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Resume #72599

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Automation & Control Systems Engineer

Nationality: Saudi
Date of Birth: 11-19-1973

Education:
August 1997, Bachelor Degree of Science in Systems Engineering (Automation & Control) with Honors from King Fahad University of Petroleum and Minerals (K.F.U.P.M.).

Work Experience:

March 2008+
Control Systems Design at Berri Gas Plant Department/Engineering Division/Projects Support Unit (Saudi Aramco).
Major Responsibilities:
* Design Scope Writing
* Multiple Projects Management
* Conducting review meetings, acceptance tests, and commissioning
* Verifying Standards Compliance in Design
* ESD logic / Process control design & Analysis

September 98 – February 2008
DCS Engineer at Berri Gas Plant Department/Engineering Division/Specialist Unit (Saudi Aramco).
Major Responsibilities:
* Honeywell system configurations and implementations
* Triconex system configurations and implementations
* ESD logic design and analysis
* Process Control design, analysis, and tuning
* Systems experience: Honeywell DCS, Triconex, Wonderware MMI, PI, and Mitsubishi Diasys Netamtion

PROJECTS PARTICIPATION:

* BI-3167: Additional Sulfur Handling/Export Facilities
* BI-3150: Ethane Recovery Plant
* BI-3182: Cogeneration Plant
* BI-10-0054: Tricon PLC Systems Upgrade
* BI-10-0188: ESD System Upgrade for Sulfur Recovery Units

Major Accomplishments Samples (more details available upon request):
* ESD Systems Degradation S/D:
The diagnostic shutdown logic for ten Tricon ESD systems have been restored to 3-2-0, which means immediate shutdown only when 2oo3 main processors fail. This include all plant F20 areas, trains 200, 400 and 500 in plat 475, train 600 in plant 474L, and one system controlling K1D, K3s, and Qatif inlet areas in plant 470.The suggested scheme by P&CSD, which should activates a delayed shutdown of 3000Hrs or 150Hrs when part of the system is operating in dual or single modes respectively, has been configured in the DCS for monitoring only and will be used to asses the consequences of implementing such logic on both operations and maintenance.

* F14 – Control Interface Reliability:
One of the Wonderware PCs for plant F14 had experienced crashed hard disk which lead to operation loss of the interface to monitor the field equipments and process variables. This station handles communication with Triconex control system in a dual configuration of two PCs used to monitor and control the plant. The other PC handles the alarming and archiving. For a quick restoration of the full functionality of the interfacing system, the other PC was configured to work as a standalone system and Triconex communication restarted. The incident questioned the reliability of the system and triggered the need to have a full redundant MMI where loss of one PC should not affect the other PC access. The two PCs working together or one working in a standalone pattern should provide full functionality of Triconex communication, alarming and archiving. An image backup of the working PC is created and used to configure another PC that will be installed in parallel. The PC communication was tested and will be installed once a new cable is fabricated by maintenance.

* 475: Common Suction Header Pressure Control:
A new control philosophy was designed and commissioned to maintain the pressure of the common acid gas header and distribute the demand among the suction valves of the trains according to their capacity. One train can be on pressure control to absorb header pressure disturbances from DGA trains, or on flow control. The configuration for suggested control scheme had been checked and response simulated on test bed covering all safety, efficiency, and control initialization requirements.

The control program has been enhanced such that the load is distributed among the trains according to their adjusted capacity; this will minimize the flow disturbances during high load and make all trains reach their adjusted flow capacity at the same time. The master pressure control interface has been modified to give the operator capability to change the desired maximum flow for each train. With this option operator can limit the train capacity without having to take the train out of master controller loop. Supervisor key is required for max flow entering. Also, a target was added to the interface so operator can disconnect all trains from master loop and change their mode to auto in case of major upset from DGA plant.

* 474L- Vent Flaring Control:
The process venting flare control for trains#100, 200, 300, and 600 was implemented as concluded with operations meeting. The logic function is to control the amine contactor overhead pressure at 180 psig, being below the relief valve setting of 220 psig, and maintain the common flare header restrictions. The logic checks the number of valve opened on other trains and restricts the flare valve not to exceed to common header capacity. If any other valve is in manual mode it is not accounted for in the restriction calculation applied to the vent valve.

* 476- F1A/B-F2A/B/C Air Control Cogen Integration:
After successful simulation on test bed, the program to adapt air control scheme for the boilers F1A, F1B, F2A, F2B, and F2C was implemented in redundant application module. The program adapt the air control scheme once boilers ramping start in case of cogeneration trips, and put back the normal control scheme once steady state reached in reliable manner. Adapted scheme switch the ratio controller to auto mode to independently manipulate the air. Then it sets the set point of ratio controller so that the air controller set point and process variable matches; this lets the air damper ramp promptly once fuel starts increasing. After transient unstable conditions ease and the load demand becomes steady, verified by standard deviation calculation, the ratio controller mode is put back to cascade in a smooth manner not to cause step disturbance to air flow.

