Vijayan Prabu

Commissioning and Maintenance -Instrument and Control Engineer  in Iraq past 2 years on projects Buzurgan & Halfaya oil field .(Total Exp – 14.1 years, Gulf Exp – 9.4 years)

1. ANTON OILFIELD SERVICES DMCC IRAQ BRANCH

PROJECT TITLE:

HALFAYA & BUZURGAN OIL FIELDS: CENTRAL PROCESSING FACILITIES AND POWER PLANT

CLIENT                 : PetroChinaInternational Iraq FZE and Mission oil Field in Iraq 

POSITION HELD :   Maintenance – Expert Instrumentation & Control  Engineer

DURATION            :   NOV 2018 to  Till Date.

Gas Turbine            :  3 x 12.26 MW  (SGT 400) - Siemens

                                  :  2 x 47.5 MW    (SGT 800) - Siemens

                                 :  5 x 42.1 MW    (MS6001B) - GE

2.SOGEX OMAN INDIA PVT LIMITED   

PROJECT TITLE:

ONGC TRIPURA POWER COMPANY (OTPC )   IN  INDIA

CLIENT                      : ONGC Tripura Power Company

POSITION HELD      :   Maintenance - Assistant Manager  of C&I   

DURATION               :  Sep 2015 to  Oct 2016.

Gas Turbine               :  2 x 255.6 MW  GE 9FA.

Steam Turbine           :  2x 123 MW – BHEL

3. DAEWOO   ENGINEERING AND CONSTRUCTION COMPANY

PROJECT TITLE:

PHOENIX   POWER  COMPANY (SAOC )   IN  OMAN.

CLIENT                      : Phoenix Power Company  – Sur city, Oman.

POSITION HELD     :  Instrumentation  and Control  Engineer.

DURATION               :  Sep 2012 to Feb 2015. 

Gas Turbine               :  5 x 217.138 MW (Dual Fired  ) –SGT5 -4000F - Siemens

Steam Turbine           :  3 x 328.2 MW - Condensing Type -Fuji.

4. HYUNDAI ENGINEERING AND CONSTRUCTION COMPANY 

PROJECT TITLE:

RAS LAFFAN C INDEPENDENT WATER AND POWER PROJECT  IN  QATAR.

CLIENT                      : Ras Girtas Power Company – Ras Laffan Industrial city, Qatar.

POSITION HELD     :  Instrumentation  and Control  Engineer.

DURATION               :  Jan 2010 to Jan 2012 

Gas Turbine               :  8 x 234.59 MW (Gas Fired) -F Series -Mitsubishi Heavy Ind. 

Steam Turbine           :  4 x 260 MW - Condensing Type - Mitsubishi Heavy Industries.

HRSG                         : 8 x 450 t/hr- Single Pressure Natural Circulation -Doosan -Korea.

MED Plant                 : 6.4 x 10 MIGD – Sidem – Veolia France

5. HYUNDAI ENGINEERING AND CONSTRUCTION COMPANY 

PROJECT TITLE:

DUBAI  ELECTRICITY  &  WATER AUTHORITY  IN JABEL ALI  L –PHESE  2  IN  DUBAI.

CLIENT                   : Dubai Electricity & Water Authority – In Jabel Ali, Dubai.

POSITION HELD   : Instrumentation  and Control  Engineer.

DURATION             :  Sep 2008 to Sep 2009 

Gas Turbine             : 4 x 203.56 MW (Dual Fired  ) – V94.3A - Siemens.

Steam Turbine         : 2 x 200 MW - Condensing Type M30-40 – Alstom.

HRSG                       : 4 x 424.8 t/hr- Single Pressure Natural Circulation –Nem.

MSF  Plant               : 4 x 13.75 MIGD (MSF Type) 

