Engineer Plant
Resume:
NEMATULLAH KHAN
Mobile: +971*********
E-Mail: ******.****@*****.***, ***********@*****.**.**
Job objective
Results-oriented Electrical Automation, Instrumentation and Control Engineer specializing in high-level problem solving, process efficiency and day-to-day maintenance in manufacturing environment. An ardent analyst, seeking challenging assignments in Instrumentation&Control/Electrical&Automation/PLC & SCADA Programming/Project Management with an organization.
Preferred Industry: Metal & Iron / Oil & Gas/Fertilizer/Glass/Paper and Pulp
Summary of Skills:
Working as an Instrumentation Automation & Control Tech. Engineer at Emirates Global Aluminum - Emirates Aluminum, dealing with supervision and leading the team in improvement projects and breakdown analysis and having more than 8 years of experience as an instrumentation and control systems engineer in detailed maintenance, commissioning and development co-ordination of instruments and control systems in Aluminum smelter and power Plant.
PFROFILE SUMMARY
Summary of Skills
Project Planning & Execution
PLC & SACDA Programming
Software Development
Maintenance Operations
Designing, Development & Implementation
Automation, Commissioning & Calibration
Quality Assurance
Training & Development
Team Management
SNAPSHOT
An accomplished professional with nearly 25 years of experience in Project Management, Automation, Technical Evaluations, Troubleshooting, etc.
Currently associated with Emirates Aluminium Company Ltd., U.A.E as Technical Engineer – Instrumentation Automation & Control
Well versed with concepts of OSI PI, Rockwell Factory Talk Historian, SAP
Sound knowledge of PLCs including Siemens S7, Schneider Quantum, Rockwell ControlLogix, etc.
Conversant with SCADA systems such as WinCC, Wonder Ware,, FTView SE & ME, I fix; efficient in commissioning & calibration of all field instrumentation devices
Advanced skills in steering the entire project development life cycle for automation projects with PLC and SCADA
Skilled at system designing, implementing, commissioning, troubleshooting and maintenance
Expertise in handling Project Management initiatives including planning, organizing, securing and managing resources to bring about the successful completion of project
Proficient in managing plant equipment downtime within specified limits, preventive & breakdown maintenance in compliance with the safety & environmental policies
Deft in directing, leading & motivating workforce and imparting continuous on the job training for accomplishing greater operational effectiveness/ efficiency
Skills:
Knowledgeable in basic pneumatics, electro pneumatics and hydraulics system including servicing of solenoid valves and cylinders.
Knowledgeable on calibration of different smart instrument such as level, pressure, temperature, consistency, I/P - P/I transducers.
Knowledgeable on different types of sensors such as proximity switches, ultrasonic, vibration sensors such as Bently Nevada.
Knowledgeable on different types of process calibrators such as Fluke 702, Premiere, Beamex MC5P, Dead Weight Tester.
Knowledgeable and familiar w/ different brands of process instruments such as Rosemount, Neles James burry, Yokogawa, Endress Hauser, Siemens, ABB.
Knowledgeable on different types of process instrument communicator such as HART communicator, Brain Terminal (BT200).
Knowledgeable on PLC software program such as RSlogix 5000, 500, 5, Siemens S5 & S7.
Knowledgeable in Device net and Control net network.
Knowledgeable in Supervisory Control and Data Acquisition SCADA system and Honeywell Distributed Control System (DCS), HMI configuration, RsView Studio.
Knowledgeable in Enterprise Resources Planning software such as SAP, Smart Plant Foundation.
