Raja Bhowal
C&I Reliability Engineering & Maintenance Lead
Chennai
Summary
Qualified Control & Instrumentation Engineering maintenance & reliability Lead with proven ability to implement and maintain cost-effective methods of system testing and troubleshooting to reduce operating costs and downtime. Reliability Centered Maintenance (RCM), Performing RCA/Causal Learning as Lead, Carbon management with core knowledge on powering progress & Net Zero Emission (GHG reduction). Reviewing and suggesting modifications as per design documents and actual process conditions to increase reliability of instruments. Technically savvy and skilled at quickly learning new concepts, software, and equipment. Collaborative team player with excellent communication skills. Seeking challenging assignments in Instrumentation reliability and maintenance, Project execution, Commissioning, project management, Design engineering with an organization of repute industry. Expertise in QA/QC projects. Leading a team of 16 Engineers & Technicians with a focus on team development, training needs, coaching & mentoring by providing technical expertise, safety incidents sharing, cadences, project allocation & billing. Instrumentation Front End Engineering Design (FEED).
Overview
12
12
years of professional experience
5
5
Certifications
Work History
Technical Specialist/Lead (Reliability Engineering & Causal Learning), Continuous Improvement Lead
Shell Business Operations (Upstream, IG, C+P Oil & Gas)
03.2022 - Current
- Developing FMEA & drafting detailed Equipment care strategy (ECS) for prioritized equipment identified from MTO bad actors (Metering Instruments including Metering Class). Developed FMEA & finalized Failure modes, dominant failure modes, task types, task freq. with TA2 for Fire & Gas system, ESDV & BDV, Control System. ECS drafting under progress. KPIs on track with no red indication status.
- Prepare Gap analysis report for WI project by taking IVD approach for capacity enhancement from 6000 to 30000 m3/d and secure the new opportunities. WI project ARR, data gathering completed. Identified gaps by doing PM/CM analysis/Bad actor analysis and use of Pareto chart to find out vital few causes for Electrical & Inst. System. Gap analysis report preparation started. KPIs on track with no red indication status.
- Continuous Improvement Lead with assisting team in generating shareholder value through monetary benefits. Delivering Hard save & soft save for the Assets & also on wage arbitrage. Process safety Practioner with knowledge of Bowtie analysis for Major Accident Hazards.
- LOPA and SIF designing SILPro tools with identification of PFD and fault tolerance.
- Carbon management with core knowledge on powering progress & Net Zero Emission (GHG reduction).
- Criticality Assessment based on RAM matrix, doing RCM study then optimizing the Eq care tasks in unit level by optimizing all the risk-based studies (RCM, RBI, SIF), comparing with intelligent solutions as part of digital transformation & provide 20 Y outlook for Strategic Asset Management Plan (SAMP). Shifting Time based tasks to Condition based tasks.
- Member of TAO AC Mental Health Wellness Awareness team, it is a part of Shell Health. Digitalization focal for all digitization projects and budgeting.
- Leadership is attributed by Upskilling as SME for Causal Learning (RCA) & PM optimization for 16- member teams.
- Team lead for Causal Learning & PM optimization activity for Upstream & C+P assets.
- Initiative to apply & develop automated tools for Statistical Reliability Analysis through Weibull study & Crow AMSAA(RGA) plots for team development.
- Development of Shell Global Standards on Optimization & Equipment care strategy with preparation of Best Practices Guide.
- Track on project KPI for the team with measuring & defining performance metrics for projects as well as work process like RCM, PM Optimization, RCA/Causal Learning.
- As a Team Lead creating Terms of Reference with clear expectations & deliverables.
Manager (CES Inst Reliability Maintenance Design)
Reliance Industries Limited
12.2018 - 02.2022
- Solved hardware and software interface issues for positions, enabling improved integrity of entire system. IO option settings for AO block fault mode.
- Communicated strategies and results with stakeholders.
