Syed Kamil Raza

Poly Condensation Unit Development (N14-B: 350 TPD, $10M):

• Played an instrumental role in the development and implementation of control logic and graphics for a poly condensation unit on Emerson DeltaV v14.3.
• 590 I/Os, 20 graphic pages, 413 control modules.
• Implemented control strategies including 2-step motor control, PID, cascaded PID, feed ratio controls, and totalizers.
• Development of all graphics.
• Configured trends, alarms, and interlocks for optimized process monitoring and safety.
• Performed all loop testing, and instrument calibration (including 17 level transmitters, and 16 flow meters).
  

Cost Savings Initiatives:

• Saved $70,000 by implementing PROFINET communication between Siemens S7-1200 and DeltaV via Vim2, eliminating the need for 63 DeltaV DSTs and associated cabling.
• Achieved $10,000 savings by developing a DeltaV OPC server for SAP MII data transmission, eliminating the need for external vendor support.
  

Energy Optimization Projects:

• Enhanced process column temperature stability by implementing Fuzzy Logic Controls on the reflux loop, reducing temperature deviation (DeltaT) from ±20°C to ±3°C. This stabilization minimized EG evaporation, resulting in a combined annual cost savings of PKR 35M.
• Currently optimizing chips conveying system timings, projecting annual energy savings of 1,100,000 units by establishing PROFINET communication between Siemens S7-1500 I-Device and DeltaV Vim2.
  

Technical Training & Support:

• Provided training to technicians on instrument calibration, HART communication, motor control cabinets, and DCS loop testing.
• Conducted Permit to Work training.

Daily Activities:

• Carry out preventive and corrective maintenance for Poly1, Poly2, and SSP plants.
• Ensured all maintenance activities were logged and managed through SAP.
• Conduct daily analysis of critical motor parameters via trend analysis on the Emerson DeltaV DCS, providing timely anomaly reports to top management.
  
  

Poly Condensation Unit Development (N14-A: 400 TPD, $15M):

· Played an instrumental role in the development and implementation of control logic and graphics for a poly condensation unit on Emerson DeltaV v14.3.

· 812 I/Os, 36 graphic pages, 610 control modules

· Implemented control strategies including 2-step motor control, PID, cascaded PID, feed ratio controls, and totalizers.

· Development of all graphics.

· Configured trends, alarms, and interlocks for optimized process monitoring and safety.

· Performed all loop testing, and instrument calibration (including 24 level transmitters, and 21 flow meters).

SCADA System Revamp (Network of 250 Energy Meters):

· Revamped the SCADA system, increasing active energy meter count from 57 (22.8%) to 238 (95.2%).

· Implemented MODBUS 485 communication for data collection from 25 Schneider PM5300, 6 Siemens PAC3200, and 5 Circutor C4 energy meters, utilizing a Schneider gateway to convert data to MODBUS TCP for seamless integration with the WinTr SCADA system.

· Implemented load segregation for enhanced energy usage analysis.

Energy Optimization:

• Successfully reduced regeneration air consumption of N4's pressure swing adsorption dryer by 67% by implementing dew point controls, resulting in savings of 47,000 units of energy.
  

Instrumentation & Configuration:

• Successfully configured Emerson's Micromotion Coriolis mass flow meter to volumetric gas for HTM oven's fuel consumption.
  

Technical Review:

• Reviewed PIDs, Electrical drawings, DCS IO schemes, and Instrument manuals.