Ajay K.

At CHEMANOL (Methanol Chemicals Company), Jubail, KSA [April 2022 - Aug 2023]

As Sr. Lead - Process Control & Instrumentation, ICSS And Digitalization (Engineering & Reliability Department); Responsible for Process Control/ Engineering/ Reliability/ Asset management / Process Digitalization of Methanol Division (MD) & Formaldehyde Division (FD). The MD plants consist of a 700 TPD Methanol (process licensor: HALDOR TAPSOE), 100 TPD CO plan (process licensor: Air Liquid) along with Utilities, Mono/ Di/ Tri Methyl Amine (MMA/ DMA/ TMA) and Dimethyl Formamide (DMF) units (process licensor: Davy Process Technology). The FD plants consists of Aqueous Formaldehyde (AF), Urea Formaldehyde Concentrate (UFC), Hexamethylene Tetramine (HMT), Paraformaldehyde (PF), Urea Formaldehyde Powder Resin (UFPR), Melamine Formaldehyde Powder Resin (MFPR)         Melamine Urea Formaldehyde Resin (MUFR), Pentaerythritol (PENTA) and Sulphonated Naphthalene Formaldehyde (SNF)

          units. The major control systems are of OEM- M/s. Honeywell Experion Process Knowledge System (EPKS with C200 &     

          C300 PCNT01 controllers, versions R301.1) and Yokogawa CENTUM CS 3000 / CS1000 as DCS, Honeywell Safety Manager

          (SM) as ESD, M/s Bentley Nevada 3500 systems as Machinery Protection System(MPS), SIEMENS & NOTIFIER as FDS,   

          DETRONCS as GDS, along with other packaged units with Allen Bradley, GE and SIEMENS systems ( PLC : Rockwell 1756

         –L71 , ControlLogix 5571/5572, GuardLogix 5580Control, Factory Talk view (SCADA), RS View 32 (SCADA), GE Cimplicity  

          V.7.0 & V.11.0, SIEMENS S7 400/300 based systems). Additionally, responsible for below projects:

Ø FEED of “Revamp (Brownfield)” project of additional Methanol production by 500 TPD capacity (Licensor: HALDOR TAPSOE) with provision of new ATR and new SMR as pre – reformer to ATR. FEED completed, now under award of EPC.

Ø Working on feasibility/Estimation/ ROI/implementation strategies of Process Digitalization of the complex to Chemical 4.0.

Ø HMI upgradation for Steam Turbine Generator [{OEM FINCANTIERI, Italy; Model: 56BE (R1)}, {SG & NG Compressor ( OEM GE/ Nuovo Pignone, Italy; Centrifugal Compressor BCL 458 & 2BCL 458/N with Steam Turbine SAC 1 -6)}]. Existing

“Lookout” based SCADA replaced with “Runtime” based SCADA and Historian. SW migration: GE Cimplicity V.7.0 to V.11.0.

Ø Rationalization of Process Alarms of both the MD & FD complex and establishing Alarm Management System (AMS).

Ø Upgradation of CCC make “Anti surge and Performance Controllers” of series 3+ to series 3++ for SG & NG Compressors.

Ø Migration of Honeywell EPKS from supported base release R301.1 to R301.2 – R301.3 - R311.3 - R501.6 – R520.2 (HIVE); Also, the C300 PCNT01 controllers upgraded from R301.1 to R502.2; Control Firewall CF9 also upgraded from “VV” to

“UU”; Server OS changed to Windows Server 2019 from Windows Server 2003. Honeywell Safety Manager (SM) software upgrade from R133.5-R146.2-R154.4-R162.6 along with CPU card QPP-0001 to QPP-0002 And USI card 0001 to 0002.

At SIPCHEM (Sahara International Petrochemicals Company), Jubail, KSA [Aug2020 - Mar2022]

          As Sr. Principal Engineer / Lead / Head / SME (Instrumentation & Control); Responsible for Major Projects,           

          Reliability / Asset management of EDC / PP / PDH / LDPE plants. Along with this, also responsible for ITB preparation,

          FEED / Detailed Design, Engineering Review and Approval, SOW preparation for EPC aspects of projects, Erection, Testing     

          & Commissioning, Start-Up of below projects:

Ø Hydrogen Transfer from SIPCHEM to SASREF Refinery. This project also has Metering Skid (USFM based) from M/s. KROHNE and PSA SKID from M/s. LINDE. DCS of Emerson Delta V DCS, SIS of  Schneider’s Triconex and HIMA’s HIMAX

Ø Ethylene transfer from TASNEE to SIPCHEM(IPC) as well as Synergy of Ethylene transfer between ALWAHA (PP/PDH) and SAMAPCO (EDC) plants of SIPCHEM. The major control systems are Yokogawa CENTUM VP R5.04 with ESD pro-safe; DCS

of OEMs Emerson Delata V 11.3, Honeywell EPKS R511 with C300 controllers and SIS of OEM Shchneider’s Triconex.

