Competency Demonstration Report: Control System Revamp Project-Yanbu

This document presents a competency demonstration report for a Control System Revamp project undertaken at Yanbu, Saudi Arabia, by a Project Engineer from Yokogawa Services Saudi Arabia. The project involved designing, procuring, installing, and commissioning a Yokogawa Control System, including DCS, ESD, and FGS. The engineer's responsibilities spanned from detailed engineering and design to factory and site acceptance testing, ensuring compliance with project specifications and SABIC standards. Key accomplishments included cost reduction through the reuse of existing system cabinets and negotiating discounts with vendors. The report highlights challenges such as meeting deadlines, tracking project progress, and innovative solutions like replacing power supply units with a more reliable brand. The project's success is attributed to effective teamwork, clear communication, and adherence to quality standards, resulting in enhanced plant operations and increased productivity for the end-user.

COMPETENCY DEMONSTRATION REPORT
Career Episode 1
MOHSIN BAJWA

CE 1.1 Project Information
Name of the project: Control System Revamp Project
Location of the project: Yanbu, Saudi Arabia
Project Duration: Jan13, to Aug, 13
Organization: Yokogawa Services Saudi Arabia Company
Role and Designation during the time: Project Engineer
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
The Arabian Industrial Fibers Company, a subsidiary of SABIC (Saudi Basic
Industries Corporation), has selected Yokogawa as their Process Control System (PCS) vendor
for their Control System Revamp project. The project scope was to Design, Procure, Install, and
Commission the Yokogawa Control System which includes Distributed Control System (DCS),
Emergency Shutdown System (ESD) and Fire and Gas Control System (FGS).
CE 1.2.2 Objectives developed for the project
As a project engineer, I set the following objectives and goals for the successful delivery
of the project:
 To provide quality hardware, software, engineering services, Installation services
and commissioning services
 To manage and deliver the entire project within the budget and agreed schedule

 To deliver the highest standard of the products and services
 To manage the operational activities in an efficient and effective manner
CE 1.2.3 My area of work
I was assigned as the project engineer, and hence, it was my job to ensure that the project
does not lack in any sector and all the expected outcomes are being delivered. I had to manage
the site and assure that every individual is delivering and accomplishing their sector of jobs. I
developed the schedule of the project and relative activities of the project and executed LDs
(Liquid Damages) on vendors in case of failure to meet the project deadlines. I prepared the
documentation of the regular progress and growth of the project in manner to collect and store
the on-going growth of the project. I was very much aware of the given timelines for the
completion of 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 1.2.4 Project Group
CE 1.2.5 My responsibilities throughout the project
I was responsible for the successful and smooth implementation of control system
revamp project from Design till Commissioning as per project specifications and SABIC
Standards. In addition to this following are some of my explained responsibilities for the delivery
of the entire project:
 Reporting to the Yokogawa Project Manager
 Responsible for the detailed engineering, design, assembly and testing of the system
 Responsible for Factory Acceptance test (FAT) of the System
 Responsible for Installation of the control system at site
 Responsible for the Site Acceptance test (SAT) of the System

 Compliance with the relevant Project Specifications/ SABIC Standards
 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
 Preparation and control of project documentation (revisions, quality checks,
transmittals etc.)
 Liaison with Project Administrator for maintaining Project Document Register
 Adhering to the Project Schedule & Project Quality Plan
 Tracking of Scope of Work deviations
CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the theory of the project
The project was all about providing better services to the end users and assure that the
project being delivered is meeting the project constraints and end users are satisfied with the
products and services being provided to them. I set the standard and quality of the services being
delivered at the most crucial factor for the satisfaction of the end users. I had to accomplish every
responsibility as mentioned above in an efficient and effective manner.
CE 1.3.2 Engineering knowledge and skills applied in the project
I prepared DED (Detailed Engineering Designs) in accordance with the new design
calculations, and presented to the Project Manager along with the overall cost reduction which
would have a greater impact on ultimate gross profit. I was able to have an overall 10-15 percent
cost reduction of Control system Hardware due to the reuse of existing System and Marshalling
cabinets. Twenty percent discount was taken from power supply unit vendor for giving
preference and getting them approved by End-user. I took the next step to prepare and submit

