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Over thirty years work experience covering all project stages from pre FEED, FEED, EPC, Commissioning and plant operations.
Excellent technical and managerial skills in the field of Instrumentation and Process Control Systems as applied to Upstream and Downstream Oil & Gas, Petrochemical, Chemical, Pharmaceutical, and Food industries.
Highly skilled in specification, implementation, commissioning, FAT and SAT for DCS, ESD, SCADA, Fire & Gas, General Metering Systems and Custody Transfer / Fiscal
EXPERIENCE
May 2011 to present Technical Director, Fortware Limited, Milton Keynes, UK
During this time I have been responsible for various projects as indicated below.
Carried out metering system audits through Letton Hall Group, Houston USA. The audits were prepared for the Iraq Ministry of Oil. The audits were required to show that the systems met the requirements of Iraq Ministry of Oil operational requirements and International Standards for custody transfer systems. The audits covered four locations in Iraq, two onshore turbine based metering systems, two offshore tanker loading systems and one onshore tank gauging system. After the audits were completed an audit report was prepared detailing the findins and giving recommendations for improvement where required.
Working on brown field projects Wood Group PSN in Aberdeen with a main responsibility for a replacement subsea multiphase booster pump. Work involves review of pump vendor package for top side pump control unit plus HPU unit for pump barrier fluid and control fluid and the subsea valve controls and pump monitoring and control. Preparation of installation procedures for the removal of the existing equipment and for installation of the new equipment and hook up to platform control and safety systems.
Working on brown field projects for AMEC in Aberdeen with main projects being replacement of field instruments for ESD systems the purpose being to improve reliability by replacing switch type inputs by analog transmitters.
Feb 08 to Feb 2011 Senior Instrumentation & Control Engineer, WorleyParsons resources & energy, Seoul South Korea and Ruwais United Arab Emirates (Takreer GDP PMC Project)
Initially based in Seoul in EPC Contractors office (GS Engineering & Construction) for 15 months during EPC Detail Design Phase.
Acting in the role of PMC Engineer providing technical advice for the Client and assuring Contractor designs meet both the Takreer Contract requirements as well as Company Project Specifications, Local and International Standards and requirements.
Responsible for design reviews of EPC Contractor detail design documents for field instruments, DCS, ESD, Fire & Gas, Tank Gauging, Machine Condition Monitoring, Process Area CCTV and Public Address systems. (Main vendors were Invensys Foxboro Process Area DCS, Invensys Triconex ESD for Process Area, ABB for Utilities Area DCS, Hernis CCTV, Enraf Tank Gauging, Bently Nevada machine condition monitoring).
Participate in P&ID reviews and HAZOPs
Participate in SIL Study and SIL Verification according to IEC 61508 and IEC 61511 requirements.
Review of Intrinsic Safety requirements including suitability of Zener Barrier and Galvanic Isolator selection, Safety Calculations and Earthing as required by IEC Standard 60079
Paricipate in FATs for Foxboro and ABB DCS systems plus Triconex ESD systems.
Based at site in Ruwais UAE from June 2009 and responsible for continued detail design reviews, support for site activities. Review of Construction Method Statements and Construction Material approvals.
Jun 03 to Dec 07 Lead Engineer I, All Disciplines, FLUOR International Limited, Kuwait ( KOC PMC Project )
Responsible for managing the Control Systems Group by setting priorities for tasks and the allocation of tasks to engineers.
Ensure that Control Systems group work to both Fluor work practices and KOC Project requirements. Ensure that quality checks are provided for all work completed by the Control Systems Group.
Responsible for coordination of Control System Group activities for FEED studies carried out for KOC.
Trouble shooting on root causes of control system and instrumentation malfunction in operating centres.
Attend Hazops and Safety Integrity Level (SIL) studies for various projects.
Seconded to Contractor’s offices to assist contractors in design work related to DCS, ESD, Fire & Gas and Metering systems. Acted as Superintendants Representative during such secondments with signing authority for technical issues.