Ø Revalidation of B.A. Tank to be used for E.A. @ SABTANK, Jubail Port, that utilizes DCS of Yokogawa and ESD by Silvertech.

Ø Implementation of Marine Vapor Combustion System (MVCS) consisting of Dock Socket Unit (DSU) @ Jubail port, KSA for products: Acetic Acid (AA), Acetic Anhydrite (AAn)and Vinyl Acetate Monomer (VAM) of Product Export Pipelines, Port facilities and Ship loading division of SIPCHEM. Interconnection to existing Marine Vapor Combustion System (MVCS)

Ø PP/PDH plant; utilizing UOP’s Oleflex technology for PDH and LyondellBasell’s Spherizone technology for PP; have Yokogawa CENTUM VP as DCS and Prosafe-RS as ESD.

Ø Implementation of “Advanced Process Control -APC” based on Aspen DMC3 & “Real Time Optimization-RTO” based on AspenOne Engineering suite for PP / PDH plants.

At Saudi ARAMCO– Oil & Gas, KSA [May 2019 - July2020]

As Lead Project Engineer (I&C / Electrical /Telecom) in PMC role with Saudi ARAMCO: Responsible for ensuring Detailed Engineering review, Erection, Testing & Commissioning for Instrumentation & Control, Electrical and Telecom scope of work for Saudi ARAMCO’s “Marjan Increment Projects Department” (MIPD) – a “Green Field”, an Onshore/Offshore Upstream Oil & Gas facilities as a part of “Marjan Development Program” for Tanajib Oil Plant (TOP) / Tanajib Gas Plant (TGP), Tanajib, Saudi Arabia. The Main Automation Contractor (MAC) is YOKOGAWA’s CENTUM VP and other Automation Systems are of M/S Honeywell – Experion (EPKS) / ESD Safety Manager (QPP as SIL3)  / EPKS SCADA system / Control Edge RTU etc, Telecom of NOKIA PSS II node, OTN150, DWDM, SDH, PDH, TETRA tower for wireless communication, I.T. infrastructures, Fibre Optic Backbone System, and Cybersecurity.

The Marjan Increment Program is an integrated development project for Oil, Associated Gas, Non- Associated gas, and cap Gas from Marjan Offshore field. The purpose of MIPD is to provide Marjan onshore/ offshore facilities to produce and process an overall 300MBCD (300 thousand barrels of oil per calendar day) and 1,800 MMSCFD of blended gas.

At CAIRN (VEDANTA)– Oil & Gas, India [May2018 – April 2019]

As Project Lead (Instrumentation & Control and Electrical) with HALLIBURTON –Responsible for all EPCC aspects of a brownfield Onshore Upstream-Oil & Gas (Exploration & Production) project “Integrated Development Services for MBA field in RJ-ON-90/1 Block”. The major control system is YOKOGAWA’s CENTUM VP DCS / ESD (ProSafe-RS).

At QEWC (Qatar Electricity & Water Corpo., UHP IWPP project (Facility D), Qatar) [May2017-May2018]

As Lead – Instrumentation & Control with SAMSUNG; Ensured successful Erection, Testing & Commissioning (E/I&C scope) of Umm Al Houl IWPP project (Facility D) , Qatar (IWSPP of 2520 MW and 136.5 MIGD RO/MSF-DESAL) for QEWC,

Qatar.[Power : 2520 MW { 6 GTG( Siemens SGT5-4000F i.e; V94.3A), 6 HRSG( Nooter Eriksen make; horizontal with S/F),

4 STG ( Siemens SST5-4000 ) , 10 Air cooled Generators( Siemens SGen5-1200A)}, 60 MIGD RO ( by ACCIONA) and 76.5 MSF DESAL ( By Hitachi Zosen)].The major control systems are SPPA-T3000 for GTG/STG and YOKOGAWA’s CENTUM VP DCS / ESD   (ProSafe-RS) for BOP/HRSGs/RO/MSF Desalination plants, Firefighting systems of Siemens make Cerberus (FC722) with SINORIX supress Sys, Gas Detection sys by MSA and AAQMS of Teledyne, CEMS of SICK/Teledyne/Siemens.

