EPC Construction, Commissioning, and Start-Up

Kuwait National Petroleum Company (KNPC) Clean Fuels Project, Mina Abdulla Refinery. – Lump Sum Turn Key (LSTK) ProjectSite Construction ManagerFDH JV responsibilities include upgrade (revamping of units and shut-downs) and tie-in to the existing MAB refinery, Utilities and off-sites to entire 2020 facility, Hydrogen Production and Recovery, Sulphur Recovery and Amine Regeneration, Feed Gas Compression and Treating, Gas Plant, a total of 20 Units and 10 Revamp Units (including… Show more Kuwait National Petroleum Company (KNPC) Clean Fuels Project, Mina Abdulla Refinery. – Lump Sum Turn Key (LSTK) ProjectSite Construction ManagerFDH JV responsibilities include upgrade (revamping of units and shut-downs) and tie-in to the existing MAB refinery, Utilities and off-sites to entire 2020 facility, Hydrogen Production and Recovery, Sulphur Recovery and Amine Regeneration, Feed Gas Compression and Treating, Gas Plant, a total of 20 Units and 10 Revamp Units (including revamp of old generation control systems to new state of the art systems for interfacing into the new units). Responsibilities: Oct 2021 – Feb 2022 - conducting the Performance Guarantee Testing Runs (PGTRs) with KNPC on MAB2 UnitsIn my previous role on this project as Turnover Manager, with the team and Project Management, we successfully obtained Full PTOP (Provisional Turnover of Portion) for all units and Final Turnover of Facility (PTOF)In my current role my main objective is leading the Construction and Precommissioning Teams to final completions of the MAB2 CFP Project. As a Lump Sum project, I am also managing the budgets and recovery costs to maximize profits. Site Manager IV :• Assisting KNPC with the commissioning and start-up of all the units in including the performance testing.• Client liaison• All construction & turnover completion activities for Mechanical, E&I, Piping, Buildings – Punch & PSSR items, DCNs and Exception items.• All precommissioning completion activities for Mechanical, E&I, Equipment – ie Refractory Dry outs and Mechanical Running Tests during commissioning.• Maintain HSE Adherence, Currently 88,648,283 hours without LTI (Oct 2021).• Subcontractors Management, and Contract Closeout.• Monitoring Budgets and Expenditure.• Start-up and commissioning support.• Facilitate Site “Close Out” Show less

Kuwait National Petroleum Company (KNPC) Clean Fuels Project, Mina Abdulla Refinery. – Lump Sum Turn Key (LSTK) Project.The Clean Fuels Project 2020 (CFP) is a major upgrade / expansion of the Mina Al-Ahmadi (MAA) and Mina Abdullah (MAB) refineries to increase capacities and increase conversion of LSFO to higher end products through Bottom of Barrel (BOB) processing utilizing ARDS / Coker / Hydrocracker technologies. Upgraded refineries output will include Naphtha, Kerosene, Diesel, Fuel… Show more Kuwait National Petroleum Company (KNPC) Clean Fuels Project, Mina Abdulla Refinery. – Lump Sum Turn Key (LSTK) Project.The Clean Fuels Project 2020 (CFP) is a major upgrade / expansion of the Mina Al-Ahmadi (MAA) and Mina Abdullah (MAB) refineries to increase capacities and increase conversion of LSFO to higher end products through Bottom of Barrel (BOB) processing utilizing ARDS / Coker / Hydrocracker technologies. Upgraded refineries output will include Naphtha, Kerosene, Diesel, Fuel Oil, and increased MOGAS production. FDH JV responsibilities include upgrade (revamping of units and shut-downs) and tie-in to the existing MAB refinery, Utilities and off-sites to entire 2020 facility, Hydrogen Production and Recovery, Sulphur Recovery and Amine Regeneration, Feed Gas Compression and Treating, Gas Plant, a total of 20 Units and 10 Revamp Units (including revamp of old generation control systems to new state of the art systems for interfacing into the new units). Responsibilities:Managing the precomissioning, turnover, start-up and commission assistance to KNPC for the three Joint Venture Parties of Fluor, Daewoo E&C, Hyundai Heavy Industries. Fluor is the JV leading partner.Pre-Comm Management activities All activities for Mechanical, E&I, Piping, BuildingsSteam Blowing and Chemical CleaningMechanical (Compressor and Pumps) Run In, Gross Leak Air testingRefractory dry outs and boil-outsChemical and Catalyst LoadingFinal flushing and Gross Leak Air testingSupport PSSR, final reinstatements and gross testing for start-up readiness.Start-up and commissioning support.Turnover Management activities Systemization management and controlPreservationConstruction completion tracking/managementSchedule impact and start-up sequencing.First Systems expediting (Driving to completions)Walk downs and Punch ListingCloseout of Mechanical Completion and Provisional Turnover. Show less