I was responsible for all the metering systems for two projects, one was for metering all crude oil from North Kuwait Gathering Centres to Tank Storage in Ahmadi the second project was for three onshore metering skids at North Pier for crude oil loading of tankers offshore at calm buoys and an additional system used to measure bunker fuel from KNPC Refinery to offshore tankers. All the systems were supplied by Daniels. The system in North Kuwait was turbine meter based with a bidirectional prover. The three systems at North Pier were based on turbine meters / positive displacement meters (used to line pack) and each of the three metering skids had its own bidirectional prover. A fourth system was installed for KNPC for bunker fuel loading to tankers at the calm buoys. I was responsible for design review / approval of all design documents, coordinating activities between the EPC contractor and Daniels. In the csase of the North Kuwait system I was also responsible for the FAT, installation and commissioning of the system. All the systems utilised Omni flow computers with a PC based supervisory / operator interface system.
Coolection of raw data required for the establishment of Uncertainty calculations.
Responsible for training own engineers and also Kuwaiti trainees with regard to new technology, basic instrumentation and systems related topics.
Attended Factory Acceptance Tests for DCS, ESD, Fire & Gas, SCADA, and Custody Transfer Metering Systems on behalf of KOC.
Projects range in value from $100 Million to $1 Billion
2002 – 2003 Lead Control Systems and Instrument Engineer , ARAMCO Gulf Operations Company, Al – Khafji, Saudi Arabia
Responsible for all instrumentation and telecommunications related to projects for a New Power Plant, a 40kV Subsea cable plus new platform, New Offshore Flow Stations, Investigation into systems for Well head telemetry, and new Offshore control system. Commissioning work on small offshore multiphase meter supplied by AGAR. Responsibilities include review and sign off of contractor documents, front end engineering for offshore control system and well head telemetry, preparation of tender documents and specifications. Work in contractor offices during detail design phase. Involved with Hazop and SIL studies for all projects.
2001 – 2002 Lead / Project Control & Instrumentation Engineer, W. S. Atkins Limited ( Epsom, UK ), based in Al Khafji, Saudi Arabia
Part of a three man PMC team working for ARAMCO Gulf Operations Company at their Al Khafji facility. Role includes bid evaluations for a new 3 x 30MW Gas Turbine Power Plant, a new sub sea 40KV cable including fibre optics plus a new offshore Utility Platform and a new Perimeter Security System comprising CCTV, fibre optic fense sensors, micro wave detection and the all the related control and imaging systems. My specific responsibility is for all technical aspects related to C&I and other Systems related to these projects. The process control systems are all Honeywell TPS and FCS based.
Responsible as Lead Engineer for a refurbishment project for all offshore instrumentation and the replacement of an obsolete SCADA system by a new Honeywell TPS linked to the on shore Honeywell installation. Preparation of specification of onshore fiscal metering system for crude oil measurement utilising turbine meters and prover.
1999 – 2001 Lead Systems Control Systems Engineer, ABB Limited, Stevenage, UK
Project was for a modernisation / revamp of an existing Production Unit and changeover of the DCS System from an old Kent K90 System to a modern ABB System.
Responsibilities covered design of Unit Operations to be used as part of Production Recipes using guidelines set out in ISA SP-88.
Management and design of database for process plant I/O including allocation of I/O to controllers and I/O modules. Responsible for the Preparation of test specifications for unit operations. Carried out Factory Acceptance Tests (FAT) with client.
Provided commissioning assistance to client on site during plant start up, i.e. OQ phase of project plus assist with documentation for FDA Validation
1999 Senior Instrument & Electrical Engineer, Abu Dhabi Oil Company, Abu Dhabi, United Arab Emirates
Instrumentation and systems work related to three projects, Sour Gas Injection Project, A Zero Flare Project and a DCS renewal project.
All projects were for ADOC’s offshore facilities at Mubarraz Island and their Central Facilities Platform. Reviewed and approved the design documents (specifications, drawings and designs) produced by consultant companies.