At DEWA (Dubai Electricity & Water Authority, Jebel Ali Power Station Complex) [May 2014 – April 2017]:

          As Dy. Manager / HOD / Lead – Instrumentation & Control (O&M and Projects) : A total capacity of around 10   

          GW of Power Generation/Distribution and 470 MIGD of Desalinated/RO water Production /Distribution.            

          The major Control systems are Siemen’s SPPA - T3000, Teleperm ME, TXP /SPPA-T 2000, SIMADYN D, Fail safe systems

          of Siemens, INFI 90 DCS of M/S ABB (Bailey), ABB’s Symphony Plus (S+) Operations HMI system, Siemens OS-265 HMI  

          system, PLCs of Allen Bradley (CONTROL LOGIX 5563, 5/40) /Siemens (SIMATIC S5 & S7 series)/GE (PAC systems Rx

          3i/7i, SCADA/ HMI with Historian), Control System of M/S GE’s Speedtronik Mark V/ VI /VIe, ABB’s PGIM (Alarm   

          Management) system, OSI soft’s PI system and Fire Fighting Systems of SIMPLEX /MINIMAX /TYCO/NOTIFIER/Kidde etc.    

          Worked in one of the Power Station (Power Generation of ~ 900 MW from 5 Gas/Oil firedSiemens V94.2 Gas Turbines with  

          ANSALDO make HRSGs &2 ANSALDO Back Pressure Steam Turbines (BPST),4X360 TPH, Aux. Boilers, 9X7.5 MIGD MSF     

          Desalination units & 25 MIGD RO plant) of the Generation Division at Jebel Ali Power Station Complex (DEWA).

Ø Successfully implemented SAP PM module as per DEWA’s SAP Wave 3 project

Ø Upgrade of Simplex/ Miniplex4100 Fire Detection systems (FDS) to Simplex 4100ES | GMI Gas Leak Monitors 4801 to 4802

Ø Leveraged skills in replacement of Minimax firefighting system – (FFS) - (FMZ4100) with Minimax (FMZ5000)

Ø Replacement of obsolete Siemens Teleperm ME systems that comprises of Automation system (AS220EA), Protection system (AS220EHF), Alarm system (AS231), GT Governor control (Simadyn-D), HMI system (OS-265) used for 3 Gas Turbines, 3 ANSALDO make HRSGs, 2 ANSALDO make Auxiliary Boilers, 2 Common systems (FW-ACCW) with SPPA-T3000

systems that include Engineering, Installation, Erection, Testing & Comm. in phases as per approved RLA/LTE roadmap

Ø Upgradation of GE Cimplicity SCADA HMIS in PJRO from SCADA server version 7.0 to 9.2 & Hist. Server V 3.1 to 5.1

Ø Upgradation of OTC+ and of Exhaust thermocouples of V94.2 Gas Turbines as per Siemens TIL for control optimization

At M/s Torrent Power Limited : As HOD – Instrument. & Control (O&M and Projects);[May 2012 – April 2014]

Ø It has 4 operational units @ 382.5 MW each of Siemens make Machine (A single shaft machine for both GT – model V94.3A and ST – model SGT5 - 4000F) with HRSG (3 Drums) by M/S DOOSHAN. The major control systems are Siemens TXP (SPPA-T2000 with SIMADYN D GT controller, Siemens 95F fail safe system), Siemens SPPA-T3000 and Fire Fighting Systems of SIMPLEX/ MINIMAX/ NOTIFIER , Flight Recorder, FODS-KUES, ARGUS systems | Transformer DGA Analyzer – GE’s HYDRAN

Ø Steered Installation, Erection & Commissioning, Warranty and O&M of 382.5 MW IPP having Siemens V94-3A Gas Turbine, Doosan make – 3 drum HRSGs with DCS Siemens SPPA-T3000 system, WIN_TS, TDY (web) server

Ø Operation & Maintenance of 1147.5MW (3 @ 382.5 MW) IPP having major control system of Siemens TXP-T200 with SIMADYN D GT Controller & Siemens 95F fail safe system, 400KV GIS, Static Frequency converters, Excitation systems

Ø Shutdown Planning and Execution of Outages with Siemens LTSA | WIN CC SCADA | PD Monitor of QUALITROL DMS