Revamp Area Pre-commissioning and Turnover Manager.FDH JV responsibilities include upgrade (revamping of units and shut-downs) and tie-in to the existing MAB refinery, Utilities and off-sites to entire 2020 facility

Fluor provided EPCm services for the utilities and off-sites of a grass roots, world-scale, integrated chemical complex located in Jubail Industrial City II, in the Eastern Province of the Kingdom of Saudi Arabia.The primary products of the Sadara chemical complex include the following:• Ethylene Amines• Ethanol Amines• Butyl Glycol Ethers• Polyols• Polyglycols• Toluene Di-Isocyanate (TDI)• Methylene Diphenyl Di-Isocyanate… Show more Fluor provided EPCm services for the utilities and off-sites of a grass roots, world-scale, integrated chemical complex located in Jubail Industrial City II, in the Eastern Province of the Kingdom of Saudi Arabia.The primary products of the Sadara chemical complex include the following:• Ethylene Amines• Ethanol Amines• Butyl Glycol Ethers• Polyols• Polyglycols• Toluene Di-Isocyanate (TDI)• Methylene Diphenyl Di-Isocyanate (MDI)• Elastomers• Polyolefins – LLDPE and LDPEThe Sadara Project awarded to Fluor was divided into 3 different envelopes:• Utilities, Power, and Infrastructure (UPI)• Chemicals I and II (Chem I/II)• Site Development and Logistics (SDL) Show less

Santos is progressing with the development of Coal Seam Gas (CSG) resources in the Roma, Fairview and Arcadia fields of Central Queensland, for future sale as LNG. The first LNG train of nominal 3 MTpa will be built on Curtis Island near Gladstone. It is scheduled to start-up 3rd Qtr 2014. Collectively this project is called the GLNG Project (GLNG is an acronym for Gladstone LNG).The GLNG Project is being progressed on three parallel fronts:1. Upstream GLNG – the field… Show more Santos is progressing with the development of Coal Seam Gas (CSG) resources in the Roma, Fairview and Arcadia fields of Central Queensland, for future sale as LNG. The first LNG train of nominal 3 MTpa will be built on Curtis Island near Gladstone. It is scheduled to start-up 3rd Qtr 2014. Collectively this project is called the GLNG Project (GLNG is an acronym for Gladstone LNG).The GLNG Project is being progressed on three parallel fronts:1. Upstream GLNG – the field development necessary to deliver gas to the Gladstone Transmission Pipeline (GTP). This in turn is separated into 3 components:• CSG production, • Gas storage and withdrawal and • Upgrading the Comet Ridge to Wallumbilla pipeline (CRWP).2. Gladstone Transmission Pipeline (GTP).• LNG Plant and Marine Load-out facilities on Curtis Island.3. The Upstream GLNG Surface Facility Project:• Is designed to collect gas and water from about 3000 wells spread over 10,000 km2;• Initial gas compression of gas gathered from the wells using nodal compressors;• Secondary gas compression at the Hub Compressor Stations (HCS) to deliver gas to the GTP at up to 10.2 MPag;• Dehydrates the gas to comply with the gas transmission pipeline specification;• Collects the associated water, treats it and delivers it for beneficial use by the local community, irrigation or injection into local aquifers (with EPA approval), and discharge to the Dawson River;• Provides for storage and withdrawal of produced CSG into nearby depleted conventional gas reservoirs.Fluor is selected as the EPC partner on the 3rd parrellel phase, also known as G2LNG. This is where I work :-) Show less

IMT (Integrated Management Team) Construction manger SAPCo SAP, SAMCo AA, and Port – LSTK US$3,3BillThe mechanical completion for the construction phase for these projects included the pre-commissioning and commissioning activities thus having the units (systems) ready for feedResponsibilities:1. Construction and Commissioning performance of the consortium (Linde and Samsung) and sub-contractors.2. Monitor and approve project strategies, programs (as an example… Show more IMT (Integrated Management Team) Construction manger SAPCo SAP, SAMCo AA, and Port – LSTK US$3,3BillThe mechanical completion for the construction phase for these projects included the pre-commissioning and commissioning activities thus having the units (systems) ready for feedResponsibilities:1. Construction and Commissioning performance of the consortium (Linde and Samsung) and sub-contractors.2. Monitor and approve project strategies, programs (as an example, piping and hydro testing acceleration), processes, systems, procedures, method statements, execution plans and risk management.3. Implement project (Fluor) HSE programs and reporting along with HSE director.4. Conduct constructability model reviews.5. Evaluate and monitor manpower utilization.6. Ensure QA/QC programs are implemented.7. Pre-Commissioning and Commissioning.a. Accelerate pre-commissioning activities to meet system completion schedules for mechanical and water test runs.i. Loop and Function Checks, Hydrotesting, Solo runs, Energization sequences, cleaning, steam blowing, and general system readiness.ii. Electrical commissioning to facilitate pre-commissioning activities.iii. System walk downs and punch clearing management.b. PSSR (Pre Start Up Safety Reviews)c. Mechanical Test Runs Show less

