MANOJ MATHEW
LIST OF PROJECTS EXECUTED
1996
1. Process Control Modernisation Project, YANPET – Honeywell 1996/1997
Designed over 30 Modicon Quantum and 800-series PLC control panels from I/O list and BOQ for Process Control Modernisation Project, Saudi Yanbu Petrochemical Company Limited (YANPET), Yanbu, Saudi Arabia. The system had various combinations of 800-series and quantum I/O racks interfaced to Hot Standby Quantum processors in the same panels as well as remote locations connected through RIO coaxial and optic-fibre cables.
1997
1. Khatiyah North & South, KNS Project, QGPC – CCIC, 1997
Designed and assembled two Allen Bradley SLC500 based control panels and two relay-based ESD (emergency shutdown) panels for Khatiyah North & South Degassing Stations, Dukhan for Qatar General Petroleum Corporation (QGPC). Conducted full scale Factory Acceptance Test in our workshop with input/output simulator boards and SCADA system. Assisted on site for loop tests, commissioning and performance tests.
2. Powered Water Injection, PWI - Phase 5 Project, QGPC – CCIC, 1997
Designed and assembled three Allen Bradley PLC-5 based control panels with Bentley Nevada Vibration Monitoring systems for Pressurised Water Injection pumping stations PS2, PS3 & PS6. Conducted full scale Factory Acceptance Test in our workshop with input/output simulator boards and SCADA system. Assisted on site for loop tests and commissioning on site in Dukhan.
3. Green & Baked Anode Conveyor System - Falcon Project 1997, DUBAL - Fredenhagen GmbH., 1997
Commissioning and software support services for the new Kiln3 Green & Baked Anode Conveyor System, DUBAL (Dubai Aluminium Company Limited), Jebel Ali, U.A.E. 24 Hour on-call service to attend to any problems in the conveyor systems in the Plant. Conducted training classes for the Operators and Maintenance personnel. Wrote the Operations and Maintenance Manual for the Anode Conveyors System.
1998
1. Early Production System, QGPC - Mid-East Constructors Ltd., 1997/1998
Designed an Allen Bradley SLC500 remote I/O rack control panel and relay ESD panel for the expansion project for Khatiyah North Degassing Station, Dukhan for Qatar General Petroleum Corporation (QGPC).
2. PTA & Aromatics Project, Ibn Rushd - CCIC / Technimont / ABB August. 1998
Commissioning services for the PTA Plant Emergency Shutdown System, Arabian Industrial Fibers Co. (Ibn Rushd), Yanbu, Saudi Arabia. Developed ESD logic based on new Cause & Effect document for the TMR (Triple Modular Redundant) ESD system based on ABB August.
3. PLC Test Panel for Zakum Development Company. 1998
Commissioned Modicon 584-series PLC test panel for Zakum Development Company (ZADCO) at Zirku Island, Abu Dhabi. 1998
4. Arak Petrochemicals – FIMCO, 1998
Designed and assembled a Siemens S5 PLC based control system with LED mimic panel for tank farm control. Installed and configured a Rochester annunciator panel for two-level alarming. Conducted Factory Acceptance Tests.
1999
1. Anode Conveyor System Kilns 3 & 4 - Condor Project, DUBAL - KEMPE International, 1999
Programmed and commissioned the modified Anode Conveyor system for Kilns 3 & 4 for DUBAL. Interlocked the Allen Bradley PLC-5 with other existing PLCs – Storeroom Stacking Cranes, Furnace Tending Cranes, Anode Cleaning Stations, Motor Manager VME PLCs. Developed the new SCADA operator interface using RSView32.
2. Instrument Revamping Project, ADNOC – Cegelec, 1999
Modified and commissioned existing PLC program and new Utilities ESD PLC based on redundant Allen Bradley PLC-5 for Sea Water Pump / ESD for ADNOC Ruwais Refinery, Abu Dhabi. Configured modbus communication for new systems to the existing Foxboro DCS.
3. Compressed Air System Expansion, Gas Turbine Stations GT17 & GT18 – Condor Project 1999, Mott MacDonald – DUBAL, 1999/2000
Programmed and commissioned a new Allen Bradley SLC500 control and PanelView550 MMI (Man Machine Interface) unit for the new Compressed Air Supply Control Systems for DUBAL.
