Profile Instrument Technician (Pre-Commissioning)


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NameProfile Instrument Technician (Pre-Commissioning)
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Muhammad Shahzad Zafar Instrumentation & Control Professional

E-mail: shahzadzafararl@gmail.com,

Cell: +966 59 714 5021
Professional Profile

Experienced Instrument & Control Professional with hands-on experience performing troubleshooting, repair, maintenance, calibration, installation, testing, commissioning, inventory management, design, systems engineering and quality control.

Total Experience: 20.6 Years

Experience Profile

Instrument Technician (Pre-Commissioning)

Air Products (Jazan Gas)

Jazan Economic City, Saudi Arabia

May 2018 to Present
World scale largest industrial gas plant to carryout pre-commissioning activities and troubleshooting of field instrumentation.

  • Use the PCA (Plant Completion Application) online software for job assignment, progress monitoring and task completion for Train-1 to Train-6 and Utilities.

  • Simulation of field instruments to Siemens SIMATIC S7 Control System and monitoring at HMI.

  • SIS Validation test for all trains and utilities.

  • Simulate vibration probe through TK-3 and adjustment of probes for compressors and verify the configuration of Bently Nevada System.

  • Performed loop test and troubleshooting of field instrumentation.

  • Job risk assessment, SIMOPS and prepare work request for all activities.

  • Meeting with site commissioning, Engineering and Operation team.

Instrument Technician CSU (Commissioning & start-up)

Sadara Chemical Company

Al-Jubail, Saudi Arabia

Oct 2015 to March 2018
To carryout pre-commissioning verification and commissioning activities. Onshore facility therefore ensuring a safe and timely start-up of the new facilities in line with company standard and specifications.

Support the project teams in implementing flawless project delivery. Monitor the construction activities and provide assistance to the team to resolve problems. Witness pre-commissioning tests carried out by vendors and contractors to ensure compliance with standard at UPI (TTU Unit), CHEM-III (EO, Amine, BGE & ESS Units).

  • Verified that instrument installation conformed to engineering drawings.

  • Performed quality control for field instrumentation along with PCS and SIS Panels.

  • Verified (HART, Fieldbus) loop testing from field to PCS (ABB 800X) and SIS (ABB).

  • SIS Validation test according to PCSD.

  • Ensure to commission instrumentation effective following with repair and replacement.

  • Comply with every approved operation and maintenance procedures.

  • Responsible for promoting safe and clean working environment.

  • Planned work and determined appropriate tools and equipment.

  • Performing operation support to troubleshooting of instruments for smooth operation.

Supervisor E&I

BHP Billiton

Zamzama Gas Plant, Dadu, Sindh, Pakistan

July 2012 to Sep 2015
Supervision of Electrical Switchgear, Instrumentation & Control System, telecommunication equipment installation, Loop testing, calibration, troubleshooting, maintenance, commissioning & start-up of wellhead and tie-in with existing gas processing facilities.
Ensure job compliance according to IFC drawings GA, Layout, PFD, P&ID, ILD, Hook-ups, MTO, Schedule, Cause & Effects, FLD, System Architecture, Red marked & as-built drawings.

Lead vendor technicians and subcontractor to ensure project compliance and interface between management.

Ensure job compliance and integrity standards in order to meet schedules.

Close coordination with production operations, maintenance and engineering teams in activity planning and engineering change.

Ensure safety management systems and a basic understanding of local safety management legislation.

Ensure that procedures for the safe execution of jobs are in place and adhered to including Method Statements, Work Instructions, SIMOPS, Job Risk Assessments, Permits-to Work, Toolbox Talks.

Inspection, installation, testing and commissioning of Flow lines, Solar Power System (Redundant PV Module, controller’s ,Battery Bank), DCS, ESD, cable laying, glanding, termination, loop testing, instrument gas tubing and impulse line installation and testing , Calibration of all field instruments and control valves, PSV’s, Switchboard, earthing, UPS verification of equipment and cables numbering and tagging.

Prepare & review QA/QC documentation submits to operation team before sanction to test.

Followings are the projects detail which my role as supervisor;

Completed Projects:


  • Infill Well Campaign 2012 & 2013 (Zam-8 & Zam-9) along with inlet manifold tie-in (Including field instrumentation and electrical equipment’s, wellhead control panel, DeltaV PCS, INTech & Hi-Phrasere ESD Panel and hookup with existing HIMA PSS).

  • Solar power system at Wellheads for lighting, field instrumentation, RTU’s, Interface Control Panels and PDHG (Permanent Down Hole Gages).

  • Automatic weather station at zamzama air strip

  • Effluent treatment unit

  • Permanent down hole gauges at two wellheads (Halliburton PDHG installation, configuration).