Construction 1. Closing out of punch items (new SK Butane pumping and surge protection system) and demolition of old Ibn Sina pumping and metering.2. Pumping System at Aramco Juaymah Gas Plant.3. Ammonia pumping and custody metering system. We have a design flaw in the suction piping and are modifying the piping and adding vapor columns.4. Aramco (OSPAS) butane leak detection system at Ibn Sina.5. Aramco (OSPAS) wide area network RTU system including… Show more Construction 1. Closing out of punch items (new SK Butane pumping and surge protection system) and demolition of old Ibn Sina pumping and metering.2. Pumping System at Aramco Juaymah Gas Plant.3. Ammonia pumping and custody metering system. We have a design flaw in the suction piping and are modifying the piping and adding vapor columns.4. Aramco (OSPAS) butane leak detection system at Ibn Sina.5. Aramco (OSPAS) wide area network RTU system including infrastructure.6. SK Main Site – Polycarbonate Plant Heat/Jacket tracing. Show less

Saudi Kayan Petrochemical Complex is a grass roots complex in the industrial city of Al-Jubail, Saudi Arabia for cracking Ethane and Butane to manufacture commercial grade petrochemicals. The objective to upgrade the existing Butane surge & pumping system at Juaymah Gas Plant (JGP) from 52 MBD to 134 MBD. The system upgrade is required for the additional supply requirements to Saudi Kayan.The scope includes installation of two new surge spheres, Three new shipping pumps, feed… Show more Saudi Kayan Petrochemical Complex is a grass roots complex in the industrial city of Al-Jubail, Saudi Arabia for cracking Ethane and Butane to manufacture commercial grade petrochemicals. The objective to upgrade the existing Butane surge & pumping system at Juaymah Gas Plant (JGP) from 52 MBD to 134 MBD. The system upgrade is required for the additional supply requirements to Saudi Kayan.The scope includes installation of two new surge spheres, Three new shipping pumps, feed lines to surge spheres, vent and level equalization system between the spheres, pump suction piping, 600 # pump discharge piping, surge relief system, Royalty metering and prover facility, new leak detection skid at Ibn Sina, and replacement of SADAF and Ibn Sina inlet flow control valves to provide a maximum capacity of 134 MBD at 60°F through the existing JJBUT-2 pipeline.Gary was responsible for the planning, execution, and commissioning of this facility. His team consisted of project management, materials, purchasing, planning, engineering, mechanical, piping, civil, Electrical, Instrumentation, pre-commissioning, and commissioning. He also had a sub-contractor of all related disciplines which peaked at a workforce of over 350 people.Responsibilities• Construction.• Coordinate with Project Management Team.• Planning and Execution. Schedule the project in logical steps and budget time required to meet deadlines.• Resource Management. (Manpower, materials, equipment), including vendors.• Change management and documentation. (Incl. Turn over)• Contractual Management. Incl. specification, engineering standards, and quality management to meet customer requirements.• Reporting.• Plan, organize, and direct activities concerned with the construction and maintenance of structures, facilities, and systems.• Punch list management and implementation/clearing.• Pre-Commissioning and Commissioning. Show less

This post included all the previous responsibilities but was extended to the project management and construction of the entire PCIMS implementation and Integration effort.Responsibilities (PCIMS Integration)• Coordinate with Project Management Team.• Coordinate with vendors (DCS, ESD, MMS, F&G, Suppliers)• Planning and Execution. Schedule the project in logical steps and budget time required to meet deadlines.• Resource Management. (Manpower, materials… Show more This post included all the previous responsibilities but was extended to the project management and construction of the entire PCIMS implementation and Integration effort.Responsibilities (PCIMS Integration)• Coordinate with Project Management Team.• Coordinate with vendors (DCS, ESD, MMS, F&G, Suppliers)• Planning and Execution. Schedule the project in logical steps and budget time required to meet deadlines.• Resource Management. (Manpower, materials, equipment)• Engineering Change management and documentation. • Contractual Management. Incl. specification, engineering standards, and quality management to meet customer requirements• Reporting.• Plan, organize, and direct activities concerned with the construction and maintenance of structures, facilities, and systems.• Punch list management and implementation/clearing.• PCIMS support for Pre-Commissioning and Commissioning (Plant Sub-Systems). Show less

