RecruiterPK

Description

Profile

Seasoned professional with an engineering mindset and operational excellence achiever; having 8 years of proven expertise in Instrument and Control, Project Management, CAPEX & OPEX Budgeting, Technical Evaluations, Material Procurement & Inspection, Job Contracting, Shutdown & Turnaround Job Planning, Systems Upgradations and Machines & Equipment Troubleshooting and Maintenance.

Achievements:

>       Achieved record of maintenance excellence by continuous operation of urea plant for 546 days without any nuisance tripping. Uninterrupted operation incremented the profitability of the organization by 7% in 2013.

>       Successfully upgrade the Honeywell PLC for additional I/O capacity in 2008 turnaround. This upgradation accommodated the imminent projects within the available system and reduced the additional hardware cost.

>       Installed GE-Fanuc PLC on Emergency Diesel Generator (EDG) by replacing relay logic and effectively enhanced its operational reliability by providing cost effective solution.

>       Commendably retrofitted the obsolete hydraulic speed governor of CO2 compressor with the modern electronic system without the intervention of OEM. Performed managerial and technical tasks including the Factory Acceptance Test (FAT) & Site Acceptance Test (SAT) with the third party solution provider (PM Controls, Singapore). This capital project relieved the organization from purchasing the costly mechanical parts of the obsolete system and save USD 1.2million per year.

>       Productively implemented the ISO-9001, 14001, 18001 and 50001 standards in the minimal period of 10 months with zero- nonconformity in the external audits. The organization achieved the combine ISO standards certification in the first attempt. This increased the indirect profits of the organization in term of the product export.

>       Implemented the NFPA 85 Standard on boiler control to ensure the highest integrity of the plant equipment & personnel safety.

>       Successfully enhanced and maintained the electrical capacity of the plant by installing 11.6 Megawatt gas turbine generator in consultation with   TurboMach, Switzerland.

>       Performed FMEA of critical instrumented system installed at plant facility, evaluate and completed the OPEX and CAPEX feasible projects for continuous improvement of the organization.

>       Received three promotions and a job confirmation after completing one-year rigorous training within the period of eight

years.

Professional Experience

Magna International (Integram Seating, Canada)

Temporary Part Time (TPT) Seat Assembler [July 7, 2016 to currently working]

Assemble Seats on the manufacturing line, occasionally performed inspections and assure the quality of the product.

Fauji Fertilizer Company Limited, Pakistan.

Instrument and Control (I&C) Engineer [Sept. 2007 to Dec. 2015] CAPEX Projects:

1)    I/O Expansion of Honeywell Safety PLC in 2008.

Role: PLC Configuration and Hardware Verification Engineer. Type: Operational Enhancement. (De-Bottlenecking)

Upgrade the PLC I/Os capacity for the future expansion projects. Performed software configuration, hardware installation and designed a new electrical cabinet as per OEM drawings, performed the FMEA to ensure operational integrity and safety, test the hardware as per drawings and update it, wherever needed. I also involved in this two-year CAPEX project with the lead control engineer in the project justification, hardware specification & proposal writings, ordering, technical evaluation, material inspection, and strategic planning during the execution of the entire project.

2)    Installation of GE-Fanuc 90-30 PLC on the Emergency Diesel Generator (EDG) Role: Installation Engineer

Type: Reliability and Safety

The emergency diesel generator (EDG) was the main lifeline of the plant in case of complete power failure. The upgradation of the obsolete relay based system was necessary for the operational reliability and safety of the plant’s equipment. Unavailability of EDG in case of emergency was destructive and unsafe. The cost-benefit analysis suggested that the upgradation was inevitable, this project was capitalized and the system was upgraded successfully with GE-Fanuc 90-30 PLC in combination with relay logic. This modification improved the safety of the plant equipment and increased the production confidence with respect to the consistent availability of the machine.

3)    Rectify the Problem of PLC Logic Tester: Role: Troubleshooter (Self-Initiative) Type: Productivity Enhancement

Resolved the problem of Honeywell PLC controller testing & training facility in the FFC, which was faulty before I was hired. I took the self-initiative to rectify the chronic issue and revived the throughput of the logic testing facility. After, working in depth in an offline environment, I found the fault, presented it in front of the management and convinced them by giving the presentation. Moreover, I gave the cost and benefits overview for the procurement of the new cards. After approval as a CAPEX project, rectification was implemented, which provided the facility to simulate the new logic modifications in an offline environment before downloading into actual PLC. This achievement reduced the maintenance downtime and indirectly benefit the organization.

4)    Installed the Turbomach SOLAR TITAN-130 “11.6” Megawatt Gas Turbine. Role: Instrument Engineer for System Integration

Type: Cost Optimization

To improve the energy performance of the plant and to overcome the electricity shortfall, engineering department initiated this CAPEX project. The total cost of this CAPEX project was USD 100Million. This project reduced the production cost of urea fertilizer and increased the long-term profitability. As a lead instrument engineer, I reviewed all the technical documentations provided by the supplier, performed material inspection, and ensured the safety and quality of the on-site commissioning works. Integrated the newly installed system with existing hardware, provided day-to-day support services to the contractors. After completion of the project performed the long-term A, B, C class maintenance of the equipment as per BOA contract with the OEM.

5)    Installation of RTK Sequence of Event

Role: Installation, Configuration, and Maintenance Type: Reliability of Boilers (B-601 & 602)

During my job, I encountered the problem of troubleshooting the two auxiliary boilers. Whenever the boiler tripped because of a nuisance, I could not be able to find the first initiation cause. This posed a depressing situation as a maintenance engineer, not to know the actual cause of failure. To rectify this problem, I initiated the project for the installation of a sequence of event (SOE) system, which was approved as a CAPEX project. After successful installation of the new system, the downtime of the boilers was reduced to few hours in case of tripping.

Various other CAPEX and OPEX projects included:

ü  Installed Woodward 505E speed control system and Electronic Speed Trip (EST) on eight Mega- Watt Steam turbine driven power generator.

ü  Installed Portacell chlorine dosing system in the water treatment plant.

ü  Replacement of float type level measurement instrument with guided wave radar.

ü  Procured and Installed Ammonia Detection System on the request of safety department.

ü  Installation of nine PH and six conductivity analyzers and integrate it with the Distributed Control System (DCS) for better monitoring of the process parameter.

ü  Installation of GE-Bently Nevada 3500 Vibration monitoring system on CO2 and Air compressors.

Professional Certifications:

§  Certified Safety Integrity Level (SIL) Professional.

§  IRCA Certified Lead Auditor of ISO 9001 Quality Standard.

§  Knowledge of codes & standards like API, ISA, NFPA & IEC.

Management Training and Certifications:

ü  Problem Solving and Decision Making
ü  Effective Communication Skills
ü  Skills in Goal Setting and Work Planning
ü  Time is money
ü  Effective Presentation Skills
ü  Emotional Intelligence (The care & growth way)
ü  Organizational Climate
ü  The “Art of Management” by Excellence.