Knowledgeable in computer software application such as MS Office, Windows Internet Browser, MS Outlook and AutoCAD
ORGANIZATIONAL EXPERIENCE
Since Jul'09: Emirates Aluminum Company Ltd., U.A.E
Technical Engineer – Instrumentation Automation & Control
Overseeing project activities from conceptualization to execution including business definition, feasibility and optimization, project planning, implementation, site management and manpower planning
Managing preventive and predictive maintenance schedules of equipment to minimize stoppages in critical areas
Ensuring condition monitoring of various equipment; identifying areas of obstruction/breakdowns and taking steps to rectify the equipment
Analyzing various processes/applications and recommending modifications & equipment calibrations to enhance operational efficiency
Coordinating plant activities for setting up standards with accountability for strategic utilization & deployment of available resources to achieve organizational objectives
Administering all technical & managerial aspects, developing reports on performance analysis and handling planning operations for better productivity
Conducting in depth analysis of recurring issues to imply accurate solution
Anticipating possible problems, diagnosing the problem, gathering information and implementing forward/ conceptual action to resolve it
Taking stringent quality measures including preparation / maintenance of necessary MIS reports to ensure compliance with objectives, standards & customer requirements
Developing maintenance, operations procedures to increase the efficiency; implementing standards and ensuring adherence to quality standards through in-process checks.
Work as Acting Instrumentation & Control Supervisor handling all the maintenance and improvements of Instrumentation section.
Involve in material spare management planning for all instrumentation equipment and devices.
Handling all the maintenance breakdown failure analysis and troubleshooting including instrumentation, automation, electrical and mechanical issues.
Performed Planned Maintenance and Improvement Project Review and maintain instrumentation and control spares parts availability.
Participated in all the Project documents review related to Instrumentation and Controls during Commissioning Period.
Attended walk down inspection during Pre-operational Verification and work with Commissioning Engineer in testing and commissioning jobs.
Review and participate in suggestion scheme program for the improvement of the machine design and development of assigned area.
Review and develop Standard Operating Procedures in Instrumentation and Controls.
Completed Maintenance activities and work order thru SAP system
Conduct calibration and servicing of process instruments and accomplish Certificate of Calibrations.
Technical Training :
Basic and Advance Programming of Control Logic PLC RSlogix 5000 Software - Rockwell Automation, UAE
Advance training for Homogenizing Furnace, Batch homo furnace and Billet SAW by Hertwitch Engineering.
Control Logix Essentials with RSLogix 5000 Software - Rockwell Automation, UAE
Control net and Device net Training - Rockwell Automation, UAE
RSView ME Program for Panel View Plus - Rockwell Automation, UAE
Guard Logix Maintenance & Troubleshooting - Rockwell Automation, UAE
Basic Pneumatics - Festo, UAE
Cooling Tower Instrument Maintenance and Practical - Emirates Aluminum, Co. Ltd.
Overhead Crane Instrument Maintenance Training - Emirates Aluminum, Co. Ltd.
Sodium Reduction Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd. (STATS)
Deep Bed Filter Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd. (STATS)
Sheet Ingot & Billet VDC Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd. (WAGSTAFF)
Alscan Compact Degasser Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd. (STATS)
Electro Magnetic Stirrers Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd.
Ingot Casting Machine Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd. (BEFESA)
Holding & Melting Furnace (83ton & 130ton) Instrument Maintenance - Emirates Aluminum, Co. Ltd. (MECHATERM)
Spectrometer Electrical & Instrument Maintenance - Emirates Aluminum, Co. Ltd.
Fuel Gas Skid OEM Training - Emirates Aluminum, Co. Ltd.
DOMINO Inkjet Marker Operation and Maintenance - Domino UK Ltd. Packaging Jebel Ali Free zone UAE
Advanced Programmable Logic Controller ( Allen Bradley) - MECHATRONICS Technologies Corporation
Basic Pneumatics Systems and Design (Intercostals Training Center) - Paranaque, Philippines
Industrial Hydraulics FESTO DIDACTICS Philippines
SPC-1000 HANHELD COMMUNICATOR use for MEK & MBT - BTG Pulp & Paper Sensors AB Philippines
Forklift Training - Emirates Aluminum, Co. Ltd.
High Lift / JLG Training - Emirates Aluminum, Co. Ltd.
Melting Furnace (83ton & 130ton) Maintenance - Emirates Aluminum, Co. Ltd. (SOLIOS)
Safety Training
Aluminum Water Explosion Course - Emirates Aluminum Co.Ltd.
Basic OHS Knowledge - Emirates Aluminum Co.Ltd.
Personal Protective Equipment Management - Emirates Aluminum Co.Ltd.
Safe Manual Operations - Emirates Aluminum Co.Ltd.
