B.PRADEEP KUMARSENIOR I&C ENGINEER

PROFILE

Companies Worked forADMA – Zakum Central Super Complex De-mothballing Project

Major Projects handled

ADMA – Umm Shaif Gas Injection and TOTAL - USAN – FPSO Project

Sohar Aromatic Project

Sabine Pass LNG project

500 MW Thermal Power Plant

13 MW coal based power plant

ADMA – Zakum Central Super Complex – De-Mothballing Project (ZCSC)

Central Accommodation Platform (CAP / NAP)

Role: Area Lead Engineer for F&G System / MDS upgradeIntroduction –F&G system in ZCSC were in Risk-1 factor in ADMA ZCSC site risk assessment. ADMA wanted to migrate from GE FANUC 90-70 PLC installed in all platforms to an Ethernet based solution, however Ethernet compatibility with 90-70 was a failure due to CPU loading. GE Next step decided that most of the GBC, CPU etc shall move from active to mature and some from active to discontinue. NPCC advised ADMA that Rx7i PLC - CPU shall be suitable and the new Accommodation module shall be provided with Rx7i CPU with Rx3i IO modules. Specification / FEED was suitably modified based on this.

Production Platform BH cabin – PLC / OIT

Utility Platform CCR PLC

System Architecture

a)     Procurement of F&G system: Specification / Technical Bid Evaluation between Silvertech , ICS triplex and L&T Automation / vendor and client meetings . L&T was selected and site survey was conducted. b)    FAT - Phase-1 (MDS upgrade – April -2011) The MDS in CCR had to be modified and the existing QNX based software had to replaced. This was tough as there were no existing graphic pages which was working (Risk-1), now all had to brought to the new cimplicity software and make the system running with existing detectors at site. Existing PLC dump was collected from 90-70 PLC and was used for Cimplicity based MDS softwareSince there was no interface between platforms and standalone F&G system and to make CCR a central one, Serial communication was suggested by ADMA….interface issues – GE FANUC 90-70 PLC – has only RS485 port and it was converted to optical and taken to CCR…in CCR after converting back to RS-485, RS485 to RS232 converter was put in place to communicate with MDS. Parallel it was RS-485 was connected to CCR port. This configuration was temporary and this ensured that PLC communicated between each other and MDS. The following were performed in FAT. Wiring termination inspection, input output status test - remote IOS, graphic panel test, alarm & event recording list, system diagnostics, PLC redundancy test. FAT was successfully tested and approved. ADMA Level-1 risk was mitigated and well appreciated from ADMA operations, DED etc.

Old MDS and Matrix

c)    FAT - Phase-2 (Stage-1 CAP / NAP PLC & IOS - November-2011CAP / NAP was has 6 remote I/O with Rx3i system I/O modules. It was the first platform in ADMA to have Rx7i PLC with field Rx3i I/O modules connect through Ethernet. It has 3 FACP for addressable smoke and heat detectors, HSSD system for panels, void and ceiling connected serially. F&G system has interface with electrical panels, HVAC, packages like EDG etc.

FAT team – ADMA DED, TSD, Site Operations team, NPCC engg & Comm, TYCO FACP, GL, TUV

Integrated FAT – F&G IOS and F&G detector and devices

d)    Phase-2 (Stage-2 LUP - LPP - IOS - December-2011) – refer FAT certificatee)     Phase-2 (Stage-3 LUP-LPP Logic - Graphic test (March-2012) - refer FAT certificate

Design issues and Lessons LearntEngineering issuesa) Cause and Effect, F&G layouts (construction and demolition) were fully modified based on existing condition and F&G performance target studyb)  I-O list discrepancy between site collected PLC dump and project I-O list. The I-O delta was analyzed and logics was properly amended. Construction Issuesa)     FACP – panel location – corridor location, recessed into wallb)    Relocation of CCR matrix panel and F&G PLC panel. All existing cables into these were identified and termination details were collected from site, accordingly a document was prepared with proper IJB’s.c)     IOS panel location – CCTC, sub contractor made top entry of cables instead of bottom entry. Client comments were resolved and got approval.d)    Existing detectors which were replaced / relocated were properly advised based on 3D modeling. Commissioning Issuesa)     Phase-1 – SAT supportb)     Phase-2 Rx7i compatibility issues with Genius Bus Controllers (on-going issues)c)     Phase-2 NAP – Site technical query through video conferencingd)     F&G interface with EDG package, Electrical panels, HVAC panel etc were fully supported

> Detector and devicea)     HC IR point detector – calibration issues – site coordination – PVC tube extension , male adaptor etcb)    Flashing Beacon – over load fault issues – o/p routed through relay and initial surge in current was negated.c)     Addressable detectors – protocol issues with FAST 2000 tyco – series 200 sensor protocol only with system sensor UK – Vendor Pre-Qualification ADMA approvald)    NAP detectors were inspected at NPCC yard for installation.