- Hands on experience in troubleshooting, calibration & maintenance of various & HART protocol-based field instruments like Vortex flow meter, Coriolis flow meter, Radar type instruments, DP type instruments, Ultrasonic Flow meters, Seismic and proximity vibration sensors, Custody Transfer Meters (CTM).
- Hardware and software troubleshooting in Foxboro System manager, latest image upgrade in FCP and FBM to increase reliability of DCS system.
- Hands on experience in third party (FDSI) integration with DCS and addressing, solving serial link communication error in FBM 230/231/232/233.
- Implementation of Maintenance schedule & its adherence and other PM objects like equipment, work centers, BOM linking, PR, PO etc., through SAP.
- Hands on experience in troubleshooting problems in Field instruments (including Metering systems & Flow Computers).
- Troubleshooting for valves and positioners related issues with design review for control valves. Valve health monitoring through IAMS & saving potential production loss.
- Lead Spare management, identification, codification, Inventory modeling (VED Analysis), AMC/ARC service PR and procurement of spares (PR-PO) of C2 complex using SAP PM-MM module.
- Actively involved in activity like BOM and inventory compliance of critical package and plant spare, capturing all the instruments in preventing maintenance scheduling in SAP. Calibration Management Module SAP compliance in planned and unplanned routine job. Knowledge of all MM Module T codes.
- Spare procurement planning based on criticality and stock consumption pattern, RFQ clearance and timely availability of same.
- Root cause analysis using fish bone, Pareto Chart and why tree analysis.
- Led engineering reviews and approvals of equipment design bases, ensuring alignment with petroleum, refining, and petrochemical standards and regulatory compliance (OISD, CCOE, PESO, SIL).
- Instrument Management of Change preparation, participation and implementation.
- Lead Planning Job/material/manpower and execution of shutdown activities & Instrument Reliability activities of LLDPE, LDPE, MEG, ROGC, CPP Units.
- Review, update and develop I&C technical documentation / drawings including Piping and Instrumentation Diagrams (P&IDs), cause and effect, logic and architecture diagrams and control narratives.
- Leading a team of Engineers & third-party vendors.
- Instrumentation Design & Engineering:
- Designed and developed instrumentation systems for rotating equipment, ensuring compliance with industry standards (e.g., ISA, IEC).
- Created detailed P&IDs, loop diagrams, and instrument index using SPI (Smart Plant Instrumentation).
- Selected and sized field instruments (Transmitters, Thermowell, Measuring Elements, Orifice, Control Valves) based on process requirements and environmental conditions.
- Developed control philosophies and instrument data sheets for new and retrofit projects.
- Ensured instrumentation design adhered to safety standards such as SIL (Safety Integrity Level) and participated in HAZOP/LOPA studies.
- Develop and execute instrument surveillance programs:
- Collect data using Computer Maintenance Management System (CMMS) & Historian system.
- Analyze maintenance records to determine instrument failure rates, availability / reliability calculations, bad actor / failure modes identification, and program effectiveness / cost analysis.
- Managed and motivated employees to be productive and engaged in work.
Assistant Manager & Addl BTG Lead
Bharat Aluminium Company Ltd, Vedanta Resources
10.2013 - 12.2018
- Achieved recognition from senior management for contribution to reliability improvement projects, risk assessment and mitigation plan to avoid plant upsets.
- Lead tendering and procurement activities.
- Hand on experience in Foxboro DCS CP40/FCP270, ICC, and FOXDRAW, Triconex, Enterasys networks switch configuration, port blocking in HyperTerminal s/w.
- Hands on Experience Bentley Nevada TSI system & SYSTEM1 configuration and troubleshooting.
- Hands-on experience in troubleshooting, calibration & maintenance of various HART protocol-based field instruments.
- Expertise in programming and troubleshooting of FOXBORO INVENSYS IA SERIES DCS, YOKOGAWA DCS CS3000, MAXDNA DCS DPU4E, G.E FANUC SC 90 30 PLC, Allen Bradley PLC.
