MAHADEVAN MARTHANDA PILLAI
SENIOR INSTRUMENT ENIGNEER
Summary
Dedicated and seasoned Instrument & Control Engineering Senior Engineer with a bachelor's degree in Instrument Engineering and with 25 years of comprehensive experience in delivering excellence in subject area engineering, maintenance, project management, construction, commissioning of Control System and Field Instruments in various oil and gas facilities with in-depth technical knowledge and leadership skills. I am also a TUV Certified Function Safety and IET Chartered Engineer. Adept at leading teams, providing safety leadership, and contributing to operational performance improvement with my 25 years of experience, proven track records in large scale projects and operations with in-depth working knowledge about Instrument and Control Design, Engineering, Commissioning, Operations support and to secure a responsible position in a challenging environment. Profile highlights in BP: A result-oriented Instrument/Control Systems Engineer offering over 25 years of experience (10 Yrs. in Azerbaijan, 5Yrs 6 months in Dubai, 5Yrs 2 months in Kuwait and 4Yrs 3 months in India) in Oil & Gas, Petrochemical and Refinery industry handling operations, and maintenance. As a responsible Senior I&PS Engineer with Asset Facility Support Squad, all EPC projects with Woodgroup, Worley and Amec deliverables and Engineering assurance were reviewed and approved for Management of change Process. As a responsible Engineer, I have led to deliver a cardon reduction project and successfully commissioned Flare gas recovery project (FGRU1). FGRU1 successfully recovered 1MMSCFD from flaring. As a responsible Engineer, I have led to deliver a cardon reduction project and successfully tested Flare gas recovery project (FGRU2). FGRU2 is ready for startup once required N2 quantity is ensured by Operations by which 1MMSCFD gas from flaring will be recovered. Talented engineering professional with a passion for developing innovative solutions to complex engineering problems. Specializes in design, development and implementation of cutting-edge technology. Adept at analyzing and interpreting large amounts of data to create effective solutions. Highly motivated and organized with strong communication and problem-solving skills. Innovative team player with a knack for creating efficient solutions to complex engineering problems. Highly experienced in design, development, and implementation of innovative systems. Proven track record of successful project completion and meeting project deadlines. Possesses excellent communication and problem-solving skills, with a strong focus on customer satisfaction. Accomplished engineering professional with experience in designing and developing complex engineering projects. Skilled in computer-aided design, problem-solving, and project management. Proven track record of delivering successful projects on time and within budget, while ensuring superior quality standards. Adept at working with cross-functional teams and a wide range of stakeholders to achieve desired results. Hardworking, highly motivated professional eager to lend combined knowledge and skills to enhance business performance. Operates well in both individual and team capacities, leveraging seasoned work ethic to quickly adapt to different processes and drive company objectives. Resourceful and results-driven with a passion for growth and efficiency to meet company needs and increase service value. Ambitious individual with strong organizational and multitasking skills, as well as an aptitude for technology. Ready to apply knowledge and skills to any challenge. Dedicated professional with proven performance in management, leadership and communication. Detail-oriented in problem-solving and planning. Ready to make an immediate contribution to your organization. Possesses versatile skills in project management, problem-solving, and collaboration. Brings fresh perspective and strong commitment to quality and success. Recognized for adaptability and proactive approach in delivering effective solutions. Experienced leader with strong background in guiding teams, managing complex projects, and achieving strategic objectives. Excels in developing efficient processes, ensuring high standards, and aligning efforts with organizational goals. Known for collaborative approach and commitment to excellence. Results-oriented achiever with proven ability to exceed targets and drive success in fast-paced environments. Combines strategic thinking with hands-on experience to deliver impactful solutions and enhance organizational performance.
