Josh Smith

Experience

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  Goodman Fielder

  Aug 2002 - Jan 2003

  Trainee Engineer
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  Amaze Communication (AU)

  Aug 2003 - Nov 2004

  Internet Support Techician
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  EnergyAustralia

  Sept 2004 - Feb 2008

  Quality Control Officer
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  Orica

  Feb 2008 - Feb 2014

  The project scope includes replacement of the existing Nitric Acid and Ammonium Nitrate plants Toshiba/Citect DCS with a Honeywell C300/Experion system before the end of 2013 via three staggered cutovers. The first being NAP3, followed by AN1 & NAP1, then AN2 & NAP2. • A member of the Global Excellence Committee, with the purpose to review and improve Orica’s global EI&C procedures and specifications.• Provide leadership to project team by coordinating work activities across varied work fronts, including peer review of completed work activities.• Actively managed much of the Management of Change process, interfacing with site to ensure the project met schedule deadlines and site requirements including SH&E and basis of safety.• Perform structured training sessions for Maintenance, Engineering and Operations Teams on DCS engineering and operation.• Perform structured training sessions for Engineers and Technicians on the approved process for cutover activities including termination, loop, function testing and commissioning.• Coach and mentor Maintenance, Engineering and Operations Teams on DCS automation & controls activities and maintenance as a certified Honeywell Trainer. • Perform program changes to DCS code, ESD code and graphics.• HAZOP/HIRAC reviews for new DCS equipment and architecture.• Interfacing SCADA/DCS with vendor package PLCs either via Modbus or hardwired.• Create cutover management systems to monitor cutover progress.• Perform loop and function testing, including troubleshooting of plant instrumentation and logic.• Improve site alarm management performance to ANSI/ISA 18.2 standards.• Interface SCADA/DCS with reporting systems including Matrikon Alarm Manager and Historian.• Work closely with scheduler to ensure a realistic and practical timeline for project execution.• DCS Hardware and Software FAT and SATs.• Awareness of sites Hazardous Areas and their impact on instrument selection. Show less 2IC for E&I site based commissioning of an Ammonium Nitrate and Nitric Acid plant for Orica, in Bontang, East Kalimantan, Indonesia. Working a 6 week on and 2 week off roster. At the time the Bontang Project constituted Orica’s largest ever project costing approx. US $500 million.• Acting E&I Commissioning Superintendent, this included the management of the E&I Commissioning Team.• Perform loop and function testing, including troubleshooting of plant instrumentation and logic.• Review and edit project specifications including instrument, electrical and control systems.• HAZOP, HIRAC and P&ID reviews for scope changes and new plant areas.• Interfacing with QA/QC personnel to address quality issues/progress.• Inspection of E&I equipment installations to required standards utilising a management of change process (punch listing, plant modifications, site change notices, technical queries).• DCS & ESD Hardware and Software FAT and SATs.• LV MCCs, UPSs, HV Switchgear and Transformers SAT. • Integration of DCS & ESD with Smart Motor Control Relays (SIMOCODE) and VSDs via Profibus.• Creating Control System test procedures including ESD trip test procedures.• Review of instrument datasheets, vendor data, technical queries and design changes.• Work closely with scheduler to ensure a realistic and practical timeline for project execution for E&I scope.• Interfacing with EPC contactor labour during construction and commissioning phases providing a focus on safety, quality, schedule and cost.• Marking up documentation to As-Built, such as instrument datasheets, LV motor schematics, loop drawings, logic diagrams, P&IDs, control philosophy and trip test procedures.• Trained in the use of Root Cause Analysis.• Proficient in the use of SAP for site based Management of Change process. Show less Detailed Engineering Design of an Ammonium Nitrate and Nitric Acid plant in Bontang, Indonesia. • Review field instrument data sheets and specifications for pressure, temp., level, flow and valves. • DCS & ESD Control and Interlock logics.• Review specifications for LV motors, MCCs, DCS, Project Cables, etc.• Participated in LOPA studies and risk assessments.PIBSA ProjectMelbourne, VIC, Australia Detailed Engineering Design of a PIBSA plant for Orica's Speciality Chemicals division in Deer Park, Victoria. PIBSA is a component in AN emulsion.• Hazardous Area Dossier creation and maintenance, including intrinsically safe equipment calculations.• Develop instrument specification for project.• Design deliverables including: Instrument Index, Hazardous Area Dossier, Loop Drawings, I/O Schedule, Range, Alarm & Trip Schedule, Rack / Cabinet layout, switchboard location. • Mechanical and process liaising. P&ID mark-ups.Honce ProjectMelbourne, VIC, Australia The Honce Project is the design, construction and commissioning of a non-electric detonator plant in Honce province of China.• Hazardous area assessment.• Electrical schematics and single line diagrams.• Estimation of site load.Dulux Powder CoatingDandenong South, VIC, Australia The Dandenong South Dulux Powder Coating plant project involved upgrading the front end of their process by automating a previously labour intensive process utilising robotics.• Liaise with various stakeholders regarding project progress and direction, including Orica ESS, Dulux and contractor management and staff.• Co-ordinated stakeholders to clearly identify and align project goals and objectives.• Co-ordinated resources to enable project progress. Show less Ammonium Nitrate 1, LV Switchroom UpgradeKooragang Island, NSW, Australia Upgrading the existing switchroom to new, adjacent to the old, with minimum downtime to running plant.• Electrical schematics.• SAT of MCC cells.• Commissioning of electrical equipment under lockout/tag out procedures.Ammonium Nitrate 1, Wet Section Sump Tank ProjectKooragang Island, NSW, Australia Introducing a new sump tank to the AN1 wet section.• Selection of appropriate instrumentation.• Datasheets, loop drawings, calibration, loop testing and commissioning of all instrumentation.• Managing labour and liaising with contractors to perform work.• Purchase of all instrument and electrical equipment.• Logic diagrams and programming of AN1 DCS.• Training of maintenance and operations staff in the functionality of the new equipment.• Electrical schematic and SAT of MCC cells.• Commissioning of electrical equipment under lockout tag out procedures.• Updating P&ID drawings. Show less