  • Cathodic protection for flow lines and storage tanks

  • Annulus pressure transmitter installation at diff. wellheads

  • Hubbell Heaters installation for hot water

  • Solar Gas Turbine Tuarus-60 Upgrade project (Upgrade Control Console, VFD, Fuel Module, Bleed Valve, Guide Vane, Fire Detectors, Gas Detectors, Thermal Detectors, Fire Control Console, Mass Flow Meter and Anti-Surge Valve)

  • Water disposal well facility development project 2500 BPD produced water capacity.(Including wellhead, flow line, package units, Instrument Control Room (PCS, PSS Panels etc.) and Power Switch Room (ACB’s, Feeder’s and field LCS, Lighting and Earthing network).

Senior Officer (E&I)

Attock Refinery Ltd. Morgah Rawalpindi, Punjab, Pakistan

Jan 2005 – Jul2012
Officer (E&I)

Jan 2001 – Dec2004
Trainee JMS (E&I)

Jan 1999 – Dec 2000

Apprentice Technician(Instrument)

Pak-American Fertilizers Ltd. Daudkhel Mianwali, Punjab, Pakistan

Jan 1998 – Dec 1998
Hands on Experience:
Troubleshooting, Maintenance and Calibration of following Instrumentation;


  • Pneumatic and Electronic Pressure, Flow, Level and Temperature Transmitters (Foxbore, Honeywell, Yokogawa, Azbil, E+H, Emerson)

  • Pneumatic PID Controllers Foxboro, Yokogawa

  • Electronic PID Controllers Yokogawa, Honeywell, ABB

  • Analyzer(pH, Conductivity, Thermal Conductivity, Oxygen, Moisturre) DKK, Servomax, Teledyne

  • Chart Recorders Foxboro, Taylor, Hpneywell

  • Control Valve with accessories Fisher, Masoneilan, Metso, Bettis, Rotork MOV

  • Pressure, Level, Flow & Temperature Switches

  • Carryout Corrective & Preventive maintenance, Shutdown, annual turnarounds

  • Condition monitoring for critical equipment’s data collection by historian, prepares reports, maintain files and history

  • Develop PM plans basis of reports for Crude Distillation Units, Catalytic Reformer Unit, LPG Storage Facility, and Crude & Product Storage Tanks.

  • Prepare and review Work Request, Work Orders, Purchase Requisition and training of new technicians.

  • Installation, testing and commissioning of solar power system for office building.

  • Programming of new or modification in existing control

  • Track the data for analyze the equipment, instrument and control system reliability.

  • Monitoring the Electrical VFD’s, High and Low Switchgear status monitoring.


Capable of using of following test equipment’s & Control Systems;


  • Field communicators HART-275, 375, 475 (Emerson & AMS Trex), SFC-I & II (Honeywell), BT-100 & 200 (Yokogawa)

  • Temperature Calibration Bath (Ametek),

  • Pneumatic & Electronic Simulator (Yokogawa, Transmation, Druk, Fluke & Beamex)

  • Dead Weight Tester (Ashcroft)




  • DCS System Experion PKS & TDC 3000 (Honeywell)

  • ESD System FSC (Honeywell)

  • PHD Historian (Honeywell)

  • PLC Allen Bradley

  • F&G System EBI (Honeywell)

  • Flow Metering GeoFlo & Sybertrol (FMC Smith)

  • Boilers BMS Burner Management System (Saacke)

  • CMMS MAXIMO


Special Assignment

Revamp of old pneumatic controlled light crude units 20000BPSD & 7000BPSD Light crude units.

Install new transmitter’s, JB’s, Cable, Cable tray’s and replace Pneumatic field instrumentation with HART Transmitter’s and DVC Intelligent positioner’s. Install all Panels for DCS & ESD and consoles station’s in control room. Successfully transfer all the DCS loops from pneumatic to DCS without shutdown the plant. Tune the loops and ensure the process stability.

Make the reports (Shift, Daily, Monthly and Material balance) for both distillation units in Historian.
Achievements


  • ARL Management appreciate my contribution in successful up gradation of DCS System TDC3000 to Experion PKS R300 and shifting of existing DCS Panels & Consoles to new Control Room.


Educational Profile
D.A.E (Instrumentation) 1992 - 1995

GPI Sargodha PBTE Lahore Punjab Pakistan
Personal Profile
Place of Birth: Khushab, Punjab, Pakistan

Date of Birth: 2nd October, 1977

Nationality: Pakistan

Marital status: Married

Religion: Islam

Passport No. BR5520041

Visa Status: Transferable

Present Residence: Jazan Economic City, Saudi Arabia







Muhammad Shahzad Zafar






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