Overview
26
26
years of professional experience
2
2
Certifications
Work History
Senior I&PS Engineer
BP- International Energy Company
01.2018 - 06.2024
- I am responsible for HAZOP/LOPA support, SIL verification, Barriers Health Review and IPLs Self verifications
- Being a Discipline Responsible Engineer (DRE), I am responsible to update for scheduling Self Verifications and Barrier Health review on I&C Barriers
- I review technical bulletins from different vendors and asses the risks associated with installed instruments
- Advise solutions and forward plan to Discipline lead for Engineering and execution
- I am mentoring two Instrument Engineers and one challenger
- Being a DRE, I am responsible for Instrument's and ICSS Hardware/ Software design and specifications review
- I am responsible for Emerson and ABB ICSS Systems budget forecast for four Onshore Oil and Gas assets
- I have assessed Midstream I&C Engineers eXcellence road map and related gaps are planned for actions to fill the identified gaps
- I assess my team members Discipline Responsible Engineer (DRE) reward readiness and identify the gaps
- Assign appropriate actions to fill the gaps to attain DRE ship
- I am responsible for performing incident investigation using RCFA and 5 WHYs investigations
- As a responsible Senior I&PS Engineer with Asset Facility Support Squad, I perform Self Verifications on Performance Standards and Barrier Health Review on Protection Barriers P6, P7 and P8 barriers as well as Mitigation Barrier M6 F&G mitigation barriers
- I am responsible to track the gap actions for completion
- I am responsible to provide all sort of technical support to team I&C Engineers and Challenger
- Being a Senior Engineer, I am responsible to update the Engineering Leadership Team in bimonthly meeting and provides Regional Technical performance on Control & Automation, Digital Security, major achievements, resource management, M&T, identified gaps etc
- Being a Regional Digital Security SPA, I provided quarterly update to Central PCN CoE Team on DS Performance, Gaps identified through Self Verification and action plan
- I discuss with my Line Manager for the requirement of summer internship program to select Challengers and provide chance for my team members to mentor challengers
- I do mentor for my Engineers for getting prepared for the DRE assessment and do preliminary assessment to ensure the readiness level for final assessment
- I have provided enough supportive reference materials for DRE assessment
- As a Lead, I have done the Self-verification assessment for Digital Security to ensure that all existing networks of control systems are comply to BP Digital Security Standard GP 30-60
- All identified gaps were assigned to responsible actioner for completion and ensured to get all completed on defined timeline with routine review meetings
- I am the Contractor Accountable Manager (CAM) for Siemen's contract where I am accountable to monitor and track the budget spend by the contractor
- I am responsible to add scope with all justification and present it to Stake Holders for budget approval
- As a Senior I&PS Engineer, I have attended Recruitment Training as one of the Interviewer in the Resource Selection Process
- I have interviewed Automation Engineer for promotion, Challengers, and summer interns through usual recruitment process
- I have been managing work assignments for my team Engineers and ABB Health Care Engineers to make sure work assignments are balanced and completed on time
- I am also responsible for all software modification's download sequencing to ensure no clash between ongoing projects
- I had liaised with all associated project SPAs to understand safety and business risk, accordingly, sequenced various projects
- I have led a vulnerability action which reduced spurious trip because of Power Supply degradation and Controllers Firmware Upgrade on Controllers
- This activity involved high risk to production during implementation as it was an online execution activity
- To ensure that all inhibits are in place, I have done a thorough review with respect to Cause & Effect and System configuration and, then finalized the INIHIBIT tags.With these tags, I have done testing offline on the development system with the vendor and ensured there is no error on testing
- With the test report, I did operational risk assessment in discussion with Process and Operations Team Leader and processed for management approval
- With all prior approval, I have safely executed PSU replacement and firmware Upgrade and eliminated vulnerability form two set of Controller Nodes
- I am responsible for managing eleven ABB Healthcare Engineer's work assignments and weekly timesheet approval
- I have ensured that man hours are optimized on Healthcare and Project implementation cost without any additional resources
- I have also managed to resource expertise from local and optimized project cost
- I am responsible for my team member's annual job plan, midyear and annual performance appraisals review and provided feedback to my Line Manager for appraisal ranking
- I have a formed midstream Control & Automation community and having monthly meeting to ensure knowledge through experience was shared to every member of the team in an open forum
- Individuals' development and training requirements are addressed to Line Manager for my team members development
- Every new idea as part of continuous improvement can be brainstormed for further action and implementation to enhance the business by which individuals are encouraged through rewards
- I have led two incident investigations one led to production deferral and second one led to Fire Zone alarm activation which triggered General Alarm from 13 zones
- The first incident was a Digital Output card failure for which I started with the survey at site to understand that any other simultaneous scopes were ongoing during the incident, interviewed System Healthcare Engineer, went through all diagnostics alarm messages, alarm log, sequence of events and understood the pre-alarms prior to the failure, interviewed Process Operator and took the short term action to test the DO card in test system and observed the performance
- I have submitted a 5Y report with assigned actions
- I had developed 5Ys report and found the root causes were insufficient survey and improper design on power supply requirement for new Modem
- Without clear understanding of Power supply distribution to existing modems which are daisy chained, crew disconnected power to first modem which generated alarms on all remaining fire zones which were not inhibited
- Interviewed EPCM Project Engineer and understood the reason for incomplete survey and incomplete design
- This gap has been taken as a lesson learned and I had a discussion with EPCM Engineering Manager to ensure and follow the Project Design and Execution strategy
- I am responsible for Control System and third-party System Obsolescence Management
- I have developed 5 years Roadmap as part of Obsolescence Management and submitted to management for system upgrade and additional spares budgeting for another 5 years to mitigate obsolescence risks
- I developed 5yrs road map for below systems
- ABB AC400 series Control System and application software, Allen Bradley PLC5/40, Control Logix 5563, MicroLogix, ICS Triplex Safety System, Siemens S7 PLC, BN3500, System#1 upgrade due to Digital Security risk, Siemens Fastflex PLCS and Cromos Application software, Siemens LOGO 24 and HIMA Sella H51q (HIQUAD) with Magelis HMI
- I have reviewed various projects Design and Engineering deliverables, work packs, commissioning procedure, hot cutover procedures, commissioning & Operational spares and as built documentation
- I was the Lead for Baku Tbilisi Ceyhan ABB 800XA application version upgrade and firmware upgrade at Terminal and all block valve stations at remote locations
- It was implemented successfully in 36 hours TAR
- As a pre-TAR activity, it involved disconnection of existing secondary network-B and established new Client Server B network by reconfiguring the network with already tested switches and servers.