Prepared Material Requisitions, specifications, bid evaluations and technical / commercial recommendations based on bid evaluations.
Reviewed Vendor documents and approved these.
DCS project involved true geographic distribution of I/O over distances as great as 35km.
The DCS was linked to several Modicon PLC’s performing compressor control as well as Hitachi Systems for Closed Circuit TV and Turbine control. DCS motor control for Sour Gas Project used Modbus based Multilin components in the motor control panel.
Project values totalled $50 million
1998 Lead Control Systems Engineer, China Petroleum Engineering & Construction Company ( CPECC ), Beijing, China & Kuwait
Lead Systems Engineer for the EPC contractor (CPECC) with responsibility for all DCS, ESD and Fire & Gas Systems for two Super Gathering Centres (GC27 and GC28) for Kuwait Oil Company (KOC).
Coordinated the work of two teams of Chinese Design engineers and for providing on the job training for these engineers.
The DCS systems were Fisher Rosemount RS3 based. The ESD and F&G systems were Triconex systems.
The design work comprised preparation of specifications, review of P&ID changes, Cause & Effect diagrams, Logic Diagrams, Vendor drawings and obtaining Client approval for both CPECC and Vendor drawings related to all the systems.
Directly responsible for all the design work related to Intrinsically Safe circuits including specification of IS Barriers and approval of all field instrumentation with regard to IS certification.
1997 Lead Control Systems / Project Engineer, KNPC Shuaiba Refinery & Multi Project Department, Kuwait
Project Engineer for a $22million Shuaiba Refinery revamp project working with Fluor Daniel. The project replaced all discrete panel mounted instrumentation in Shuaiba Refinery with a new Central Control Room, New Operations Building and new control systems for DCS, ESD, PLCs plus associated equipment such as UPS systems, Tank Gauging System, Compressor Control System, Fire Protection systems and multiple HVAC units. The design was based on a new central control room networked to nine satellite houses. The DCS was a Honeywell TDC3000 using GUS consoles and HPM units. Responsible for coordinating the distribution of documents, drawings, specifications etc submitted by the EPC Contractor for review within KNPC and then compiling all KNPC comments into a coherent reply and issue this back to the EPC Contractor. Ensured that the contractor executed the project according to the terms of the contract and the agreed Project Schedule.
Responsible for Steam System Revamp Project for Mina Abdulla Refinery.
Project covered provision of two new Boilers and associated equipment.
Coordinated a team of multi discipline engineers (mechanical, civil, electrical and instrumentation) and adding instrumentation expertise for the extension to an existing Honeywell DCS, new ESD system and new Burner Management System. Responsible for ensuring EPC Contractor performed according to agreed contract, cost and schedule. Project value was $21.3 million.
1996 Senior Control Systems Engineer, Pfizer Pharmaceutical Corporation, Ringaskiddy, Ireland
Provided an in house training course related to Kent 90 Process Computers and the principles of controlling application software development and change.
Provided software for software revision control and language specific editing templates. The training provided prepared Pfizer personnel for internal and external system audits of the K90 Systems by bodies such as their own QA department and the Food and Drug Administration of the USA etc.
1996 Senior Instrument Engineer ,Technip Geoproduction, Abu Dhabi, United Arab Emirates
Responsible for Front End Engineering Design for a new fiscal metering system and replacement DCS system for crude oil flow measurement, inventory control and routing. The metering system was designed based on turbine meters with a bidirectional prover. The project was for an offshore facility for Qatar General Petroleum Corp. Responsibilities included preparation of procurement specifications, design drawings, material estimates, bid evaluations etc and presentation of recommendations to the client. Project estimate was approximately $15 million.
1994 – 1995 Control Systems Project Engineer, Kuwait National Petroleum Company, Kuwait, Mina Al Ahmadi Refinery
Responsible for large system based projects for Pipeline Telemetry, Fiscal Metering. The Fiscal Metering was a continuation of the projects started with Foster Wheeler as described below. In the case of the North Pier Metering system I was responsible for installation and initial commissioning. In the case of the Waugh Controls system I was responsible for review / approval of all design work submitted by Waugh Controls and KNPC design related to the installation of the new system. Total value of projects handled was approximately $10 million.
