Wireless Temperature Monitoring of Substation Buildings in Main Control Room - Career Episode 3

The Career Episode 3 describes the implementation of a wireless temperature monitoring system in a fertilizer plant in Saudi Arabia. The project aimed to provide quality hardware, software, engineering services, installation services, and commissioning services within the budget and agreed schedule. The engineer was responsible for leading the project, detailed engineering, design, assembly, testing, installation, and site acceptance test of the system. The engineer also convinced the end-user to implement wireless technology, which reduced the project duration and cost. The project met all the requirements set in Industrial wireless standard ISA 100.11a.

COMPETENCY DEMONSTRATION REPORT
Career Episode 3
MOHSIN BAJWA

CE 3.1 Project Information
Name of the project: Wireless Temperature Monitoring of Substation Buildings in Main
Control Room
Location of the project: Al-Jubail, Saudi Arabia
Project Duration: Nov15, to March, 16
Organization: Yokogawa Services Saudi Arabia Company
Role and Designation during the time: Project Engineer
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
The National Chemical Fertilizer Company, a subsidiary of SABIC (Saudi Basic
Industries Corporation), has selected Yokogawa as their Wireless Control System (WCS) vendor
for implementing wireless monitoring technology. I was assigned as the project engineer for the
implementation of the necessary amendments those were necessary for the delivery of the
project. I had team whom I needed to motivate for the accomplishment of the entire operational
activities that could lead the project to meet the objectives and goals of the project. Project scope
was to Design, Procure, install, and Commission the Yokogawa Wireless Instruments and
Wireless system.
CE 3.2.2 Objectives developed for the project
Yokogawa project’s objective was to provide quality hardware, software, engineering
services, Installation services and commissioning services within the budget and agreed schedule

in supplying a Wireless system that will monitor the temperature of Substations and the data will
be transferred through Wireless communication to the Distributed Control System in Main
Control Room.
CE 3.2.3 My area of work
CE 3.2.4 Project Group
CE 3.2.5 My responsibilities throughout the project
I was given the responsibility to lead the project due to the successful completion of earlier
projects by me. I started this project as a ‘Project Engineer’ in November 2015 and completed
successfully in March 2016. My responsibilities were as listed below:
a) Reporting to the Yokogawa Project Manager.
b) Responsible for the detailed engineering, design, assembly and testing of the system.

c) Responsible for Installation of the control system at site.
d) Responsible for the Site Acceptance test (SAT) of the System.
e) Compliance with the relevant Project Specifications/ SABIC Standards.
f) Direct liaison with End-user Project engineers with regard to all technical issues with the
provision that all correspondence is copied to the Yokogawa Project Manager.
g) Preparation and control of project documentation (revisions, quality checks, transmittals etc.)
h) Liaison with Project Administrator for maintaining Project Document Register.
i) Adhering to the Project Schedule & Project Quality Plan.
j) Tracking of Scope of Work deviations.
CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the theory of the project
I was assigned the task to implement the wireless system in fertilizer plant. The project
was of strategic nature as it was the first installed base of Yokogawa wireless system. I managed
this project with the team of 01 DCS Engineer, 01 Design Engineer and wireless product
specialist. I managed the project with guidelines and motivation from Project Manager. I was
very much aware of the strategic nature of the project as per management instructions, budget
allocations, and fulfilling the customer satisfaction by complying with the standards for
Yokogawa product. I started my work by preparing detailed “Responsibility Assignment Matrix”
which clearly defined the participation and responsibilities of internal departments, vendors and
sub-contractors in completing tasks for a project in a given time span. I also made “Project
Execution Plan” demonstrating each and every step, clearly showing the objectives of the project
and how they will be accomplished as per site conditions.

CE 3.3.2 Engineering knowledge and skills applied in the project
I gathered the requirements set in the technical specification of project. I had a detailed
site survey along with wireless specialist to finalize the requirement of wireless instruments.
Subsequently, I evaluated End-user requirements and grouped it into “general design inputs” in
line with their technical specifications. For the successful execution of the project, I assigned the
responsibilities to specific persons and the team members for each component task. During
Bidding Stage the requirement set by the End-user was to follow conventional communication
protocol of hardwired cables. This process involves a lot of civil works as required for
establishing a network of hardwire cables between each substation to the Main Control Room
building. The cost for implementing conventional system was huge because of the requirement
of new infrastructure.
CE 3.3.3 Accomplishment and task performed
After the detailed site survey was done I analyzed the possibility of implementing
Yokogawa’s wireless technology and discussed the project scope with the wireless product
specialist. I was appreciated by the specialist for promoting company’s technology and my
suggestion of going with wireless technology was approved by the specialist. I managed to
convince the End-user about long lasting advantages of wireless technology, cost savings, and
the reduced time period of the project. The conventional protocol was going to prolong the
project duration three times as compared to the wireless protocol. The End-user was astonished
on my creative thinking and approved to implement wireless technology in the fertilizer plant.

CE 3.3.4 Identified issues and their solutions
3.3.4.1 Issues
3.3.4.2 Solutions
CE 3.3.5 Plan to produce creative and innovative work
I arranged another detailed survey for implementing the wireless protocol. I visually
checked the location of each substations for installing wireless temperature transmitters. As per
the wireless communication protocol there should not be any hurdles between the transmitter and
the Access point installed on the roof of Main control room. I gathered all the information of the
quantity of repeaters is required to have a secure and robust communication. I then prepared the
Bill of Material indicating the type and model of Yokogawa wireless instruments. I prepared
network topology by clearly highlighting the number and location of wireless access points,
temperature transmitters, and wireless routers on plant layout. The design was then reviewed and
approved by product specialist. I prepared the Material approval request and attached the
technical data sheets of wireless instruments which were to be installed in the plant. I prepared
all the other approval requests for the materials i.e. power cables, signal cables and conduits
which were to be used in the project and sent the approval request to the End-user for review and
comments.

CE 3.3.6 Collaborative work
CE 3.4 Project Review
CE 3.4.1 Project Overview
The Project was very important to the company as the wireless technology was going to
be implemented for the first time in fertilizer plant. The top management was closely monitoring
the successful completion of the project and I full filled their expectations by reporting each and
every aspect of the project on daily basis. The project met with all the requirements set in
Industrial wireless standard ISA 100.11a. I lead this project from the front foot and managed all
the teams of design consultant, vendors, and engineers for successful completion of this highly
strategic project.
CE 3.4.2 My contribution to work
I reviewed the design documents like typical installation drawings for wireless
instruments, power supply input drawings and Instrument loop drawings and submitted the
documents to End-user for necessary approvals. After receiving the approvals from End-user, I
floated the RFQ (Request for Quotation) stating the technical specifications, bill of material,
project specifications and time span for the completion of project and shared it with the
procurement department to start communicating with Yokogawa head office in Japan for
wireless instruments delivery. I instructed the procurement team to procure installation related
material locally to meet project timeline. Once all the long lead items were procured I instructed
the installation team to start the installation activities. After completing the installation of
wireless system, I was responsible to power on the system. I then drafted a Site Acceptance test
(SAT) procedure and the system was tested as per the procedure. After successful completion of

SAT I instructed project coordinator to print the design documents which includes project scope
of work, wireless instruments data sheets, wireless system configuration, typical installation
drawings, power supply input drawings, Instrument Loop drawings, Cable schedule, Material
approval requests and product catalogues and a final hardcopy was submitted to End-user as per
the purchase order terms.