“Critical Design review” (CDR) report which consisted mostly of the software parts and the
control logics created as per the project control narrative. I delivered the following deliverables
including PDR are I/O Database in MS-EXCEL/MS-Access format containing DCS/ SIS / FGS /
I/O details – Final for CDR (for software freeze), Mapping list in MS-EXCEL containing Sub-
system I/O details, List of critical loops/ valves, Graphic Display Sketches/Marked up P&ID
(Final), DCS/FGS & any other sub systems Control Narratives with Calculation details, ESD
Start-Up/Shutdown narratives, ESD Cause & Effect Diagrams, Mapping list in MS-EXCEL
containing Sub-system I/O details (in Yokogawa Format). Furthermore, I made the presentations
on completion of each milestone and present to the Project Director and Project Manager to have
their consent and guidance. I gathered the requirements set in the technical specification of
control system that was helpful in leading the project towards success. I had a detailed site
survey along with control system Engineers to finalize the space requirements for the new
system. Subsequently, I evaluated End-user requirements and grouped it into “general design
inputs” in line with their technical specifications.
CE 1.3.3 Accomplishment and task performed
I was assigned the duty to go through the scope of work and project requirements which
were requested by the End-user. I had to prepare a project schedule along with the planning
Engineer to explain the customer about the critical milestones of the project during the Customer
Kickoff Meeting. I managed the project with guidelines and motivation from Project Manager. I
prepared a comprehensive cost analysis of the prevailing System and I observed that almost 60%
of the space was consumed by System cabinets. Due to the old technology, the components
inside the existing cabinets were not of compact type. I was able to convince the end-user that we

can use the existing cabinets and a lot of spare signal requirement can be fulfilled as per the
SABIC standards that was accepted by the end-user.
CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
The accomplishment of the project within the expected deadline was the major obstacle
and identified problem while delivering the project and could have possibly influenced the
satisfaction level of the end-users. Tracking the current growth and development of the project
was another considerable factor while delivering the project as it could be the possible way for
considering the amendments and changes necessary for keeping the project on the track.
1.3.4.2 Solutions
I developed a well strategic and explained project plan that helped in motivating every
other individual to be specific and targeted towards the set goals and objectives. I developed a
detailed project plan explaining every necessary activity and involved stakeholder in manner to
make sure that every stakeholder is dedicated and concentric towards accomplishing the same
activity.
CE 1.3.5 Plan to produce creative and innovative work
Earlier control system projects which were executed in other petrochemical plants, the
power supply units used by Yokogawa for powering the electronic devices were manufactured
by Phoenix. But due to recent malfunction in the power supply devices, I stopped recommending
Yokogawa and replaced it with Weidmuller brand considering the specifications set in “project
requirements” which was recommended to go with Phoenix. I brought into the customer’s notice

about our past experience with this brand and raised a waiver against the technical specification
for using Weidmuller instead of Phoenix that was accepted by the end-users.
CE 1.3.6 Collaborative work
I was managing the project constraints however, there were almost every sector, where I
would be needing the support from the team in manner to accomplish them in an efficient and
effective manner. Every team member has successfully contributed in accomplishing the project
constraints under my guidance. I assured that effective communication is being established
among the team members and everyone is indulge in expressing their perspectives about the
growth and development of the project.
CE 1.4 Project Review
CE .4.1 Project Overview
The Project was completed within the defined time period and as per the allocated
budgets in accordance with quality standards. The main objective was to install new control
system which will help the end-user to control the plant operations and increase its productivity
level and those were effectively being accomplished. I managed to reduce the cost of the project
by closely communicating with the End-user project team and tried to convince them about the
deviations from the project specifications. The project was successful as a team work and being a
project Engineer I motivated my team to work as One Team, One Dream.
CE 1.4.2 My contribution to work
I assigned the responsibilities to specific persons and the team members for each
component task. Respective Control System Engineer’s responsibility was to design, configure,
and test the Control system Application, Software and Human Interface. They will deliver a

system with compliance to the relevant project specification/Customer Standards and
specifications. Preparation and control of project documentation relevant to DCS, ESD, FGS
Application Software (revisions, quality checks, transmittals, etc.)They were assisted by a team
of HMI graphic developers and Auto cad draftsmen. As to prepare the cost effective and project
specific hardware and software, first the “Preliminary Design review” (PDR) report was
generated which consist of documents like System Development Plan, Bill of Material, I/O
Database in MS-EXCEL/MS-Access format containing DCS / ESD/ FGS I/O details with
area/sub area segregations and Field Cable Schedule (For hardware freeze), Control room
layout / PIB layout / Cable tray Layout / Cable routing, Sub-system Interface hardware details,
Graphic Display sketches. So for this purpose, I organized a meeting of both End-user project
team and Yokogawa Project team for a review meeting to further clarify any expectations of
End-users. Following this, the Design was finalized to start procuring the hardware.