* Triconex Systems Upgrade Scope:
A thorough scope was issued that outline upgrading requirements for BGP critical process controllers to latest version as a result of system obsoleteness. This upgrade plan, expected to be completed by 2008, addresses Hardware and Software requirements in Triconex scope which will be witnessed and verified by vendor during execution. Also, it outlines the migration procedure for I/O, communication, and main processor modules and control logic program. Maintenance and operation personnel will use the procedure as a guide during project execution. It is mandatory to perform the final stage of upgrade activities on a shutdown plant which include replacing main processors and downloading reedited program. The procedure has been written per system to allow for partial shutdown of the plant; only affected equipments can be shutdown during upgrade activities.

* 476 Steam Master Pressure Control
I adopted an innovative approach in the design of steam control system as part of cogeneration introduction to the plant. The design was intended to integrate HRSG steam production with existing control system to ensure adequate and smooth response from the existing steam system when the HRSG load varies depending on CGTG performance.
The reliability and robustness of the implemented control scheme to take care of such steam pressure disturbance caused by major cogeneration plant upset situations was tested during commissioning by conducting electrical load rejection and proved its robustness during many incidents since plant startup which could had caused total BGP trips. Based on the analysis of the load rejection data conducted, that proved the perfection of the Steam Pressure Control scheme and insured that all safety provisions are provided to make sure the control strategy as safe-proof.

* BI-3182 Project
I participated heavily in review of the control system design package for cogeneration project. The layout of logic and system design approach was discussed PDR, CDR, and other meetings. It worth mention his contribution in design and implementation of F20 scenarios to cutback on cogeneration plant load.
Also, he has attended the Factory Acceptance Test (FAT) for Mitsubishi Turbine Control System (TCS) that had been conducted successfully in Takasago Mitsubishi Heavy Industries (MHI) facilities in Japan. The objective for the test was to demonstrate the TCS's capability to meet the project's requirements as specified in the design plan. The FAT included demonstrations of all functions and features defined in the design plan. Hardware and software verification tested the physical construction and operation of the control system components, operator stations, and control networks communication. Startup and shutdown procedures, as well as malfunction procedures were demonstrated to insure that all specified scenarios are simulated correctly.

I also attended the Factory Acceptance Test (FAT) for Honeywell Control System in Calgary Polyphase facilities in Canada. Hardware and software verification tested the physical construction and operation of the control system components (ESD and HPMs), GUS stations Operator Interface, PHD Database and Reporting, and Mitsubishi Turbine Control System communication.

The Functional performance verification tests I conducted for both CGTGs were an important milestone for the project and confirmed the right trend for the project progress. The pre-commissioning activities demonstrated the readiness the system and discovered any glitches in the design. The engineer showed a tremendous effort during commissioning of the project and was a valuable boost to PMT and Honeywell.

* Console Stations Upgrade
I had detailed the procedure and conducted the migration of the Operators Console of plants 474HP and 476 in the CCR, from the existing US-based classic furniture to the new GUS-based Z furniture without any disruption of the plant operation or loosing view to the process. The GUS stations were purchased as BI-1900 items and migration activities was carried-out with full in-house resources. The in-house staff, laid by the DCS engineer, did a thorough and careful planning to minimize the execution time and avoid impact on operation and daily plant activities.

* F20 Compressors ESD Input Validation
Rotating equipment shutdown because of faulty bad signal from the field transmitter had been a major issue since plant F20 commissioning and deducted a lot of confidence in the reliability of the plant and availability of the equipment. Using of transmitters instead of switches added the diagnostic feature to differentiate the real trip alarms from false bad ones. The engineer initiated and drafted the idea of input validation logic implemented for all shutdown transmitter input signals for F20 compressors, which eventually adopted by P&CSD and added to Aramco Standards. This innovative logic saved the plant many tips and increased the reliability of the control system and availability of equipments.

* F14 Stations Time Synch
To enhance the reliability of archived data and alarmed events in Wonderare Stations which are used as MMI for Triconex control system, the engineer developed a scheme for time synchronization between the two systems. Application script (100 ms interval) was written that executes once at startup, and when time difference between Triconex PLC and Desktop OS is (Hours>0 or Minutes>5). So, the two stations in F14 will by synchronized to Triconex time at application startup and every hour if time is different.

* F18 Process Variable Report
Because of limited flexibility and convenience of the old report, The engineer implemented several enhancements to the Process Variable Excel report, which lists PHD archived values. New features added included: Trending capability for tags and groups, Max/Min values calculation and marking timed occurrences, and list is created for interactive Group and Tag entering to minimize mistyping.