Senior I & PS Engineer
BP EXPLORATION (CASPIAN SEA) LTD
07.2013 - 12.2017
- ICSS System from ARMOR have multiple layers of access control starting from entry to building, second layer is access entry to ARMOR, third layer is password protected user access to Windows Operating System and fourth access to through ROHOS key which is password protected and authenticated from Centrally Managed Unified Access Control
- During every stage review of vendor deliverable, I have ensured that Vendor design is in accordance to BP ETP Standards, especially Digital Security which gives more vulnerability to Operations through ICSS
- In the project kick-off meeting, I have requested ABB to submit four key documents namely 1
- BP Standards Compliance Statement, 2)ABB's QA/QC Management Plan, 3)Inspection and Test Plan and 4)ABB's Proven experience on such technology
- I had weekly progress meeting with ABB and tracked project progress with action plan on ABB Stakeholder's and BP Stakeholders
- I had challenged ABB Engineering manhours and materials proposal and ensured ABB Proposals are at competitive price
- I have commented on lumpsum proposal and challenged ABB on Bill of Materials and Engineering man hours
- I have asked ABB to resubmit the proposal with BOM price split up and ensured materials costs are transparent for future use as well as verified with previous price
- With this revision, ABB proposed all materials and software licenses with respect to corporate prices and forced to reduce the proposal value by 110,000$ by which project cost has been saved
- As this project involved Telcom scope, design was discussed with Telecom Lead and got their approval
- I have tracked project cost by tracking all shopping carts and Purchase orders and reported to management
- I have reviewed and approved all Engineering deliverables and went for Factory Acceptance Test at ABB St
- Neots office and completed the FAT with punch lists which was asked to implement before system dispatch from ABB UK
- I have done work break down structuring for this project in discussion with ABB and Site Scheduler for offshore installation and commissioning activities and discussed with Operations for Offshore POB
- I had a review with ABB and ensured that commissioning resources are available for same time slots
- I had full control on budget and have a continuous track on ABB budget for this project
- I have challenged with my comments on each proposal from ABB both for services and materials and got it revised to ensure that the Proposals are at optimized cost
- In this project I liaised with Telecom Lead, Central PCN Team, IT&S Team, Regulatory & Company affairs Team, PSCM buyers, account payable team, Logistics Team, Area Operations of six assets, Electrical Team, Facilities Management Team and Five contractors to progress the project as per schedule
- I am responsible to review the Annual System Healthcare Asset audit report for all four assets of midstream in which I reviewed the field event queries, spares report as per spares management, system downtime audit and action closure, personnel competency matrix profile report for four Healthcare Engineers, System users register report and System Digital security audit report with respect to AV, hotfixes and Microsoft patch updates
- All conformances used to be discussed with ABB Delivery Manager and NCR used to be raised for further actions to eliminate re-occurrence
- I led the team for ABB Bengaluru Engineering Centre Audit to ensure the ABB's capability as per BP QPM for Contractor's Engineering Centre
- I did quarterly audit with TA and ABB's Baku office team
- During this audit, I have done the audit on below capabilities
- Personnel competency of the team as per asset competency matrix
- R&D Centre for system upgrade and testing
- Engineering workshop for software coding and hardware testing
- Functional safety Team competency, internal audit and Quality audit procedures
- Internal quarterly audit on job completions and NCR reports
- Center's success on completed projects for the past five years
- Internal quality rewards
- I lead new flow line addition and conversion software modifications through MOC in line with Engineering Technical Practices
- I have completed more than 20+ flowline's software installation in a year
- Responsible for revising BOD for Slug controller modifications and implementation to protect the existing production through management of change procedure