Nature of Job as Instrment Engineer

1. Commissioning of All Field Instruments.
2. Preparing Typical Commissioning Schedules.
3.  Experience in MAX DNA  1000  DCS.(METSO  AUTOMATION)- DCS .
4. Experience in  TELEPREM - XP  , SPPA-T3000, PCS7  SIEMENS  -DCS.
5. Experience in  SPEEDTRONIC Mark VIe  Control System
6. Experience in  OVATION - EMERSON   - DCS .
7. Experience in   DIASYS NETMATION – MITSUBISHI – DDC.
8. Experience in   YOKOGAWA CENTUM  VP  - DCS.
9. Experience in Auto Plant Startup  Testing ( Total  12 Modes)  Done.
10. Functional   Checking in  Every System in  Power  Plant.
11. Plant Interlock and  Trip  Test Done . (with  Simulation )
12. Calibration of  Switches, Gauges, T/C, RTDs
13. Commissioning of  GAS  FIRING  in  gas  turbine.
14. Commissioning of  GAS TURBINE   Trip , Alarm , Protection,Test and  Interlock Test Done.
15. Commissioning of   GAS  TURBINE  SIMULATION  TEST   Done.
16. Calibration  of  Gas Turbine - IGV.
17. GAS TURBINE  - START -UP  PREPARATION.
18. GAS TURBINE   - Responsibility to carry out the repair and maintenance work of all types of field instruments such as temperature, pressure, level, flow, vibration, speed, flame detectors, transmitters, switches, gauges, recorders and analyzers. Calibration and maintenance of various types of control actuators e.g. Hydraulic, pneumatic and motorized control valves.      
19. FUEL GAS SKIDS  - Commissioning of    ESD VALVE, FG  INLET  FILTER , FG HEATER , FG  PRS SKID , FG  IGNITION SKID , FG  BOOSTER COMPRESSORS .
20. FG PRS  SKID -  Calibration of Pneumatic type Positioner Control Valves & Pilot  Valve, Slam Shut Off  Valve.
21. GAS TURBINE - Commissioning of  Servo valve ,  Pneumatic & Hydraulic valve during showdown period  checking.
22. Maintenance of  Fuel gas FLOW  COMPUTER periodically calibration checking.
23. Commissioning of  DFO  FIRING in  gas  turbine.
24. Commissioning of  DE-NOX   DFO FIRING  in  gas turbine.
25. Commissioning of   FUEL   CHANGE   OVER  TEST  in  gas  turbine.
26. Commissioning of   HRSG  BOILER Trip , Alarm , Protection,Test and  Interlock Test Done.
27. Commissioning of   HRSG  BOILER DUCT  BURNER  System  Trip Test and Functional checking.
28. Commissioning of   SELECTIVE  CATALYTIC REDUCTION  System Functional checking.
29. Commissioning of  of   STEAM TURBINE  Trip , Alarm , Protection,Test and  Interlock  Test Done.
30. Commissioning of   STEAM  TURBINE SIMULATION  TEST  Done.
31. Commissioning of   STEAM  TURBINE  START -UP  PREPARATION

Checking.

1. Experience of  Steam Turbine Governor logics  DEH, SPEED CONTROL, LOAD  CONTROL , INLET  PRESSURE CONTROL .      
2. Commissioning  of     Steam Turbine auxiliaries  Lube oil, Hydraulic Oil 

System, Gland Steam System, Turbine Start-up sequence.                            

1. Commissioning of  DUMP  CONDENSER  &   SURFACE CONDENSER  System and  STEAM  JET AIR  EJECTER SYSTEM   Interlock   checking .
2. Commissioning of   HP  TO LP , HP  TO  IP  STEAM   PRESSURE REDUCE  System   Protection  Functional checking.
3.  Experience in   Logics  of  Steam Turbine auxiliaries  Lube oil, Hydraulic Oil 

System, Gland Steam System, Turbine Start-up sequence.

1. Commissioning of   DOSING  PUMPS periodically  calibration  & checking.
2. Experience of conducting  overspeed tests, valve tests, tuning of  hydraulic control valves and commissioning of  TSI  from  Turbine Control system
3. Commissioning of ID & FD & PA Fans.
4. Commissioning of Air Heaters and Trial run of Rotary Equipments
5. Commissioning of Valves & Dampers.
6. Commissioning of UCP, ECP, VMS, and DCS Panels.
7. Commissioning of ASLD System.
8. Contingency Arrangement for First Light- Up
9. Commissioning of local control panels
10. Commissioning of oil Fire skid in all Elevation of 500MW Boiler.
11. Commissioning and charging of  DCS  panel.
12. Commissioning of control signals in LT and HT Switchgear.
13. Having  good  knowledge in understanding P&I diagram

RESPONSIBILITIES

1. Function test done with clients and consultants Engineer. Hot and cold 

      Commissioning., 

1. Logic modifications for systems during commissioning according to the process.
2. Trouble Memo Clearing.
3.  Review  Instrument  control Schematics, Instrumentation Wiring Diagram, PLC Control Panels Design, Instrumentation and control Cable Lists, Schematic diagrams
4. Verification of Control Logic; Interlocks & Alarms; Check General Functionality; Check Specific Functionality; Commissioning of Control System; General I&C engineering review.
5. Review and Checking  the  Cause and Effect Diagram with DCS Logic.
6. Conduct Internal Cold Function Test  - Compare with Operation Philosophy and Cause & Effect Diagram  & DCS logic
7. Lead and supervise instrument commissioning engineers and technicians to conducts and finish all Pre-commissioning/Commissioning activities as per project requirements.
8. Check and review Engineering /OEM documents provided by EPC Contractor; check and review the commissioning, operation & maintenance, performance guarantees tests documents provided by others.
9. Provide on-site commissioning & operation & maintenance instruction and supervision service.
10. Checking instruments and data sheet, Calibration / field review (alignment) , Field Communicator
11.  - Range, measurement and alarms, Logic checks.
12. Advice and supervision about mechanical and I&C activities are developed without any deviation; equipment insulation (opening or closing manual valves).
13. Advise I&C supervisors and I&C activity leader during signal and loop testing.
14. Verification and field consulting services of I&C system and all I&C activities during commissioning of the whole plant.tests documents provided by others.
15. Loop checking in every system.
16. Modification of the new logics with existing Logic. 
17. Performing internal test and customer acceptance tests of the configured control system (HW and Application SW) in-house and at customer site.
18. Develop logic and create logic control sheets in Ovation.
19. Completion of I&C commissioning documents and preparation of the associated commissioning documentation package, as well as redlining documents which have to reflect AS-BUILT conditions
20. Initial Powering up of I&C cabinets.
21. Ensure equipment Erection & Commissioning for Safety Critical Items meets Acceptable Standards.
22. Maintenance of   CEMS  , GAS TURBINE ,STEAM  TURBINE  ,