Experience with ABB PLC’s for telemetry and metering valve alignment, Waugh flow computers and SCADA for fiscal metering including validation of design, Honeywell TDC 3000 for telemetry and valve control at loading berths. Both telemetry applications were split between onshore and offshore facilities. Harbour Master equipment comprised radar, radio and meteorological equipment.
1993- 1994 Senior Instrument Engineer, Foster Wheeler Management Operations Ltd., Kuwait, Mina Al Ahmadi Refinery
SCADA / Instrument specialist, based in Kuwait, for the Refineries Restoration Project for Kuwait National Petroleum Company.
Responsible for specification, tender preparation and bid evaluation for Crude Oil Metering system which was used for tanker loading for North Pier. This was a Smiths metering system based on turbine meters and unidirectional prover. KNPC also had a large project for a replacement of metering system flow computers etc by a more centralised system located in Mina Ahmadi Control Room. I was responsible for preparation of the specification for this system which had approximately 80 flow meters under its supervision / control. The meters were both turbine and Positive Displacement meters with several unidirectional proving systems. Only the exisiting flow computers were to be replaced all exisiting flow meters and provers were maintained. The Supervisory system was awarded to Waugh Controls in USA which was to become part of Smith Meters. Project management of engineering contractors. Specific projects covered replacement crude metering skids, flow computer systems to API specifications, pipeline surge relief systems and tank gauging systems.
Responsible for coordinating the work of the main engineering contractors design office staff. This was a multi discipline design office made up of Civil, Mechanical, Piping, Electrical and Instrument design engineers and draughtsmen. The EPC was China Petroleum Construction Company (CPECC). Deputised for Project Engineer when he was absent.
1990 – 1993 Senior Control Systems Consultant & Technical Director, Octal Engineering Limited, Dunstable, Bedfordshire, England
Provide application software, installation, commissioning and start up assistance for batch control pharmaceutical manufacturing process for Pfizer France. Also provided procedures for software revision control and validation. (Kent K90 Process Computer System).
Development of acceptance test procedures on behalf of Real Time Engineering Limited and responsibility for all in house testing of Real Time’s Supervisory system testing of three fiscal metering systems for Enron / ICI / British Gas in Daniel premises, Vendor FAT between Daniel and Real Time and then support to Daniel during their client FAT. Systems were based around Daniel Metering equipment. The systems comprised both turbine meters for oil movement and ultrasonic flow meters for gas transfer. The oil movement skids had bidirectional provers
Responsible for setting up software change control systems for application software for pharmaceutical, chemical and petrochemical industries. These systems / procedures were used by the respective companies to meet the requirements of FDA validation and BS5750 / ISO 9000. The companies concerned were Pfizer France, Pfizer Ireland, Rhone Poulenc and Shell.
Reverse engineering flow charts and application software module descriptions from old and undocumented source code. (Ferranti Process Control system)
(Experience with Kent K90 Process Control Computers, Daniel flow computers and SCADA systems, PC based systems for application software development, Ferranti)
1989 Senior Control Systems Engineer, Burroughs Wellcome, Greenville NC, USA
Design and provision of all application software for two major pharmaceutical production facilities that included a Solvent Recovery Unit and a Hydrogenation Unit.
Installation, commissioning and startup assistance for both units covering both the application software and field instrumentation.
Member of the team involved with application software verification and validation for both units in line with FDA requirements. Prepared test documentation for use as part of validation process.