  • Senior EI&C Engineer

    Jul 2012 - Feb 2014

  • Deputy EI&C Construction and Commissioning Superintendent

    Feb 2010 - Jul 2012

  • EI&C Engineer

    Feb 2009 - Feb 2010

  • EI&C Engineer

    Feb 2008 - Feb 2009
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  Yokogawa

  Feb 2014 - Aug 2014

  FAT Manager - APLNG Upstream Control Systems

  Australia Pacific LNG is already the largest producer of CSG in Australia, supplying gas to power stations to produce lower emissions electricity; major industrial customers, homes and businesses in South East Queensland. The Project will see an increase in domestic gas production to further supply gas-fired power stations, major industrial customers and residents throughout Queensland.• Prepare and check FAT documentation.• Ensure FAT test environment is prepared and ready.• Perform FAT kickoff and closeout meetings.• Ensure client sign off during FAT closeout.• Manage the punchlist database through Microsoft SQL Server.• Improve FAT document preparation workflow.• Prepare MDR for submission to client.• Initiated the use of MS Project to improve management of FAT resources. Show less

• 

  Bechtel Corporation

  Aug 2014 - now

  The Pennsylvania Chemicals Petrochemical Project consists of an Ethylene Cracking Unit (ECU) based on ethane feed and three Polyethylene (PE) units, PE1, PE2, and PE3, consuming all the ethylene. The facility also includes all supporting utilities, including heat recovery steam generators (HRSG), three GE F6B gas turbines (GT), storage, logistics, and general facilities. Responsibilities include:1. 40+ direct and indirect reports (professionals, superintendents, field non-manuals)2. 400+ craft (across various disciplines)3. I&C and Electrical Disciplines4. Work Control5. Pre-Startup Safety Review (PSSR)6. Innovation and Automation (SQL, PowerApps, PowerBI) Show less The Pennsylvania Chemicals Petrochemical Project consists of an Ethylene Cracking Unit (ECU) based on ethane feed and three Polyethylene (PE) units, PE1, PE2, and PE3, consuming all the ethylene. The facility also includes all supporting utilities, including heat recovery steam generators (HRSG), three GE F6B gas turbines (GT), storage, logistics, and general facilities. In addition to the responsibilities of the home office my responsibilities at the project site include: • Scope expanded from pre-commissioning to include support of commissioning and startup activities. • Leadership of the Pre-Startup Safety Reviews (PSSR) for CSU. • Leadership of supervisors (28+ direct reports) and field craft technicians (180+) on the execution of contracted scope.• Leadership of the CSU innovation team including 2 direct reports and responsible for management of SQL server, PowerBI, PowerApps for CSU. Show less The Pennsylvania Chemicals Petrochemical Project consists of an Ethylene Cracking Unit (ECU) based on ethane feed and three Polyethylene (PE) units, PE1, PE2, and PE3, consuming all the ethylene. The facility also includes all supporting utilities, including heat recovery steam generators (HRSG), three GE F6B gas turbines (GT), storage, logistics, and general facilities. My responsibilities as Pre-commissioning Instrument Lead for the Pennsylvania Chemicals project while at the home office were: • Definition and markup of all instrumentation pre-commissioning systems. • Defining an optimised schedule for instrumentation precomm activities of the project. • Provide input for budget forecasting. • Prepare project specific precommissioning execution procedures as needed. • Coordinate, the delivery of contractual project deliverables from the precommissioning team. • Identify and develop subcontractor's scope of work for specialty equipment precommissioning.