ALI RIZWAN

Experience

• 

  Fauji Fertilizer Company Limited

  Jan 2011 - Jan 2011

  Internee

  Learned to calibrate pressure transmitters and switches.Got familiarized with almost all the process variables and their respective instruments.Learned to troubleshoot making use of P&I diagrams.Learned to program and troubleshoot problems related to PLC,s and DCS Systems.Studied a number of control loops a little closely.Was lucky to witness the maintenance of gas turbines and pressure saftey valves.

• 

  Solutions Engineering Private Limited

  Feb 2013 - May 2013

  Intern

  SEPL is a solution provider in the field of Automation and Controls to all kinds of industries especially Oil& Gas, fertilizers, petrochemicals, nuclear and thermal power plants etc.1. Worked as a Sales and Marketing Engineer responsible for dealing with the automation queries of the fertilizer sector in Pakistan.2. I was also assigned to an Wireless Ammonia Detection project which was to be implemented in FFC.

• 

  Fauji Fertilizer Company Limited

  Sept 2013 - now

  Responsibilities included:- Turnaround planning- Ensuring safe working practices at plant.- Preventive Maintenance Planning- Necessary Spares ordering for field instrumentation and control systems.- Resource management- Cost curtailment by keenly surveying cheaper and yet reliable solutions for possible replacement of obsolete instrumentation.- Engineering of new systems or control loops when necessary.- Emergency handling and swift troubleshooting where required.- Training and development of new instrument staff Show less Responsibilities included:- Ensuring safe working practices at plant.- Preventive Maintenance Planning- Necessary Spares ordering for field instrumentation and control systems.- Resource management- Cost curtailment by keenly surveying cheaper and yet reliable solutions for possible replacement of obsolete instrumentation.- Engineering of new systems or control loops when necessary.- Emergency handling and swift troubleshooting where required.- Training and development of new instrument staff. Show less I manage the maintenance of control valves and pressure safety valves at the fertilizer plant of FFC Mirpur Mathelo. My responsibilities and experience include:• Managing a team of five technicians.• Inventory management of thousands of control valves and pressure safety valves installed at the plant.• Resource planning of valve shop for shut downs and turn arounds.• Optimizing my valve shop facilities to the extent that it can be used for maintenance of hundreds of valves simultaneously within a span of two to three weeks for Turn Around purposes.• Ensuring that Valve maintenance is in compliance with API standards 520, 526 and 527.• Exploring possible solutions to technical problems utilizing cost-effective means.• Saving thousands of dollars of company money by analyzing designs of different valve spares and sanctioning their local fabrication. • Hands-on training of technicians in the maintenance of control valves and PSVs.• Constant development of my valve shop as technical training center. I have done this by ensuring the provision of all necessary valve accessories e.g. positioners, regulators, relays, manuals and complete spare valves and actuators to my technicians and trainees.• Publishing achievements of valve shop on monthly or bi-monthly basis depending on the extent of jobs performed in shop. My particular magazine is called ‘Valvepedia’. Show less FFC enforces a rigorous and challenging training program for its instrument engineers. It is a combination of both ‘On- the- job Training’ and technical training. Some of the main modules that I have covered include: • On the job training for 1 year which included working on SAP (ERP software) which entailed preparing and execution of preventive maintenance plans, stocking and cataloguing of instrument parts and preparing job requests and purchase request for various jobs.• Getting familiarized with Field Instrumentation. • The role of regulatory control and emergency safety systems (DCS & ESD).• The study of complex Boiler Cascade Control Loops & Heat Recovery Steam Generation Systems• Understanding the operation of gas and steam turbines and generators• Importance of compressor control systems• The science of control valves, their maintenance and designing.SYSTEMS EXPERIENCE:FFC has a vast array of control systems integrated in unison to enhance the process reliability and improve production of the fertilizer plant. I have had ample experience on the following control systems:1. In-house certification of ‘Functional Safety’ 2. Detailed study of Yokogawa Centum CS 30003. Detailed study of Honeywell FSC (Fail Safe Control) System4. Thoroughly familiar with the concept of Safety Instrumented Systems and the process of calculating the SIL Level of a safety PLC.5. Bently Nevada 3500 Vibration Monitoring System6. Installation of a Woodward Speed/Frequency Governor 505E on steam turbine driven generator.7. CCC Compressor Control System8. Boiler Management System9. GE Fanuc PLC10. Micrologix 1000 Allen Bradley PLC Show less

  • Lead Instrument Engineer - Gas Compression Facility

    Jan 2024 - now

  • Lead Instrument Engineer- Urea Plant

    Jan 2019 - now

  • Instrument Control Engineer- Ammonia Plant

    Feb 2018 - Jan 2019

  • Control Valve Engineer

    Sept 2014 - Jan 2018

  • Instrumentation and Control Engineer

    Sept 2013 - Sept 2014