Responsible for main plant U&O and Port instrumentation and control systems for the construction and mechanical completions group, the coordination of loop and function testing for construction, related punch list management, and system turnover of PCIMS, Fire and Gas, Remote Interface Buildings, Backbone cabling Systems.Responsibilities• Development of Loop and Function Check Procedures• Coordination with construction to complete E&I work to facilitate Loop and Function… Show more Responsible for main plant U&O and Port instrumentation and control systems for the construction and mechanical completions group, the coordination of loop and function testing for construction, related punch list management, and system turnover of PCIMS, Fire and Gas, Remote Interface Buildings, Backbone cabling Systems.Responsibilities• Development of Loop and Function Check Procedures• Coordination with construction to complete E&I work to facilitate Loop and Function Checking.• Management of Kentz (K-034 sub contractor) loop and function check teams as well as PCIMS construction Scope.• Management of repair teams to repair and complete loops.• Coordinating the clearing of Instrumentation and Control Punch Items• System Owner responsibilities for assigned PCIMS Sub Systems.• Managed PCIMS construction contractor Show less

Primary Responsibilities:• Hydrotesting & Flushing• Speciality Cleaning• Loop checking.• system / sub-system control.• Develop scope of work for specialty cleaning and blowing with appropriate specialty cleaning contractor. Manage specialty cleaning contractors through completion of the scope.• Assist in the development and implementation of mitigation workarounds• construction commissioning teams to close out punch items, piping fabrication for blowing and… Show more Primary Responsibilities:• Hydrotesting & Flushing• Speciality Cleaning• Loop checking.• system / sub-system control.• Develop scope of work for specialty cleaning and blowing with appropriate specialty cleaning contractor. Manage specialty cleaning contractors through completion of the scope.• Assist in the development and implementation of mitigation workarounds• construction commissioning teams to close out punch items, piping fabrication for blowing and flushing, and commissioning assistance to client.• Complete construction at the end of the project after construction demob.• Fabrication of manifolds, spool pieces, and cross line specification flange fittings for air blowing and flushing of sub systems for turnover to client and subsequent commissioning. Air blowing (including target blows) and flushing. Prep and reinstatement.• Construction of a portable dematerialized water facility supplied by GE Water Solutions. The system consisted of 6 RO and 3 Filter Units.• Flushing and activated carbon/resin loading of the permanent Demin Plant• Stand in as Site Manager when Project Director on R&R.• Aramco NGL – Propane supply system to Yansab, metering skid and pumps. Completed the construction, pre-commissioning, and commissioning on the system. Programmed ICS Triplex ESD for the propane system and integration into existing DCS system. Gary is “badged” for Aramco. Show less

•Basic Engineering on complete Petrochemical Control and Instrumentation Modernisation Project•Client requirement analysis on complete control and instrumentation upgrade including execution plan and scope development.•Identification and recording of piping and flange line classes for RFQ package for control, emergency, regulation, and differential control valves. •Identification and recording of piping and flange line classes for RFQ package for pressure relief (safety) and thermal… Show more •Basic Engineering on complete Petrochemical Control and Instrumentation Modernisation Project•Client requirement analysis on complete control and instrumentation upgrade including execution plan and scope development.•Identification and recording of piping and flange line classes for RFQ package for control, emergency, regulation, and differential control valves. •Identification and recording of piping and flange line classes for RFQ package for pressure relief (safety) and thermal expansion valves.•Identification and recording of piping and flange line classes for RFQ package for thermo wells and elements•Development of Instrumentation index for detailed design, process control system, emergency shutdown system, tankage system, and gas detection system.•Development of Safety Integrity Level (SIL) review for emergency shutdown system.•Interface liaison between process, mechanical, piping, construction on site I Ndola Show less

•Statutory Management and development of turnkey E&I company. From design to construction and commissioning, including control systems, and MCC/DB manufacture.•Managed finances, HR, Marketing and Business Development included selected projects assigned.•Developed and implemented policies and procedures over company transactions, including QA/QC and SHE•Customer management and interface on projects.•Responsible for Automation and Instrumentation on Tendering and Assigned… Show more •Statutory Management and development of turnkey E&I company. From design to construction and commissioning, including control systems, and MCC/DB manufacture.•Managed finances, HR, Marketing and Business Development included selected projects assigned.•Developed and implemented policies and procedures over company transactions, including QA/QC and SHE•Customer management and interface on projects.•Responsible for Automation and Instrumentation on Tendering and Assigned Projects.•Field bus networks, Profibus, Devicenet, Modbus Plus, ASi.•Extensive knowledge gained in Mining, Process, Petrochemical, Food and Beverage, and Manufacturing segments.•Developed sound experience in LV/MV control and distribution, board manufacture, Motor Starter Technologies, and Industrial control (Intelligent electrical interface devices)•Developed expertise in PLC and SCADA systems. Show less