4. Compressed Air System Expansion, Gas Turbine Stations GT17 & GT18 – Condor Project 1999, GE Alstom, Mott MacDonald – DUBAL, 1999
Post-Commissioning Software modification services for two numbers of turbine-control GE- Fanuc PLCs for the new Compressed Air Supply Control Systems for DUBAL (Dubai Aluminium Company Limited)
5. Anode Conveyor System Kilns 1 & 2 - Condor Project 1999, DUBAL, K. Home - ALUTEC International, 1999/2000
Programmed and commissioned the revamped Anode Conveyor System for Kilns 1 & 2 for DUBAL, based on a control system consisting of 5 Allen Bradley PLC-5’s interconnected on DH+ network. Modified the existing SCADA to include the new conveyor system. Added the new Kiln Messaging & Maintenance screens in the SCADA for Control room to Furnace Tending Crane Operator Messaging (a feature that was unsuccessfully tried by a European company in the earlier Falcon Project).
6.
Modification and correction of alarm monitoring Telemechanique TSX Premium PLC and MaGelis display unit on board the tank-ship T.T. Sea-World. (Total Automation, Dubai, 1999)
7.
Programmed and commissioned a retrofitted Diesel Firewater Engine for GASCO’s NGL Extraction Plant in Buhasa using Modicon 800 series PLC and Telemechanique MaGelis display unit. (ITC – Gasco, 1999)
8.
Modification of Allen Bradley PLC-5 logic to incorporate alumina-handling conveyors for two new Silos installed in Potlines 6A & 6B of DUBAL. (Potlines 5 & 6, Condor Project 1999, DUBAL – K. Home)
2000
1. Al Khaleej Sugars, Jebel Ali Free Zone, Dubai, 2000
Programmed and commissioned a process monitoring PLC System based on GE Fanuc Versamax for monitoring various parameters of two vacuum pan boilers for a sugar processing factory in the Jebel Ali Free Zone, Dubai. Developed a Cimplicity SCADA graphical user interface with a 30-day trending cycle to replace the mechanical chart recorders in the control-room.
2. Emirates Sky Cargo Terminal, Dubai Cargo Village. Dexion, Siemens – Emirates Airlines / DNATA, 2000
Programmed Siemens Simatic-S7 PLC for automatic sequence control of underground queuing conveyors in the new Emirates Cargo Terminal in Dubai Cargo Village, Dubai Airport.
3. WED-71 Project, Shoheib Field, Al-Ain. Water & Electricity Department - Al Nasar Irrigation Company, 1999/2000
Designed, assembled, installed and commissioned one Modicon Quantum PLC and 35 Micro PLC systems for remote monitoring and control of 35 numbers of irrigation water wells from a main control room. The Control Room PLC is linked to 35 wells in the field through a RS485 network over a distance of 40 km. The remote data is displayed on two Intellution SCADA computers.
4. Fujairah Terminal Phase 2 Expansion Project. Van Ommerren ENOC Fujairah Ltd – Danway LLC, 2000
Programmed and commissioned Allen Bradley PLC-5 control system for a Tank Terminal in Fujairah for semi-automatic control of loading / unloading a product from ship, blending, re-circulation between storage tanks, implementation of operational interlocks through modbus ports to the MOV (motor operated valves), hot oil boiler, generator, Saab Radar Tank Gauging system and MCC (motor control centre) vendors’ systems, as well as safety interlocks to control 26 storage tanks and jetty area loading arms. All processes are controlled and displayed on three RSView32 SCADA stations in the Control Room.
5.
Programmed and commissioned the GE Fanuc PLC control system for automatic gate control of the tidal gate separating the Khalid Lagoon and Al Majaz Canal in Sharjah, U.A.E. (Tidal Gate Control. Al Nasr Engineering, Al Futtaim Tarmac – Ruler’s Office, Sharjah)
2001
1. Al Jimmi District Cooling System Central Plant, Al-Ain – TABREED, Kattener / Shankland Cox / VOLTAS, 2001
Programmed a GE Fanuc 90-30 PLC and Cimplicity SCADA for automatic unmanned operation of 3 chillers, 6 VFD controlled distribution pumps and cooling towers, 6 booster pumps, motor operated valves and other equipment for the supply of chilled water for central district cooling system. The PLC calculates various billing parameters by obtaining energy supplied, electrical power consumed, water consumption, etc. directly from third party equipment via Modbus, DeviceNet and ASCII communication. The SCADA generates hourly and daily reports for the equipment runhours, power and water consumed, energy supplied, etc.
2. Al Jimmi District Cooling System, Energy Transfer Station – Jimmi Mall, Al-Ain – TABREED, Kattener / Shankland Cox / Nael Electromechanical, 2001
Programmed a GE Fanuc 90-30 PLC for automatic unmanned control and distribution of chilled water received at the energy Transfer Station from the Central Cooling Plant. The PLC controls 3 VFD controlled booster pumps and 3 motor operated valves to distribute chilled water within the Al Jimmi Mall.