Ladder Safety - Emirates Aluminum Co.Ltd.
Permit to Work System / Receiving Authority - Emirates Aluminum Co.Ltd.
Lock Out Tag Out Procedure - Emirates Aluminum Co.Ltd.
Confined Space Entrant & Attendant - Emirates Aluminum Co.Ltd.
Basic Heat Stress- Emirates Aluminum Co.Ltd.
5S Housekeeping Seminar - Emirates Aluminum Co.Ltd.
Basic First Aid & CPR Training - SOS Dubai, UAE
Basic Fire Fighting Training – Emirates Aluminum Co.Ltd
Hazardous Areas Classification – Emirates Aluminum Co.Ltd
Safety Training – Neobosh
Safety Training Course for Department Safety Representative - - Emirates Aluminum Co.Ltd.
Management Training
LEAN Foundation Training - Emirates Aluminum, Co. Ltd.
Basic A3 Problem Solving Technique - Emirates Aluminum, Co. Ltd.
Environmental Management System (ISO 14001) - Emirates Aluminum, Co. Ltd.
Environmental Management System (ISO 14001) - Trust International Paper Corporation
Occupational Health and Safety Assessment Series (ISO 18001) - Trust International Paper Corporation
World Class Seminar (ISO 9002) - Trust International Paper Corporation
Occupational Health and Safety Assessment Series (ISO 18001) - Trust International Paper Corporation
Seven Habits of Highly Effective People - Trust International Paper Corporation
Stress Management - Trust International Paper Corporation
Defensive Driving - Trust International Paper Corporation
SAP PM Technician, Plant Maintenance Module & Basic Material management - Emirates Aluminum, Co. Ltd
Companies of particular interest and why?
To Carrier development and achieving new goal.
Additional Notes
Maintain an excellent level of skills when performing task adheres to health and safety procedures to ensure protect him and colleagues from accidents and equipment damage. Also performs other functions as requested by manager and also follow below responsibilities.
General Safety System Responsibilities:
To follow the safe work practice and wear required PPE.
Report near misses/incident and participate in all activities relating removal of hazards in work area.
Assist with identification of hazards arising from activities in work area, ensuring that all are communicated to relevant personnel in order to maintain a hazard free work area.
Participate in implementation of Company safety policy and communication to subordinates.
Identifing and evaluating potential/existing safety problems, suggesting solution and recommending suitable corrective measures.
Shall be able to use PTW systems for projects and maintenance activities.
General Quality System Responsibilities
Ensuring the requirement of the company’s Quality Systems is complied with the systems.
Assist with the continual improvement of the quality systems by implementing and participating in process improvement initiatives in relative areas.
Identifying and evaluating quality problem, suggesting solutions and recommending suitable corrective measures.
General Environment System Responsibilities
Report all process or other incidents that may cause environmental harm to the relevant personnal, regardless severity.
Follow the procedures and instructions related to environment within the scope work area.
General Work Responsibilities
Attend to all equipment breakdowns and planned maintenance work with minimum direction and supervision.
Technically assess the requirement of allocated jobs and select the necessary tools and equipment to complete such work.
Using the computerized maintenance system, order the spare parts from vendor and maintain record of all projects and maintenance work completed.
Ensure that all maintenance work is carried out in accordance with the safety procedures and plant operational requirements.
Monitor any repeated breakdown and take proper modification to resolve the problem.
Effectively be able test, fault find and diagnose failures on control system and instrument devices.
Communication & Working relationship
Regular contact with production and maintenance peers as well as managerial staff as and when necessary to discuss daily task, equipment defects and company /dept meetings.