(Experience with Fisher Provox systems and PC based configuration systems)
1987 – 1989 Lead Control Systems Engineer (Client engineer for BP during project.) , British Petroleum, Foster Wheeler Design Office, Reading
Project Management for Large Fisher DCS (Value of DCS was $5 million) for onshore Gathering Centre and Gas/Oil Separation facility for BP Wytch Farm Project. This was the largest Gas/Oil separation facility in Europe. Responsible for all systems work related to fiscal metering, tank gauging, rail tanker loading, ESD, pipeline integrity monitoring, well head and pipeline telemetry systems and their connection to the Fisher DCS. The custody transfer metering system between Wytch Farm and Refinery at Hamble. System comprised turbine meters and Daniel Flow computers. There was a bidirectional prover as part of the system. The supervisory system was implemented by Real Time Engineering Limited. I was involved in review of design documents and also the design of the link between the metering system and the Fisher Controls DCS. I was also responsible for the rail tanker loading system for LPG and the link from this system to the DCS. I was part of the team for Factory Acceptance tests for the Metering, Tanker Loading and Tank Gauging systems and pipeline integrity .
Reviewed and approved all vendor specifications and project documentation. Generation of all specifications for the protocols used for the interconnection of the various systems to the Fisher DCS.
BP team leader for inspection and factory acceptance (FAT) of all these systems.
(Experience with SpectraTek flow computers, Daniel flow computers and SCADA system, GEM80 PLC’s for ESD, Transmitton telemetry systems).
1985 – 1987 End User Sales Manager & General Manager Dublin Office, SK Computer Systems Ltd., Letchworth, Herts & Dublin Ireland
Initially responsible for End User sales in scientific and technical fields including Ministry of Defence applications in the UK. Promoted to General Manager with the responsibility of opening a new branch office in Dublin, Ireland.
Main markets were technical such as CAD systems and stock control / warehousing systems.(Experience with DEC systems and software plus IBM PC’s and compatibles)
1981 – 1985 Instrumentation, Control & Automation Manager, Van Den Bergh & Jurgens, Johannesburg, South Africa
Manager responsible for all instrumentation maintenance and project work for large manufacturing site with two main operating companies, Lever Brothers for detergents and Van Den Bergh & Jurgens for edible oil and margarine products.
Responsible for design, specification, FAT, installation / commissioning of five major computer based production control systems, PLC controlled automated packing lines and conveying / palletising systems.
Work encompassed both the systems and field instrumentation. Setting and control of department budget for instrument maintenance on the whole site.
Sizing of orifice plates and annubars for staem distribution system from plant boiler to plant users. In some cases use was made of dual dP transmitters to increase range over which accurate measurement could be established.
(Experience with Kent K90’s, GEC Media, Texas, Siemens and Modicon PLC’s).
1979 – 1980 Digital Systems Project Manager, Westgate Engineering Limited, Clonmel, Ireland
Project manager for all digital system based projects. Typical PLC applications included brewing / distilling and industrial diamond manufacture.
Control system applications included Fox 3 for pharmaceutical batch control plus various SPEC 200 installations. Westgate were Foxboro agents for Southern Ireland.
Orifice plate sizing for customers and advice regarding installation and calibration of transmitters.
(Experience with Fox 3, Video spec, Spec 200, ITT Director PLC and Modicon)
1973 – 1979 Control Systems Engineer, Clayton Aniline Company, Manchester, England
Responsible for the specification, design, acceptance testing, installation and commissioning of the companies first computer automated production units.
Project manager for telemetry system for site effluent monitoring / treatment and a system for batch control system for AZO dye production.
Area Engineer responsible for all mechanical, electrical, instrument and maintenance. Responsible for FAT of both the telemetry and the batch control systems.
(Experience with Kent K70 Telemetry and Kent K90 Batch Control systems plus Texas PLC’s)
1971 – 1973 Research Engineer, Mather & Platt Limited, Manchester, England
Graduate training followed by first appointment in Research department dealing with new pump technologies. This work included design of orifice plates to BS 5750. At this time this had to be done the hard way using log tables etc.
Designed and implemented several computer programs to aid analysis of experimental data and pump modelling.
Education
B. Eng. 1st, Liverpool University, England 1971
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