HISTORIAN  PC &  OPC SERVER

1. Plant Every Instrumentation  work  prepare ( Permit to work )  PTW.
2. Daily Routines Checking  Field  Instruments  & Priority ALARM  Checking  from CCR &  Trend take  out  from DCS  &  Trouble shooting.
3. Loop checking in every system.
4. Modification of the new logics with existing Logic. 
5. Completion of I&C commissioning documents and preparation of the associated commissioning documentation package, as well as redlining documents which have to reflect AS-BUILT conditions
6. Initial Powering up of I&C cabinets

1. Maintenance  of  CEMS  , GAS TURBINE  ,STEAM TURBINE  , 

HISTORIAN PC  &  OPC SERVER.

1. Logic and graphics creation and modification, Simulate the Signal, 

           trend  report preparation in  DCS.

1. Punch list Development and  tracking.

1. Maintenance  of  Field  Instruments  Weekly   & Monthly  Schedule  Done .

1. Preventive Maintenance (P.M) carried out, As per Monthly Schedule.  (Yearly & Halfly  & Quarterly & Monthly  P.Ms carried out  as Per check list.

1. Ensuring Safe and Efficient Performing of CM ( Corrective maintenance ).
2. Preparing Master Data sheet for Preventive Maintenance

& Predictive    Maintenance Schedule

1. Preparing Spare Parts Inquiries and Inventory control for all instruments Spare Parts, Special  tools, test equipment and Manpower requirements.

1. Delegate and arrange for the execution of planned and emergency maintenance works such as manufacturing, modification, rectification, replacement and repairing of electronic and instrument equipment, devices, cards, machineries.
2. Experienced in the Field Instruments and control systems Procurement Activities.

1. Monitoring As Built Drawing,

1. Shutdown Job Done with as Per Schedule.

1. Maintenance of  Defective Report Prepared.

1. Maintenance of  Monthly Report Prepared.

1. Plant Every Instrumentation work Order prepare PTW  through  CMMS & SAP.

1.  Configuring in I/O cards, links, module allocations, cabinet alarm.

1. Offline Loading of Automation processors, configuring hardwares.

1. Maintenance of  TMR  PANEL checking.

1. Calibration of Control Valves  & Stroke checking of  Hydraulic Control Valves.

1. Perform field inspection to verify conformance to project specification, standards and AFC drawing prior to final acceptance test (FAT).
2. Review and approval for the remedial measure for quality related problems.

1. Witnessed the calibration of instrument like pressure, level, temperature, pressure switch, temperature switch control valves I/P converters, limit switch solenoid valves.
2. Inspection of cable tray installation conduit, fabricated support of instrument devices and electrical equipment alignment of panel marshaling box, mounting of instrument devices such as pressure, level, temperature transmitter, RTD and thermocouple pressure switch and temperature switch. Cable pulling from control room to J.B to field instruments.
3. Supervise termination of instrument cable in junction box, marshaling panel.
4. Preparation of loop folders.
5. Conducted Inspections of Incoming material at project site.
6. Checking of all instrument and control cables
7. Involved in Inspections of calibration of various types of Instrumentation, transmitter and equipments.
8. Carrying out the inspection of work being performed at site or at shop, work and offsite facilities in according with quality control plan
9. Preparation/ review of quality control job procedure, work inst.
10. Inspection and test plan for field work, progress monitoring and conducting meeting.
11. Supervision & inspection of work in the field for the installation of electrical and instrumentation equipments like transmitters, Gauges, switches, valves J.Bs, panels and cable tray etc.
12. Preparation of Deviation statements Analyzing Non-conformities and recommending corrective action.
13. Involved in the Inspection of smoke detectors, break glass units, H2S detectors, fire alarm systems and station safe guarding systems.
14. Witnessed calibration of field Instruments at shop as well as test calibrations of equipment used in the calibration shop and verified the validity of the calibration of the test & measuring equipment’s as per standards.
15. Witnessed loop check and accepting loop packages as per Standard.
16. Monitored and reviewed the quality control procedures / inspection & test plans and ensure compliance to contractual requirements.
17. Involved in the inspection of panel & cabinet marshaling & system cabinet drawings.
18. Review of Hook up drawing & bill of material for instrument installation. ,. Inspections of various PLC systems and Instruments as per the Approved data sheet & QAP.

B.E

Electronics & Instrumentation Engineering