SIL Solver
LOKESH MOHAPATRA
Instrumentation & Control Professional
Bengaluru
Summary
Scaling new heights of success with hard work & dedication and leaving a mark of excellence on each step; targeting challenging assignments with leading reputed organization
Overview
14
14
years of professional experience
Work History
Lead Engineer, Instrumentation & Control
QuEST Global
05.2023 - Current
- Reliability support to Exxon Mobil assets from up-stream, mid-stream & product solution sites.
- SIL verification of safety loops in-line with IEC-61511 guidelines, identification of any potential gaps in safety practices, providing alternate approach to achieve SIL targets in order to minimize the risk & increase instrument availability
- Asset surveillance with CBM strategy to minimize likelihood of instrument failures, maximizing asset life-span, optimizing PM cost and reviewing test procedures to identify any lapse
- ACA (Asset Criticality Analysis) of Plant instrumentation
- RCA (Root Cause Analysis) of prominent failures • Developing equipment strategies for various types of filed instruments using RCM techniques• Instrument lifecycle management of critical control systems of various business units
- Risk based work selection approach for upcoming turn-around activities
- Alarm Management & Rationalization in-line with IEC-62682 & ISA-18.2
- Preparation of database for Developing Maintenance Record Mobility App for Safety critical devices
Deputy Manager
Coal Gasification Plant, Jindal Steel & Power
04.2019 - 04.2023
- Leading Instrumentation maintenance team with 6 team-members for Coal Gasification Plant
- Handling O&M activities, monitoring routine PM/CM calls, managing planned & emergency shutdowns, managing manpower resource and material planning
- Coordination with various stake holders - Plant Operation, Central reliability, Mechanical & Electrical Maintenance, Workshop, Procurement Group, Technology Group, Design & Engineering Team, Project Team and various OEM Vendors etc
- Material management through Inventory Modelling in SAP MM module
- Categorize equipment as per Asset Criticality Analysis
- Preparing Annual Budget for routine activities, reliability and shutdown jobs
- Prepare & schedule PM plans with SAP PM module
- Managing dashboard KPIs – PM/compliance, weekly & monthly planning, material inspection, MOC status
- Initiating, reviewing and executing MOC (CAPEX & REVENUE) for various upgrades, modification or expansions, Obsolescence management & system upgrades with Instrument design
- RCA (Root Cause identification) of various incidents and Implementing recommendation
- Ensuring 100% compliance on HSEF (Health, Safety, Environment, Fire), Legal advisory, Trainings with no compromise
- Developing competency and proficiency of team members through CAS (Competency Assurance System)
Control & Instrumentation Manager
Pet Coke Gasification, Reliance Industries Limited
09.2015 - 03.2019
- Successfully commissioned world's largest Pet-coke Gasification Complex (Technology by CB&I, engineered by Fluor) including units -Gasifiers, Rectisol Wash Unit (AGR – Technology by Linde), Sour Water Strippers (SWS), Sulphur Recovery Units (SRU – Technology by Worley Parsons), Sulphur Formation Unit (SFU – Technology by Enersul) by strategic planning and optimized resource management.
- Installation, Commissioning & Maintenance of AGR Instrumentation
- Project commissioning & execution with design basis and specifications for DCS, ESD, PLC, Control Valves, Isolation, Shutdown Valves, & Field Instrumentation
- Supervise and execute all instrumentation calibration and maintenance of control valves
- Investigate & troubleshoot maintenance problems for different types of control valves like Globe, butterfly, ball etc.
- Implement permit to work procedures.
- Ascertain availability and operability, update maintenance records & history in SAP.
- Control loop tuning for various types of controls loops like normal Level/Flow/Pressure/Temperature loops, Cascade loops, Split range loops & Ratio control loops etc. for smooth plant operation.
- Logic & Sequence checks of program as per Cause & Effect Matrix & Control narrative.
- Rationalizing alarm set-points based on operation & implementing Alarm Management System as per IEC-62682 standards.
- Creation of instrument tag database and linking to spares & BoM (Bill of Material) in SAP.
- Carry out I/O segregation & allocation to achieve redundancy.
- Factory Acceptance Tests (FAT) of DCS & ESD systems.
- Inspection of instruments at site as per their spec (datasheets,hook up drawings,P&ID & inspection check-lists).
- Readiness of DCS & ESD system for plant operation as a part of Site Acceptance Test (SAT).
- Completing Pre-Power on checks & powering on all Instrument control panels.
- Verifying installations of all field instruments, JBs, transmitters, control & on-off valves as per ITP (Inspection Test Plans).
- Loop check of Fire & Gas devices, machine monitoring MCMS instruments, analyzers.
- Cold & hot loop check of all field instruments before start-up.
- Configuration of FF (Foundation Fields) & HART instruments (Transmitters & control valves).
- Calibration of all field transmitters.
- Testing serial link communication between third party items to DCS.
E&I Maintenance Engineer
Pokarna Engineered Stone Limited
12.2013 - 09.2015
- Reduced downtime through efficient troubleshooting and root cause analysis of equipment failures.
- Developed preventive maintenance schedules to minimize downtime and optimize performance.
- Performed root cause failure analysis on critical equipment, leading to more effective preventative measures.
- Documented maintenance activities and confirmed compliance with relevant regulations.
- Enhanced safety standards by conducting regular inspections, identifying hazards, and recommending corrective actions.
- Reviewed technical documentation to complete equipment maintenance and repair.
- Trained and supervised staff on equipment maintenance and safety procedures.
E&I Maintenance Engineer
PSL Limited
06.2010 - 11.2013
- Reduced downtime through efficient troubleshooting and root cause analysis of equipment failures.
- Developed preventive maintenance schedules to minimize downtime and optimize performance.
- Performed root cause failure analysis on critical equipment, leading to more effective preventative measures.
- Audited existing preventive maintenance plans, updating them based on current needs to reduce unnecessary expenses or redundancies.
- Coordinated with cross-functional teams to develop and implement process improvements for enhanced efficiency.
- Streamlined work order processes, resulting in faster response times and reduced backlog.
Education
Bachelor of Technology -
Biju Patanaik University of Technology
Odisha 04.2001 -
Higher Secondary Education -
M.P.C Junior College
Baripada, India 04.2001 -
Secondary Education ( 10th) -
M.K.C High School
Baripada, India 04.2001 -
Skills
Project Management
Installation & Commissioning
Testing & Inspection
Process Enhancement
Operation & Maintenance
Troubleshooting
Material Management
Safety Management
Coordination
Team Building
Reliability
Asset Management
Software
ExSILentia
Conval
Credo
SAP
Siemens Sematic Manager step 7
GE Mark VIE
Invensys Foxboro
Triconex
Honeywell Experion SCADA & Honeywell Safety Manager
Languages
English
Bilingual or Proficient (C2)
Hindi
Bilingual or Proficient (C2)
Timeline
Lead Engineer, Instrumentation & Control
QuEST Global
05.2023 - Current
Deputy Manager
Coal Gasification Plant, Jindal Steel & Power
04.2019 - 04.2023
Control & Instrumentation Manager
Pet Coke Gasification, Reliance Industries Limited
09.2015 - 03.2019
E&I Maintenance Engineer
Pokarna Engineered Stone Limited
12.2013 - 09.2015
E&I Maintenance Engineer
PSL Limited
06.2010 - 11.2013
Bachelor of Technology -
Biju Patanaik University of Technology
04.2001 -
Higher Secondary Education -
M.P.C Junior College
04.2001 -
Secondary Education ( 10th) -
M.K.C High School
04.2001 -
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