Highlights:
Played a pivotal role in implementing:
ISO - 9001 - 2000
ISO – 14001
OHSAS - 18001
TPM activities & ITS
Maintenance module of ERP - SAP front end user of SAP 4.6C
TPM activities and ISO 14000
Integrated Management System
Holds the credit of commissioning Rockwell Factory Talk Asset Center software and Acronis® Backup & Recovery
Efficiently modified system depending on operational requirement and carried out troubleshooting in order to tackle breakdown
Instrumental in Automation system maintenance activity like: backuping servers and PLC program etc
Recognized for improving on - going cast house process
Appreciated for implementing best technology in order to improve overall efficiency and to reduce downtime which in turn reduced break downtime
Recipient of:
Best Suggestion of the Month Award for (Fuel consumption on the furnace and Molten level control)
Time Project Completion Award for (Completion of Hot rolling Mill)
Oct’04 - July’09: Ispat Industries, Dolvi Maharashtra Mumbai
Assistant Manager (Electrical &Instrumentation)
Role:
Managing project activities right from the conceptualization stage to execution including finalization of technical specifications, project scheduling, progress monitoring, site management, manpower planning, etc.
Evaluated project details and designed technical scope for revamping designated project
Supervised project activities; identified recurring issues and suggested corrective actions in order to enhance overall plant reliability
Proposed modifications in DCS and PLC systems
Prepared loop wiring, interconnection, logic, cable schedule drawings; managed installation and calibration of field instruments
Implemented technical recommendation/modifications for spares and recorded new instrument requirements
Eliminated redundant / obsolete processes involved in the design, development processes and worked towards value-addition
Planned and effectuated preventive maintenance schedules of various equipment in order to increase machine up time and equipment reliability
Identified areas of obstruction/ breakdowns and take steps to rectify the equipments through application of trouble shooting tools
Coordinated material/ spare parts planning related activities encompassing identification of vendors, requirement specification & offer evaluation
Documented:
oISO records and designed procedures & work instructions as per current industry standards
oApplication software & trouble shooting guide for DCS, PLC and Analyzer systems
Updated and enhanced CMMS functionalities and database; accountable for indenting and preparing specifications for Spares through SAP
Conducted RCA and documented trip analysis reports of plants.
Imparted continuous on job training to enhance technical/non-technical skills of manpower
Detailed planning for plant turn around maintenance including manpower, spares, services etc. and Budgeting for the same.
Carried out:
Design reviews in order to make required changes as per specifications
Technical studies and conducted audits in order to enhance overall plant performance & reliability
DRI Plant:
Administered planning, procurement, erection & commissioning of automation and instrumentation system for the plant
Managed settings tuned control loops as per process requirements
Converted hardwired relay based panels to PLC (U84) for Instrument air compressors, refrigerant dryers and inert gas generator
Identified major loopholes and resolved them effectively for capacity enhancement of plant; also, added EFCD station (Bus Participant) to the DCS (CENTUM-XL)
Established oxygen injection system and propane injection system in order to enhance overall capacity
Initiated modifications in DCS and PLC as per specifications of field Instrumentation in order to reduce downtime
Initiated changes in data-logging system in order to identify and analyse recurring faults/loopholes
Implemented:
(IC2000) SCADA system communicating a remote PLC (U84) through modem
AGA 7 /AGA3 requirements necessary for custody transfer of natural gas metering
Efficiently converted LDO based firing system into gas based firing system
System Handled:
DCS (Distributed Control System)-CENTUM –XL by YOKOGAWA for Midrex DRI Plant
Programmable Logic Control (PLC) Systems:
YASKAWA PLC’s (4000 I/Os) with Dual redundant configuration for Midrex DRI -Plant Interlocks
Siemens SIMATIC S7-300 for Instrument Air Compressors
L&T QUATUM PLC for Material Handling Area
