Project Plant
Resume:
http://sa.linkedin.com/pub/rachakonda-sastry/*b/b*8/770
Name:- RACHAKONDA VISWANADHA SASTRY
R V SASTRY
House no-16, Nasr Hizza compound-1
AL-KHAFJI-31971-eastrn province
KINGDOM OF SAUDI ARABIA
Kuwait Mobile: +965-********-present
Saudi Mobile: +966-**-*******
*.*******@*****.**.**
Date of Birth 17-11-1953
Qualification M.Sc (Tech)-INSTRUMENTATION-1977
Experience
PROJECT ACTIVITIES related to INSTRUMENTATION early from Concept to Commissioning in OIL, GAS and PETROCHEMICAL INDUSTRIES. New Projects, Expansions of existing Units, Retrofit//Debottlenecking to improve the quality, yield and Environment. As Lead Instrument Engineer completed projects involving 4 centrifugal Air compressors, 3 Instrument Air driers, 3 DM plants. As Lead Instrument Engineer, I worked in good projects like Hydrogen purification unit, SGGU, Gasifier. Worked on good systems like INVENSYS, YOKOGAWA, HONEYWELL, TRICONEX and Instruments of reputed make like Rosemount, Fisher, and ABB. I worked on full range of process plants from full vacuum to 250 bar g & temperature from -160 to 1500degC. Worked on different MOC, involved in Design, detailed engineering, HAZOP Studies, procurement shut down activities, commissioning and ISO 14000 related activities.
Presently in Kuwait to supervise EPC contractor’s Project work
In SAUDI ARABIA for commissioning of ONSHORE CRUDE PROCESSING FACILITIES that includes up-gradation of existing DCS to HONEYWELL DCS(Experion) and PLC(Q M R).
Previously sent on deputation to PERTH-WESTERN AUSTRALIA for supervising FEED engineering activities for OFF-SHORE & ON-SHORE CRUDE PROCESSING PROJECT- US$ 4 billion ( included are oil processing, gas processing & compression and sulphur Recovery unit along with all utilities) FEED Engineering consultant- Worley parsons
CHIEF MANAGER (INSTRUMENTATION). 25 years overall experience at G.N.F.C. Bharuch-India
Job Title: Chief Manager (instrumentation)
Period: 2000 to 2007
Instrument activities related to projects/schemes
• Debottlenecking of D M plant.
• Methanol/acetic acid storage tanks.
PROJECTS
1. Ammonium Nitrate melt project
2. Terminal Automation project
These projects were done together as two independent projects with two different consultants but with same DCS and common filling stations.
AN Melt engineering by FEDO (Indian counter part of TOYO) 2004-05&
Terminal Automation by Jacobs H & G. -2005-2006
Automatic Loading on road tankers for methanol (4 stations) acetic acid (4 stations) concentrated nitric acid (2 nos) Weak Nitric acid (2 nos) Formic acid (1 no) AN Melt (2 nos) & carboys filling Stations
AN Melt project: Preparation of AN Melt solution, transfer to loading station and automatic filling activities on road tankers
Responsibilities:
• DCS:- Approval of engineering specifications,
• Techno commercial discussions (Honey well, Invensys & Daniel measurement& control)
• Order placement on Invensys, Approval of vendor documents,
• GA layout, assisting in graphic building& approval,
• Loop Schematics, Factory Acceptance Test,
• Site Acceptance Test,
• Site installation,
• Site acceptance test and commissioning.
Field Instrumentation:
• Approval of instrument specifications,
• Floating enquiries,
• Techno commercial discussions,
• Approval of vendor documents, inspection of instrument items at vendor’s works/site.
• Techno commercial discussions for Instrument Installation works
• Order finalization, erection supervision, commissioning and handing over to operation/maintenance groups.
(Consultants services were not utilized. Erection supervision done departmentally.)
JOB TITLE: 3RD Gasifier project -Instrumentation
Period 99-2000-01
Project New Gasification Train and conversion of pneumatic instrument system to DCS (invensys)/PLC (Triconex) of 2 nos old Gasification trains.