Ø Vibration Monitoring System VM600 | ABT Metering of L&T iVISON | CEMS_Siemens ULTRAMAT 23 | Islanding Schemes

Ø Fire Detection and Suppression Systems (FDSS) of MINIMAX, SIMPLEX, NOTIFIER , TYCO etc

Ø Elster’s Flow Computer and Turbine Flow Meter with Daniel 500 Series Gas Chromatograph for Custody Transfer Metering

At Saudi Aramco’s Refinery/Gas Plants: Lead– I & C (Brown Field Projects And O&M);[April 2006–April 2012];

           As Lead–Instrumentation & Control for Saudi ARAMCO’s Gas Plants (UGP / SGP / JGP) and Ras Tanura Refinery  

          (RTR). The major   control systems are OEM Honeywell, Yokogawa, Emerson, Schneider Electric, GE, SIEMENS, A/B etc.  

          Also achieved the successful commissioning of 3^rd  Party COGEN plants of ARAMCO facilities @ UGP/SGP/RTR/JGP.

Ø Revamping of GE’s Speedtronik Mark VI WINDOWS 2000 based HMI/SCADA-cimplicity version 5.5 to windows 7 based Proficy HMI/SCADA cimplicity version 8.2 & GE’s toolboxST/ WorkSatation ST (4.3) – in MEA (2011)

Ø Revamping of metso DCS – max DNA( to DPU 4F & maxStation ver 4.3 SP1 to 4.5 SP2) | Management of DCS account

Ø Planning/ scheduling/ execution of all C & I jobs for Minor / Major Inspection of GE’s Frame 7FA/ EA machines

Ø Upgradation of Fiscal Metering system comprising of Daniel’s USFM mark II to mark III and Elester+Instromet’s USFM Qsonic4C series-3 to series-4 | Asset management using System1

Ø GE’s Speedtronik Mark 6E/6 Control system for Frame 7EA/FA machines with DLN combustors

Ø Successfully upgraded OSI soft PI server from version 3.1.2.2 to 3.1.2.8 Win7 based. PI client PI SDK version 1.3.6 and PI ProcessBook 2015 R2 (version 3.6.0.82) & data link version 4.1.1

Ø Exciter Control EX2100 and LCI Control LS 2100 of M/S GE | Tariff metering (Energy) of Landys + Gyrr max SYS 2510

Ø Fiscal metering system with USFM of Daniel’s Mark III and Elster’s Q sonic-series 4 along with OMNI 6000 flow computer and Daniel’s Gas Chromatograph (500 series) for natural Gas

Ø OSI soft PI server-based SCADA system – administrator level experience for central data monitoring. PI server version 3.1.2.2, PI client PI SDK version 1.3.6. PI user interfaces as process book and data link version 4.1.1

At Reliance Industries Limited, Dahej (Gujarat) – Former Indian Petrochemicals Corporation Limited (a PSU of Gov. of India) in the capacity of Manager / HOD (Instrumentation & Control); [Dec 1995 – March 2006]

Worked as HOD (Manager) / Engineer-in-charge during Detailed Engineering, Erection, Testing & Commissioning, Project Inspection, Start-up, O & M, Engineering Services for 10 Y 4M in various process plants like VCM/PVC, EO/EG, HDPE /PP/ Gas Cracker, Captive Jetty, Captive Combined Cycle Co-Generation Plant – CCPP ( GE make Gas Turbine and BHEL make HRSG), Offsite & Utilities {Air Separation cryogenic N2O2 plant, handling of various fuels

(Naphtha/DFO/HFO/LPG/LSHS etc.) in tanks & spheres, DM water, Effluent treatment, Compresses Air Systems, Finished Product Transfer Metering, Fire Fighting system, ESD TUV6 ak 5 compliant} having following systems:

Ø Terminal Automation system: (UNIX based supervisory computer) of M/s Advance Spectra Tech for Loading

Ø DCS TDC-3000 / GUS TPS of M/s Honeywell / FSC 620-35 of Honeywell | DCS rs 3 / Provox / Delta V of M/s EMERSON

Ø Speedtronik Mark V / VIe (TMR) of M/s GE & CSI 7500(TMR) of M/s IHI: GTG Control System for GE Frame 6B & GE LM 6000(Aero-derivative) Machines |PLC (HRS-H51) of M/s HIMA: Burner Management System (ESD), TUV 6 approved

PLC (5/40), SLC (5/03), RS Logix of M/s Allen Bradley | NETCON 5000 (F / T) of M/s Woodward: STG Control System