GE Fanuc PLC for Cold Briquetting Plant
Carried out Field Instrumentation of the following:
Vibration Monitoring Systems - IRD, BENTLEY, NEVADA and SPM
Gas Analyzers - CO, CH4, CO2 based on NDIR Principle of MAHAIK Makes
O2 Based on Paramagnetic Principle and H2S based on Colorimeter Principle
ON-LINE Gas Chromatograph For Natural Gas –Model VISTA3100 –ABB Make
Gas Detection and Personnel CO Monitoring Systems
Control Valves - Neles James Bury, Fisher, Masolenian, I L Palghat, Arca
Ultrasonic Level Transmitters - E&H Make
Flow Measurement Meters -Turbine Meters, Vortex Meters, Target Meters
Mass Flow Computers for Natural Gas
Static And Dynamic Weighing Systems
SMART Transmitters For Pressure / DP - Siemens, Rosemount and E&H Make
Hydraulics System For The Slide Gates And Burden Feeders
Migration From DCS YOKOGAWA Centum-XL To DCS YOKOGAWA CENTUM CS -3000
Up Gradation of U-84 PLC’s to Quantum PLC
SCADA Systems Handled:
Simplicity For Midrex DRI Plant
Simatic Wincc for Instrument Air Compressors
Citect for material handling area
Simplicity for Cold Briquetting Plant
Key Projects Handled:
Installation & Commissioning of Instrument Air Compressor PLC by using Siemens S7-300 PLC
Installation of Gas Analyzers or CH4, CO2 and O2 Of Maihak Made
Installation & Commissioning of 10” And 2” Turbine Meter Along With Flow Computer For Natural Gas Metering
Annual Shutdown Maintenance of NG Metering And NG Distribution Area
Highlights:
Successfully handled instrument & electrical maintenance and automation of:
Midrex Direct Reduction Plant with capacity of one million tons per annum
Cold Briquetting Plant
Material Handling Area
PREVIOUS EXPERIENCE
Dec’94- Sep’04: Jindal Stainless Ltd., Hissar (Haryana)
Growth Path:
1994: Engineer Trainee– Instrumentation
1995: Junior Engineer- Instrumentation
1998: Assistant Engineer- Instrumentation
2004: Executive Engineer-Electrical & Auto
Role:
Administered installation, commissioning and maintenance of:
Isotope thickness gauges in hot as well as cold rolling complex
Molten Metal control by Cobalt 60 Radioactive source
Roll Force/ Tension measurement and weighing systems in mills / lines
Temperature Control in Hood as well as continuous annealing, Hot Dip Galvanizing line
Effectively supervised the selection, installation testing and commissioning & maintenance of Instrumentation & Automation Systems [using PLC as well as discrete Components] of following units; 80-ton AOD converter and Continuous Caster & VOD, Fume Extraction systems and
Managed maintenance operations of Electrical & Automation of steel making to hot rolling and installation, testing & commissioning of instrumentation & automation systems of following units:
Slab Re-heating and roller hearth furnace& Walking beam furnace
220 bar de-scaling system Continuous Annealing and Pickling Lines
Modernization of Electrical and Automation Systems at 0.2 MTPA Reversible Hot
Automatic Material Tracking, Sequencing, Pass Scheduling and Gap Control
Automatic Hydraulic Gap and Gain Control & Gauge Control using X-Ray Thickness Gauge
Roll Alignment Control, taper rolling & Level – 2 Automation
Highlight:
Holds the credit of successfully increasing availability of AMLC from 60% to 90%, which improved quality of product & reduced casting and break downtime
Successfully implemented ISO 9001 in Instrumentation Section
SKILL SET
IT Skills
Conversant with:
oTCP/IP, SNP, HART, Field bus, Profibus, Mod Bus, Genius Bus, RSTP
oWindows 2000, X, DOS
oMicrosoft SQL, Office 2K, SAP, and Lotus
Technical Skills
Well versed with:
oERP: PM and MM module
oConnectivity with Data Server, Historian Server, Wag staff SCADA, Her twitch Server with EPMS System
oConnectivity of all PLC
oPlant Management System Server
ACADEMIC DETAILS
Completed EMBA (Project Management System) from ISMS Mumbai 2014
B.E. (Electronics Communication Engineering) from Institute of Engineers, Kolkata in 2003
Diploma (Instrumentation& Control Engineering) from Institute of Engineering &Rural Technology, Allahabad, U.P. in 1993
PERSONAL DETAILS
Date of Birth: 1st June 1972
Permanent Address: C-401 Krishna Tower, Sector 5E, Kalamboli- 410 218, Maharashtra
Present Address: Jamal Bldg Flat No. - 506, Jamal Nasser Street 12 Sharjah
Location Preference: Middle East/India
Languages Known: English, Arabic, Urdu, and Hindi
Marital Status: Yes
No. of Dependants: 5
Visa Status: Residence
Driving License: Yes (U.A.E)
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