- SPA for Mechanical Key interlock on Oil and Gas Pig Launchers of four assets which involves review of key interlock sequence based on SOP, minimize number of keys to avoid any complexity for Operators, review engineering deliverables, process MOC with all necessary documents, do What-IF analysis, liaison with offshore team for safe execution
- Debottlenecking of slug controller performance by upgrading the choke communication through Modbus through Management of change procedure
- Responsible for review of ABB Workpack, witnessing software FAT, Hardware FAT, quality audit on hardware, MOC closeout after implementation
- Responsible for update of Standard Operating Procedure, SRS, P&IDs, Cause & Effect and Function logic diagrams
- Responsible for explaining ongoing projects like flowline and slug controller software modifications to challengers and ensure fully familiar to witness software FAT
- SPA for a 3.0 M USD ARMOR Room Project with an objective to provide collaborative support for six offshore assets where ABB XA800 Systems are installed
- It is a cost optimization project where BP will save 1M USD per year on Healthcare Management
- Basis of Design developed for ABB
- As a project lead, I am accountable and responsible for the completion of this project
- I have reviewed the FDS and addressed all concerns from different stake holders of sex assets and approved for detailed design
- Liaised with vendor and local contractors for the survey, Proposals review, review of FDS, Details design of ICSS and Network, Digital Security Design, Firewalls rules setting, Project schedule, material delivery, Unity Engagement construction, commissioning, and handover
- Project is expected to complete by Dec 2017
- As a SPA for Produced Water management Project (Cat C Project) for West Chirag tie-in with CA & DWG assets, I am responsible for the review of the EPC Contractor's I & C related Engineering deliverables, contribution in HAZOP and LOPA, and Management of change process to ensure Project deliverables are in line with BP best Practices for safe and reliable operation
- SPA for High Valve action to ensure Instrument Protective Systems in Produced Water System is highly reliable and integrity of the safety functionality to protect the “Oil Release to Environment.”
- I am responsible to review Instrument Specifications and third-Party Control System devices in SAP
- I am also responsible in doing quarterly audit in ABB INOPC Engineering Centre to ensure ABB INOPC is capable to deliver AGT software modifications with high-level of integrity, having resource development plan in place, having plan to overcome resource attrition, facility capable of doing hardware and software modifications in time, capable to do 4Q analysis
- As a Discipline Responsible Engineer, I am responsible to ensure Instrument and Control related Modifications are as per BP Technical Practice Standards for safe execution and reliable operation
- Since the project involves multi-disciplinary (IT&S, OCT, DET and ABB Contractor) scope, I am in liaise with
- SPA for upgrading Level Transmitter to Nucleonic Level Tx on four Separators which involves gate review, design document review, Engineering deliverables review, preparation for nuclear source import license, Liaison with Vendor and Contractors, Process MOC, do risk analysis, review Workpack, liaison with Project and Mods team for vessel entry for mechanical installations and liaison with offshore for safe implementation
- SPA for Mechanical Key interlock on Oil and Gas Pig Launchers of four assets which involves review of key interlock sequence based on SOP, minimize number of keys to avoid any complexity for Operators, review engineering deliverables, process MOC with all necessary documents, do What-IF analysis, liaison with offshore team for safe execution
- Review Survey report, MTO, Engineering drawing and, Workpack submitted by contractors and ensure that all documents are complied with BP Policies and Procedures
- Responsible for review of ABB Workpack, witnessing software FAT, Hardware FAT, quality audit on hardware, MOC closeout after implementation
- Responsible for update of Standard Operating Procedure, SRS, P&IDs, Cause & Effect and Function logic diagrams
- Responsible for determining the risks versus projects benefits for online software implementation and mitigate the risks with appropriate risk reduction steps and ensure mitigation measure are followed.