* 476 Superheater Temperature Control
Because Superheaters steam temperature was experiencing large deviations from set point of 700F during load upsets, and to achieve the objective of controlling the temperature of the steam outlet of plant 476 super heaters at 700F despite upsets from steam supply and consumers. I applied number of control modifications: fuel flow controller changed from ideal to interactive & retuned, temperature controller gain option changed to linear & retuned, and temperature controller algorithm changed to KFF; introducing the steam supply flow as feed forward signal. Verifications data used to prove the new scheme included: Minimized disturbances caused by steam supply upsets; Minimum and maximum steam supply flows doesn't translate to temperature upsets anymore, temperature cycles amplitude is reduced to half, and temperature distribution standard deviation is reduced from 2.6 to 1.4

* Plant 471/475 Triconex Upgrade:
This project was the first in a three-phase project to eventually relocate all existing electro-mechanical relay-based logics in plant 475 to the Triconex to enhance their reliability. It involved upgrading the existing plants 475/471 Triconex from hardware/software Release 6.2 to Release 8.2, allowing the use of the Triconex Safety Manager Module (SMM) to interface with the Honeywell's UCN, thus eliminating the need for the SOE functionality of the existing APM.

* PLC5 EEPROM Memory Cartridge Installation in Plant F-13
For each Tower, an EEPROM cartridge was installed in the PLC5 processor and configured to load the program to the processor's memory at every power up. This new feature canceled the need to restore the program to the processor's memory from a laptop after each power outage that lasts more than 20 minutes. Also, a PCMK card, that allows a laptop to communicate to all PLC5 processors simultaneously through a DH+ network, was installed in the DCS group laptop.

* MICAA REQUESTED DATA
A Visual Basic program has been developed. This program calculates the operational hours and the number of starts of selected list of motors since the beginning of year 1998, which is our limit in the PI system archive files. This data will be entered to software that can eventually predict the performance of the motors and gives its recommendation.

* Refrigeration Compressors Control Upgrade
I have participated heavily in the design, acceptance test, and commissioning of this project which upgraded the controls of four parallel refrigeration compressors from Honeywell DCS to Tricon PLC with integrated load-sharing system, designed primarily to provide compressor anti-surge, load-sharing, start-up and shutdown

PRSENTATIONS:

* ALARM MANAGEMENT GUIDELINES & ENHANCEMNTS
This presentation showed, in the first part, the general guidelines that should be adopted during alarms design and analysis. In the second part, Honeywell system MMI resources for alarms displaying and historizing were posted. Finally, the Hi-Spec developed package called AMO (Alarm Management Optimization) that resides in windows operating system was demonstrated discussing its functionality and benefits in saving the effort in alarms analysis and management.

* FIELDBUS TECHNOLOGY OVERVIEW
This presentation was primary intended to give BGP management an idea of this evolving technology and to evaluate if does worth implementation in the coming projects.

* CONGEN STEAM CONTROL INTERFACING:
A presentation has been submitted during BGP hosted technical seminar. The presentation demonstrated an innovative approach in the steam control system design by proceeding through integration of HRSG steam production with existing control system to ensure adequate and smooth response from the existing steam system when the HRSG load varies depending on CGTG performance

March 98 - September 98
Process Control Technician at Berri Gas Plant Department/Maintenance Division/IED Unit (Saudi Aramco).
Major Assignments:
* Installation and calibration of temperature, pressure and flow measuring devices
* Connections of measuring devices to I/O modules in Honeywell system
* PM checks and calibrations of valves
* Troubleshooting of compressors local controllers

Summer-1998
Industrial Engineer at O&IE Department/Industrial Engineering Division (Saudi Aramco).
Major Assignment:
* Manpower study of AIN DAR Producing Maintenance Division. The study objectives were to:
1.Review the existing workload and determine the most efficient manpower for each unit
2.Review and analyze the existing grade code mix
3.Search for areas of improvement and safety measures

Courses:
Course Title Provider
TDC 3000 Saudi Aramco
PCI 102 Saudi Aramco
PCI 104 Saudi Aramco
TRICON Saudi Aramco
TRICONPRO Saudi Aramco
Compressor Control Saudi Aramco
Boiler Control Saudi Aramco
CCC SER4 Saudi Aramco
Distillation Control Saudi Aramco
Networking Essentials CompuBase
Windows NT Core Technologies CompuBase
Windows NT Administration CompuBase

Email News Subscriptions:
* Control Engineering
* Plant Engineering
* Men's Health
* ISA

Other Capabilities & Hobbies:
* Good Programmer in Visual Basis and MATLAB
* Fluent in Conversational Arabic and English.
* Athletic Training

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