• Along with the principal members of the project team, participate in providing input for definition and tri-party alignment of the DOR (Division of Responsibilities) as per contractual agreements. • Assist in preparation of the project execution plans, cost estimates, subcontracts requirements, and risk management. • Provision of input to project controls for the development of a detailed precommissioning to RFC (Ready For Commissioning) schedule. • Coordination with the Project MAC (Main Automation Contractor) to utilise 'smart' I/O checkouts during precommissioning phase with Emerson CHARM technology.• Develop and coordinate with automation leads digitisation of test record work flow.• Develop and coordinate with automation leads digitisation of work package creation. Show less Reporting to the Manager of Startup for Infrastructure and supporting all business lines.• Supervise commissioning of projects and act as additional field support such as field superintendent where required• Develop proposals• Develop estimates• Develop system scoping, turnover sequence and schedules for projects• Revise corporate procedures where required• Audit project site adherence to function procedure and guidelines• Develop automated project status reporting Show less The APLNG project is currently one of the worlds largest LNG projects. Project scope includes two LNG trains providing a combined capacity of 9million tonnes of LNG per year. • Provide leadership to a team of over 15 ICSS (Integrated Control and Safety System) Engineers, including 8 direct reports, by coordinating work activities across varied work fronts, including pre-commissioning, commissioning and SATs of ICSS Equipment.• Act as an interface between client and contractor to ensure project deliverables are met and inline with client expectation.• Actively managed much of the Management of Change process, interfacing with engineering to ensure the project is executed safely, meets schedule deadlines, project specifications, industry standards and best practice. • Complete the detailed design for the ICSS through coordination with Bechtel Resident Engineering and Bechtel Construction to ensure client acceptance at handover. This included the development and revision of a number of key design inputs including the Network Specification, IP Address Schedule, Fibre & Ethernet Cable Schedule, SCADA Engineering to Vendor Packages, SAT Procedures, Function and Interlock Testing Procedures and BPCS configuration guidelines.• Create management systems to effectively monitor and schedule pre-commissioning and commissioning activities.• Utilise Visual Basic for Applications to automate printing of Loop Pack Coversheets and Loop Checksheets to expedite the Loop Workpack creation process and minimise errors.• Coach and mentor CSU Clerks on the creation of Loop Workpacks. • Create a Work Implementation Guide to detail CSU work processes incorporating key aspects of Bechtel and Project specifications and standards to ensure alignment of all stakeholders. Show less

  • Project Development Manager

    Feb 2023 - now

  • Innovation and Deputy Commissioning Manager - Pennsylvania Chemicals

    Apr 2022 - Feb 2023

  • Innovation and CSU Instrument Lead - Pennsylvania Chemicals

    Sept 2018 - Apr 2022

  • Pre-Commissioning Instrument Lead - Pennsylvania Chemicals

    Dec 2017 - Sept 2018

  • Technical Support Manager

    Nov 2016 - Dec 2017

  • Startup ICSS Lead - APLNG Downstream

    Aug 2014 - Nov 2016