Senior Systems Engineer
DUBAI PETROLEUM
12.2007 - 06.2013
- Lead for a Control System Revamping Project which involves replacement of RS3 DCS with FOXBORO I/A DCS and TRICONEX ESD System for which Engineering is under progress
- My role involved reviewing of Vendor documents, configuration (ESD & DCS), Construction, installation, execution through cutover and as built markup
- Worked as Team Leader for the DCS upgrade project for AFP/K2 Production Facilities Platform of Dubai Petroleum
- This project deals with migration fromRS3 DCS to Foxboro DCS and Triconex ESD
- Engineering & design activity of DCS upgrade project is carried out in-house in coordination with DCS vendor
- Preparation of Commissioning Procedure, Task Risk Assessments and Hot cutover Strategy for System Commissioning
- Hot cutover of two platforms was successfully completed ahead of schedule and saved $100, 000 of vendor services
- Presented Hot Cutover Strategy to Management Staffs for approval
- My role involves Engineering, Design document for construction and demolition, software modification and as built review
- Monitored system performance, troubleshot issues, and applied software patches to maintain stability
- Diagnosed and resolved technical problems related to server infrastructure or application environment
- Planned for and coordinated upgrades, patching, and maintenance of enterprise server and storage systems
- Evaluated system architecture to verify security and scalability
- Developed and approved project plans, schedules, and budgets.
Lead Control System Engineer
ALMEER TECHCIAL SERVICES
10.2002 - 12.2007
- For a team of 10~12 executives for Control System Design, Detailed Engineering Services for EPC Projects & Local Contractor Projects, Preparing Quotation, Bill of Materials, Document preparation for Client approval and Maintenance Services of EMERSON DCS (RS3 & DeltaV) Projects; report to the Systems & Solutions Division Manager
- I have been to visited Spain, Netherlands, Cyprus, UK and Korea for Project Kick-off Meeting, Conference and FAT
- Conducting well organized System FAT & IFAT
- Attended FAT for DeltaV System of KOC in EMERSON-KOREA
- Had been performing DCS Maintenance & Project Execution in PWI5, UMMBAB & DUKHAN of QATAR PETROLUEM for a span of 6 months during the year 2004~2005
- Accountable for Preventive & Corrective Maintenance jobs at 14 RS3 Centers and 4 DeltaV Centers in KOC & KNPC.
Maintenance Shift Lead
MANALI PETROCHEMICALS LTD
04.1999 - 09.2002
- Responsibly handled the maintenance of various field Instruments like Transmitters, Various types of Control Valves, Control Systems and Switches
- Also supervised Electrical, Civil & Mechanical jobs
- Oversaw the Instrument, Electrical & Mechanical Maintenance as a shift-in-charge of MPL, Chennai; assisted by a team of 10 executives and reported to the Maintenance Chief Manager & Senior Manager
- Responsible for routine shift Maintenance of all the Instruments, Control Valves, Control System, Motors & Pumps etc
- Efficiently handled the RS3 DCS, YOKOGAWA CENTUM-V & MICRO-XL
- Supervised a team of 15+ personnel across multiple shifts while overseeing their daily tasks
- Coordinated emergency repairs when necessary to minimize disruption of plant operations
- Ensured adequate staffing levels were maintained throughout shifts to meet production goals
- Implemented corrective actions as needed to address any issues identified during inspections
- Monitored daily production activities, ensuring compliance with safety standards
- Collaborated with other departments to ensure effective communication between shifts.
Instrument Trainee
KOTHARI PETROCHEMICALS LTD
06.1998 - 04.1999
- Calibration and Maintenance of various field instruments like Transmitters (Fisher Rosemount and Yokogawa), Pressure and Level Switches, pH and Concentration analyzers, Magnetic Flow meters, Vortex Flow meter, various types of Control Vales (Butterfly, Globe, Plug Diaphragm types)
- Conductivity Meters etc.
Education
B. Tech - Instrumentation Technology
Madras Institute of Technology, Anna University
B. Sc. - Physics
Manonmaniam Sundaranar University
Skills
Process Development
Certification
IET Certified Chartered Engineer
References
1. Samir Magerramov
Facility Engineering Manager,
BP AGT -PLOM; Email:
2.Hasan Bashirov
I&PS Offshore Discipline Lead,
P&O, BP AGT
Email: bashih@bp.com
Accomplishments
Chartered Engineer by IET
Functional Safety Engineer certified by TUV
Timeline
Senior I&PS Engineer
BP- International Energy Company
01.2018 - 06.2024
Senior I & PS Engineer
BP EXPLORATION (CASPIAN SEA) LTD
07.2013 - 12.2017
Senior Systems Engineer
DUBAI PETROLEUM
12.2007 - 06.2013
Lead Control System Engineer
ALMEER TECHCIAL SERVICES
10.2002 - 12.2007
Maintenance Shift Lead
MANALI PETROCHEMICALS LTD
04.1999 - 09.2002
Instrument Trainee
KOTHARI PETROCHEMICALS LTD
06.1998 - 04.1999
B. Tech - Instrumentation Technology
Madras Institute of Technology, Anna University
B. Sc. - Physics
Manonmaniam Sundaranar University
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