Other Activity in project> DCS / ESDAttended Yokogawa FAT in DubaiErgonomic Study and control room layout

> P1 , P2 , P3 – PackagesMOL pumpCorrosion Inhibitor PackageEmergency Diesel Generator PackageFire Water Pump Package

> Engineering Co-ordination

F&G Field engineering and Procurement of F&G detectors & Devices

TOTAL project – USAN FPSO

Preparation for Functional Analysis / Interface Control Narratives for the complete Hull side and also its interface with Topside/ ICSS. Work includes Tandem Offloading System-QCDC/ ERC system, Methanol storage tanks, bilge systems, Jockey Pumps, Inert Gas and HC blanketing Distribution, Service Water and and sea water distribution, etc. Functional Analysis as required for Yokogawa system engineer. Reference to TOTAL documents like Hull safe chart, HPU, FDS, I-O list, ICSS architecture , preparation of function logics and schematics, loop diagrams, cable schedule, cable block diagram, Yokogawa Typical etc Methanol / cargo system – complete loading, unloading, transfer and topside operations of storage system and preparing the interface FA of packages.

Umm Shaif Gas Injection Fielf – USGIF – 1.6 billion project

Involved in TBE, POS of Field Instrumentation, Fusible Loop Panel and condition monitoring system Cause and Effect diagram queries, ESD and F&G (Silvertech) systems queries and ESD (ICS Triplex) matrix panel design and review. Checking and approval of vendor documents through ODICS (Offshore engineering Document & Information Control System) - software from Documentum - EMC. Checking of space requirement in offshore platform through site visits and implementing the same in design. Preparation of Technical Query / concession request to the client ADMA-OPCO.  Involved in Condition Monitoring system (CMS) design and procurement - Vendor - Bentley Neveda (GE infra & energy) prepared technical clarifications with vendor , conducted meetings, revised specification, changed block diagram, reviewed vendor documents, FAT procedure, Receiving Inspection in our warehouse. Involved in preparing control room layout and made a Ergonomic Study of the control room which include checking NORSOK standards, ergonomic structure analysis of panels (icon console), control room access way, large video screen, parameter to be displayed in screen platform wise, ergonomics point of view, doors, windows specification, discussion and meeting with HHI architectural persons and client.

Daeyang Shipping Seminar

My First Korea Experience – GS E&C

> Worked on Sohar Aromatic Onshore job – Tank farm and utilities

> Preparing RFQ - TBE - Clarification for Guided wave radar transmitter, Float Level Gauges, Breather Valves (PSV), Tank Blanketing Valves etc.

GS Project Workshop

Gave a presentation to a group of GS employees representing the first expat group in GS , Seoul.

Trekking

Award for outstanding contribution

Sabine Pass LNG – onshore terminal project

Power Plant Engineering

IOCL Panipet - Refinery 500 mw thermal power plantResponsibilities include Detail Engineering like Preparation of DCS/PLC/HMS/SER I/O List, DCS/PLC Drive List, DCS Functional Loops, Instrument Index, DCS/PLC Logics, and DCS Graphics.Engineering of Control room layouts, Analyzer Room Layout and cable tray routings.Design of Instrument Rack and routing of impulse lines.Review of P&ID’S (Steam & BOP, Fuel, HRSG, and UB).Preparation and review of Instrument BOQ, Cable Schedule and Interconnection Diagrams.Co-ordination and review of Piping Layouts, Equipment Layouts, Isometrics, GA Drawing Architectural Plan.Preparation of Field Instrument Datasheets through INTOOLS-5.3.The Entire project is designed in line with EIL Specification.Involved in Documentation and quality assurance procedures (ISO Standards)Attended FAT in Tata Honeywell.

Review and Approval of all Engineering drawings and document prepared by TCE and all BHEL Units - Trichy (Boiler), Hyderabad (Turbine), Ranipet (Boiler Auxiliaries), Haridwar (Turbine Auxiliaries), EDN Banglore (DCS-MAX DNA). These include review of FSSS Logics, FD, ID, PA fan control scheme, Instrument schedule and P&ID’S for all units, RO and DM plant schematics, Coal and Ash handling units, Control and SWAS room, Cabling.

President of Ulsan – Indian Organizing Committee (UOC)

Captain of Indian Cricket Team in HHI

My Family – Wife (Journalist) and Son (5 Years old)