Know How: TEXACO (U S A)
Detailed engineering: UHDE (Germany& India)
Responsibilities:
• Assisting in simulation of existing pneumatic shutdown system to TEXACO personnel at GNFC -Bharuch.(India) and defining the requirement for new train.
• Preparation of design philosophy, Scope of engineering to EPC contractor for new Gasification Train and conversion of existing pneumatic instrumentation system to new DCS/PLC and integration of new stream with existing, old gasification system.
• Technical discussions with EPC contractor. M/s UHDE was selected.
• Kick off meeting with M/s UHDE –Germany& India at Germany and freezing parameters for discussions with M/s Texaco.
• Visit to USA along with UHDE-Germany& Indian personnel and discussions with Texaco about Design philosophy, deliverables by Texaco, Project Scheduling/monitoring.
• Assisting M/s UHDE –India & Germany in finalizing P &I.
• Participating in HAZOP Study, analysis and approval along with Texaco & Uhde
• Participation in the development and Approval of PDS.
• Implementation DCS/PLC design philosophy of M/s Texaco in the preparation of tender documents prepared by Uhde and approval of the same.
• Techno commercial discussions with vendors and finalization of DCS Vendor. (PLC was taken from M/s Triconex on proprietary basis.)
• Approval of procurement specifications prepared by M/s Uhde.
• Technical discussions with vendors jointly with Uhde and commercial discussions by self.
• Vendor drawing approvals jointly by Uhde and Self.
• Assisting in DCS/PLC graphics preparation along with vendor and approving the same along with process/operations group.
• Approval of all vendor documents of DCS/PLC along with Uhde.
• Conducting Factory Acceptance Test of DCS/PLC along with Uhde and process/operation group.
• Inspection of major instrument items at vendor’s works.
• Approval of erection documents, techno-commercial discussions with contractors and finalization of the same.
• Erection supervision departmentally. (Uhde is not involved.)
• Site Acceptance Test of DCS/PLC along with operation group and acceptance of the same.
• Mechanical completion of 3rd Gasification train.
• Simulation and acceptance of Shut down logic along with Texaco
• Commissioning assistance to operation group, Texaco and handing over the 3rd Gasification train.
• Conversion of Gasification trains to DCS/PLC and commissioning the same and handing over.
Job Title: - Wet Scrubbing System-Instrumentation- 1998-99
Job Title: - Weak nitric acid expansion-Instrumentation-1997-98
Job Title: - concentrated nitric acid-2-Instrumentation- 1996-98
Project: M/s Uhde-Germany executed these projects on LSTK basis.
Responsibilities:
• Involvement in freezing P&I and HAZOP study and clearing the same
• Approval of instrument Specification prepared by M/s Uhde.
• DCS/PLC is expanded to meet the project requirement.
• Assisting and approving DCS/PLC graphics
• Inspection and acceptance of Supply of instrument items by Uhde
• Erection supervision by GNFC
• Commissioning assistance
• Acceptance of the unit
Job Title: - Synthesis Gas Generation Unit (Jacobs H &G)
Period 1995-97
Project: - Project to produce synthesis gas from natural gas and feeding it to Methanol plant and conversion of existing methanol plant pneumatic instrument system to DCS.
We were producing Methanol utilizing synthesis gas obtained from Ammonia plant. This is a project to produce synthesis gas from natural gas and integrate it with existing methanol plant.
Responsibilities
• Explaining existing methanol plant operating philosophy/instrument system to EPC contactor during site visit
• Design basis
• Participation in Kick off meeting along with project group, EPC contractor
• Assisting in preparation of existing methanol plant pneumatic instrument construction drawings to Suit new DCS documentation and approval of the same.
• Assisting in preparation of tender documents for DCS specifications.
• Techno commercial discussions with various vendors.
• Order placement on Foxboro & Kick off meeting with DCS vendor.