- Facilitating basic core maintenance practice to identify critical assets through criticality analysis and performing Failure Mode Effect Analysis and Condition Appraisal of these identified critical assets of process.
- Drove 5S, Kaizen, RCA, FMEA, Process Improvement Initiatives to achieve operational efficiency, cycle time reduction, assets optimization, cost & energy savings. Designing documentations for activities like Quality Management: ISO9001, Environmental Management: ISO 14001 and Safety Management: OHSAS 18001, DUPONT Safety Management System.
- Planning, assigning, supervising, and executing daily instrument maintenance jobs in co-ordination with operation/ electrical/ mechanical department. Planning, execution and supervision of startup and shutdown activity.
- Handling a team of instrument engineers/ technicians and different contractors & vendors.
- Involved in loop checking, logic checking, complex control loops checking, calibration review, control valve testing, etc.
- Continuous improvement initiatives for logic & graphics modification through MOC process.
- Analysing alarm & trip values and providing troubleshooting by identifying cause of equipment/plant trip.
Education
Chartered Engineer - Electrical & Electronics
Institute of Engineers(IEI)
Kolkata, India 04.2001 -
Post Graduate Diploma Course - Power Plant Technology
Jindal Institute of Power Technology
Raigarh, Chhattisgarh 07.2012 - 08.2013
Bachelor of Engineering - Electrical & Electronics Engineering
Government Engineering College
Raipur, Chhattisgarh 07.2007 - 06.2011
Senior Secondary - Science Education
CBSE Kendriya Vidyalaya
Balco, Chhattisgarh 04.2006 - 05.2007
Skills
Engineering (Design), Maintenance & Reliability manager leading a diverse team for Reliability & RCA projects globally
Expertise in Foxboro DCS CP40/FCP270/FCP280, Triconex ESD, Honeywell DCS C300
Turbine Supervisory Instrument (TSI) Bentley Nevada System1, 3500 Rack software
Machinery instrument Maintenance for Boilers, CHP, AHP, Turbine & Turbine Auxiliaries, Petrochem
FMEA, Condition Appraisal of critical equipment and their Refurbishment plan
Understanding of oil and gas processes
Implementation of QC, Kaizen, 5S and QC tools Team lead for Instrumentation
Studying IOM manuals of OEM for troubleshooting steps Weibull & Crow AMSAA reliability study
Certification
Online Training on Safety Integrity System and Safety Integrity Level.Feb 2014 Honeywell
Software
- Valve link DTM, PACT ware 4.1, Rosemount Radar Master, GE APM Meridium, SPI
- 3500 Rack configuration Bentley Nevada, wIMS tool, SONAR tool, SILPro Tool
- Foxview, Foxdraw, Archestra IDE, X-force alarm management system, IAMS asset management system, Wonderware, Gas chromatography portal V5.20
- Weibull Analysis, Crow AMSAA plot (Reliability Growth Analysis).
- Aspen IP21 & Matrikon OPC, Power BI, Tableau, PowerApps, SEEQ, UTL, Lucid, Advanced Excel.
Timeline
Technical Specialist/Lead (Reliability Engineering & Causal Learning), Continuous Improvement Lead
Shell Business Operations (Upstream, IG, C+P Oil & Gas)
03.2022 - Current
Manager (CES Inst Reliability Maintenance Design)
Reliance Industries Limited
12.2018 - 02.2022
Assistant Manager & Addl BTG Lead
Bharat Aluminium Company Ltd, Vedanta Resources
10.2013 - 12.2018
Post Graduate Diploma Course - Power Plant Technology
Jindal Institute of Power Technology
07.2012 - 08.2013
Bachelor of Engineering - Electrical & Electronics Engineering
Government Engineering College
07.2007 - 06.2011
Senior Secondary - Science Education
CBSE Kendriya Vidyalaya
04.2006 - 05.2007
Chartered Engineer - Electrical & Electronics
Institute of Engineers(IEI)
04.2001 -