Project
Manager, Salem Automation Ltd
As the Project Manager, I had sole responsibility for scheduling,
planning, resources, procurement and progress monitoring (earned value),
cost control and variations of my projects.
Humbly Grove Gas Storage Project for AMEC,
London
Project
duration 18 months, value £1.7M.
As the Main
Instrument Vendor for this turn-key project, I was responsible for the
design, manufacture, testing and commissioning of :
·
ControlLogix
PLC systems consisting of over 700 I/O points, implemented by three
interconnected, dual redundant PLCs. MODBUS serial links interfaced to third
party Compressors, Power Management, Flow computers and Chromatographs.
·
Plant wide ESD
& FGS system consisting of over 230 I/O points, engineered to SIL 2
requirements and BS 5839/NFPA using ControlLogix and Pilz safety PLC’s.
·
High Integrity
Pressure Protection systems, consisting of over 100 I/O points, engineered
to SIL 3 requirements, implemented with two Pilz safety PLCs.
·
Operator
interface provided by an InTouch application consisting of over 14k tags
running on dual redundant servers with seven clients.
·
A RTU to
communicate fiscal metering and gas analysis information to National Grid
Transco via leased line and GSM telephone links.
·
The procurement
of all field instruments and fire and gas detection devices.
In the absence of a User
Requirements Specification, I was resident within AMEC as part of the
detailed design phase in order to compile the Functional Design
Specification. This document was enhanced by the use of sequence charts and
state diagrams (Unified Modeling Language) in order to document and convey
the intricate detail of the plant and the packages operations and
interactions. System implementation and Site Acceptance testing were
conducted primarily against these diagrams.
During this detailed
design phase the system’s size increased by over 25% and its scope extended
to include the control of small packages and the operation of the Dewpoint
Adsorbers (Advantica licensed design) including PID Lead/Lag control of the
gas burners of the regeneration fired heater.
As well as the
management of this project, I also engineered the system’s core PLC and
Ethernet hardware architecture and software structures. This included the
development of Visual Basic software to automate the production of PLC
software, panel manufacture and composite loop drawings direct from the
Instrument Index.
At the client and end
user’s request, I was a lead member of the site commissioning team.
Gas To Liquids Plant, Nigeria
for MW Kellogg, Greenford
Seconded
to MW Kellogg London, initially for 6 weeks. The effectiveness of my
contributions and efforts justified my extension to over 9 months.
Working
within the C&I Department, developing the configuration for a Foxboro
DCS and Triconex PLC Safety Shutdown and Fire & Gas systems (over 13k
points).
I
developed MS Office applications to verify process, instrumentation and
cabling data (exported from Intergraph INtools) and to compare with Vendor
configurations. These systems automated the production of “Change-pack”
documentation with increased accuracy, error detection and with a 60%
saving in engineering effort.
At
Kellogg’s request, I replaced their own Engineer to take ownership of the
plant wide Fire & Gas system through design to FAT. This required
bringing the current design up to date to meet statutory and client design
specifications. Functional design was documented in the form of Cause &
Effect graphs and I produced Logic Diagrams to issue to the control system
vendor (Invensys) for coding by their PLC Engineers.
National Transmission System 85 Bar Uprating Project for BG
Transco
Project duration 20
months, value £600k.
Managed the
identification, documentation, implementation and change control for the
modification to Kirriemuir, Bathgate & Moffat NTS Compressor Station
control systems, plant instrumentation, remote Boundary and Compressor
Control systems to permit operation at an increased design pressure.
Stringent design and
quality control measures were implemented to comply with IEC-61508 and IGE
SR15 and enforced to permit changes on live and operational plant. These
included the preparation of Risk Assessments using both quantitative and
qualitative methods.
Project duration 6
months, value £350k.
Supervised the analysis,
comparison and reporting of the PLC application and hard wired logic
reviewed against the original required design cause and effects.
Upgrade to PLC system
hardware from Version 6 to Version 8, including documentation of test
procedures and supporting certification.
185kW Fan
Inverter Drive Upgrade for Anglesey
Aluminium
Managed the
feasibility study and capital/cost savings evaluation and actual implementation
of an 185kW inverter drive upgrade complete with switchgear and MCC design
along with an 11kV/415v transformer installation.
Pharmaceutical Product Drying for Boots Contract
Manufacturing
Project duration 3
months, value £25k.
Development of an
autonomous replacement control scheme for selectable automated product
drying process requiring PID control of heating and airflow. System was
developed and documented to verify and validate compliance with GAMP4 at
DQ, IQ, OQ and PQ.
IEC 61508 & GAMP4 In-House Expert
Through self- taught
and on the job experience, I became the in-house authority on the
requirements and compliance with IEC-61508 / 61511. In particular on the
requirements for SIL calculations and fault tree and failure mode effect
analysis.
I developed
procedures to ensure and document compliance with the GAMP4 requirements
with an acceptable level of ability being confirmed by a successful
GlaxoSmithKline audit.
