2. Companies Worked for
ADMA – 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
3. ADMA – Zakum Central Super
Complex –
De-Mothballing Project (ZCSC)
Central Accommodation Platform
(CAP / NAP)
4. Role: Area Lead Engineer for F&G System / MDS upgrade
Introduction –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
6. 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 software
Since 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
7. c) FAT - Phase-2 (Stage-1 CAP / NAP PLC & IOS - November-2011
CAP / 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.
8. 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
10. Design issues and Lessons Learnt
Engineering issues
a) Cause and Effect, F&G layouts (construction and demolition) were fully modified based on
existing condition and F&G performance target study
b) 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 Issues
a) FACP – panel location – corridor location, recessed into wall
b) 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 Issues
a) Phase-1 – SAT support
b) Phase-2 Rx7i compatibility issues with Genius Bus Controllers (on-going issues)
c) Phase-2 NAP – Site technical query through video conferencing
d) F&G interface with EDG package, Electrical panels, HVAC panel etc were fully supported
11. > Detector and device
a) HC IR point detector – calibration issues – site coordination – PVC tube extension ,
male adaptor etc
b) 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 approval
d) NAP detectors were inspected at NPCC yard for installation.
Other Activity in project
> DCS / ESD
Attended Yokogawa FAT in Dubai
Ergonomic Study and control room layout
> P1 , P2 , P3 – Packages
MOL pump
Corrosion Inhibitor Package
Emergency Diesel Generator Package
Fire Water Pump Package
> Engineering Co-ordination
F&G Field engineering and Procurement of F&G
detectors & Devices
12. 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.
13. 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.
15. 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.
16. GS Project Workshop
Gave a presentation to a group
of GS employees representing
the first expat group in GS ,
Seoul.
Trekking
18. Power Plant Engineering
IOCL Panipet - Refinery 500 mw thermal power plant
Responsibilities 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.
19. President of Ulsan –
Indian Organizing
Committee (UOC)
Captain of
Indian
Cricket Team
in HHI
20. My Family – Wife (Journalist) and Son (5 Years old)
