical spares review & inventory optimization.
• Leading total strength of 10 personals including 1 Engineer & 2 supervisors.
• Counselling with instrument technicians for improvement opportunities.
• Responsible for promoting team work & improvement in workforce technical abilities & safety awareness via regular training sessions.
• Coordinate with mechanical maintenance, mechanical workshop and electrical departments.
• Procurement of new instruments through ORACLE based ERP system.
• Close liaison with production and process engineering department for improvement projects.
• Conduct internal audits of ISO 9001:2008, OHSAS 18001:2007 and ISO 14001:2004 standards.
• Responsible for the development of staff TNA (Training Need Analysis), training plans against TNA and implementation of training plans.
Project Commissioning Engineer – UREA Plant Dec 2010 – Feb 2011
Responsibilities – Revamp Activities “PACE-135 Project” (Pak-American Capacity Enhancement-135%)
PAFL worked on Capacity Enhancement Project (PACE135), the objective was to increase production capacities by additional 35%. For this project, main licensing and FEEP contractors were M/S Johnson Matthey of U.K for Ammonia Plant and M/S Stamicarbon of Netherlands for Urea Plant. The erection phase of this project has been successfully completed and currently, the plant is going through the commissioning phase.
• Lead role for the entire instrument scope of work (installation & commissioning of all field instruments & control valves) at UREA plant.
• Supervisory services during erection, pre-commissioning & commissioning phase.
• Reviews and monitors all aspects of the EPC Contractor’s instrumentation & controls design, drawings, documents and reports.
• Coordinates with EPC Contractor’s Lead Instrumentation Engineer.
• Reviews EPC Contractor’s list of instrumentation engineering deliverables.
• Reviews all document, drawings, including loop configuration diagrams for DCS, ESD, MOVs, CVs, and related procedures for calibration, loop testing and commissioning submitted by the EPC contractor.
• Technical review of general specifications for instruments, P&IDs, instrument lists, instrument requisition, installation hook-up, material to order, instrument datasheets, loop configuration diagrams, DCS/PLC I/O list received from EPC contractor.
• Review of isometrics by confirming all instruments, mechanical connection sizes, end to end distance & straight run requirement.
• Control Loop configuration on Honeywell TDC-3000 DCS & loop checking of all instruments.
• Control valve sizing, selection for interchangeability in order to ensure compatibility for new process conditions.
• Orifice plate (Flow Elements) sizing and calculations for compatibility as per new process conditions.
• Cause & effect analysis & realization of interlock diagrams.
• Preparation of Instrument Bulk Material Lists, i.e.; Cables, Air Piping & Fittings, Impulse Piping & Fittings, Conduit & Fittings, Tubing & Fittings and Junction Boxes which will be required during revamp at both Ammonia & Urea Plant, technical evaluation of quotations, P.O issuance & ensuring all material arrived at plant in time keeping in view the stringent Project timeline.
• Preparation of ”RFQ” (Request for Quotations) as per new instrument requirement under revamp scope.
• Technical bid analysis & recommendation for procurement of instruments.
Instrument Engineer – Utilities Plant Aug 2007 – Nov 2010
Responsibilities
• Looked after day to day activities including routine complaints, preventive maintenance and handling any emergencies at IGG, Cooling Tower, Polisher, Water Treatment & Power House areas (Steam + Gas Turbines).
• Worked on PLC’s (Siemens S7, S5, GEFanuc, HIMA) and process instrumentation.
• Troubleshooting of Control Systems (Pneumatic, Electronic & PLC Based).
• Maintenance of online analyzers, pH meters & conductivity meters.
• Turnaround / Shut down instrumentation jobs planning and their execution.
• Co-ordination with process engineering and operation department for improvement projects.
• Design & implementation of new control logics for enhancing plant reliability using relays and electronic controllers.
• Selection of appropriate instruments for plant modifications as per standards and best industrial practices.
• Preparing BOQ (Field Instruments & Control System) for annual shut down, new upcoming projects & modification jobs.
• Provide technical support and problem solving backup to operation department as and when required.
• Prepare conceptual and detailed designs for instrument related projects and plant changes.
• Ensuring compliance with the health and safety regulations.
Achievements
• Successful & timely completion of erection, pre-commissioning & commissioning activities relating all field instruments at Urea plant during PACE135 Project.
• Successful configuration of 18 new RTD’s (temperature elements) on DCS at urea plant using multi-dropping technique for configuring two MTL 831B – Multiplexer Transmitters in the field during PACE135 Project.
This topology is used for the first time at our plant. By using this topology, cost of the cables is widely reduced as all of the RTD’s are now terminated on multiplexers in the field from where, only two single pair cables (used as data highways) are coming to the MTL838B – Multiplexer Receiver in the control room. Whereas, previously these transmitters were installed in the control room and cables were laid from the temperature element (RTD/Thermocouple) in the field to the control room.
• Successful commissioning of new cooling tower fan control logic. This control circuit was implemented using electro-mechanical relays providing motor tripping & alarms provision on existing annunciator panel at high vibration & low oil level in gear box.
• Successful commissioning of auto-start control logic of motor driven pumps at GT Chiller & Condensate firing unit.
• Selection, procurement and installation of automation project (GEFanuc Series 90-30 PLC with Remote I/O’s) for the control of condensate treatment plant, as “Team Leader” & also performed “FAT” (Factory Assessment Test) for the same. This new control system consists of 240 DI/DO’s and 16 AI’s.
• Co-ordinated the installation, pre-commissioning & commissioning of field instruments, along with installation of the “PLC” based Control System (Siemens S7/Wincc Flexible 2005, HIMA) on Heat Recovery & Steam Generation (HRSG) Project – 30 TPH Boiler installed at Gas Turbine (TURBOMACH- 7.5 MW) downstream.
TRAINING
“Proficy Softwares & GEFanuc PLC Technical Training” at GEFanuc Intelligent Platforms Asia Pacific Ltd, Singapore. May 2009
COMPUTING SKILLS
• Technical Software’s: SAP, Control valves sizing, Orifice plate sizing, Proficy softwares (GEFanuc PLC Logic developer and HMI Development), Auto Cad 2004, Solid Edge v16.
• Application Packages: RSLogix, RSView, Proteus, Keil, Prolog, K-Vision, C++, MatLab, MS Office.
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