• Approval of specifications for field instrumentation. Techno commercial discussions with vendors and order placement.
• Approval of vendor drawings along with EPC contractor.
• Inspection of instruments at vendor’s works/ site.
• Involving in FAT activities along with project group.
• Assisting in tender preparation for field erection works. Techno commercial discussions and order placement.
• Erection supervision.(H&G is not involved)
• Site Acceptance Test of DCS.
• Simultaneous installation works related to Existing already operating methanol plant.
• Shut down, hook up and Commissioning assistance.
During the period 2002-2003, I am involved in the implementation of ISO14001 and conducted 5 nos Internal Audits (Instrumentation only)
Job title Instrument engineer- Design & construction Department
Period: 1984- 95
After commissioning the plant was undergoing lot of teething problems. To overcome these problems D&C Department was created. The primary function of this department was to identify the major problems limiting the stable operation of the plant, remove bottlenecks, and improve operational efficiency and removing all these limitations single handedly.
Job title Commissioning assistance for 300tpd Methanol plant.
Period 1991 Reactor & Distillation section (3 months only)
Projects handled:
ENGINEERING ASSISTANCE FOR PACKAGE units.
Engineering specifications for procurement of instrument items for package units, engineering assistance, erection supervision, integration with main plant/control room systems, commissioning of
• 6000 Nm3/hr CENTRIFUGAL AIR COMPRESSORS (Atlas Capco-1992 & IHI-Japan-1989, Ingressol Rand-1997)-3 nos
• INSTRUMENT AIR DRYERS-2 nos (1985 & 1989)
• LEAN GAS COMPRESSOR-1 NOS -1987
• 100M3/hr Deminaralised Water Treatment plant. –1986& 1988.
LSTK PROJECTS
Engineering assistance, approval of drawings, coordination with vendors, erection supervision, commissioning assistance of
• 4000nm3/hr Pure Hydrogen Recovery unit – LINDE-GERMANY Supply & Commissioning and guarantee& acceptance-1995-96
• Erection supervision. Integration with main plant by self.
• Fuel Oil (1985), Ammonia (1991), acetic acid (2000) & Methanol (1989) tank yard
• Co2 enhancement scheme-1993
• Butachlor project (1987-88)
• Conversion of coal fired boilers to oil/gas fired boilers. -1990-91
• Ammonium nitrate melt scheme. 1988
• Boiler feed water injection to GASIFIER-1984-85
Responsibilities:
• To work on the problem
• Assist in developing the scheme,
• To get approval internally and through KNOWHOW licenser,
• Develop detailed engineering scheme,
• HAZOP participation and clearance.
• Make procurement specifications & techno commercial discussions and recommendations.
• To approve vendor drawings,
• To prepare BOM for erection material,
• Procurement support and internal and external inspection.
• On receipt of the material at site we departmentally get the Installation jobs completed and render commissioning assistance.
• Once the system is commissioned, the same is handed over to the operation, maintenance groups.
• To make “As Built drawings” .
Job title Crude stabilization unit, compressors & pumping station
Period 1982-84
Owner Oil & Natural Gas Commission-India
• Responsibilities:-
• Tender preparation for Instrument installation works, technical discussions and recommendation.
• Receipt of material at site, inspection and acceptance of the same.
• Erection supervision, calibration supervision and approval
• Shut down and hook up of new plant with old plant.
• Mechanical completion and handing over to owner.
• Commissioning assistance.
Job title. Iraq Oil Terminus (South LPG Project)-Basra-Iraq
Period; 1981-82
Responsibility:
• Site management
• Receipt of instrument items and inspection and proper storage.
• Erection supervision.
• Manpower control.
• Mechanical completion.
Job title: Mathura Refinery Project.
Period: 1980-81
• Site management.
• Calibration of instruments (pneumatic)
• Manpower control
• Quality control, inspection
• Erection supervision of Atmospheric and Vacuum Distillation Column Units.
Job title: General engineering Assistance
Period: 1979 -80
General instrument engineering works, office back up for site personnel.
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