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Industrial Projects

PROJECTS IN OPERATIONS TECHNOLOGY (OT) CYBERSECURITY (CS)

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  • PS Pipeline (Petronas & Shell JV Terminal) IACS Security:

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  • Consultant and Team Lead to develop and present PS Pipeline Sdn Bhd (PSP) a comprehensive plan to assist in addressing the identified audit findings and to meet PSP's cybersecurity requirements in alignment with IEC 62443 and/or NIST SP 800-82.

  • Developed procedures and documents such as:

  • Situational Assessment

  • Gap Analysis

  • OT-CS Risk Assessment

  • Asset Inventory

  • Access Control procedures

  • IACS Logical and Physical Network Diagrams

  • Network Segmentation and Zoning Architecture diagrams etc.

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  • Prasarana Railway OT-Cybersecurity Project:

 

  • OT-Consultant and Team Lead to design, propose and implement on-site OT traffic consolidation with TENABLE as the main OT network monitoring & intelligence solution and NETSCOUT Network TAP as the main traffic consolidator for the IACS Security.

  • Team Leader to develop procedures and work instructions for passive monitoring of OT security for Rapid Rail Sdn Bhd and Automatic Fare Collection units.

  • Project Phase-1 was to establish a robust On-Prem OT Security Visibility, Detection, and Response system within our Operational Technology (OT) environment.

  • Project Phase 2 was to integrate the phase-1 OT Security solutions with a Cloud-based Security Information and Event Management (SIEM) and Security Operations Center (SOC) infrastructure.

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PROJECTS WITH PETRONAS DIGITAL SDN. BHD.

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  • EOC MVP 1 - Digital Twin Project (Aveva Wonderware IDE & Azure DevOps):

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  • Led the Digital Visualization and Optimization project, which forms the foundation for Petronas Digital's enterprise optimization solutions. Managed the Front-end development team for UI/UX visuals and scripts, leveraging Azure DevOps and agile methodologies to enhance product delivery.

  • Integration of UI/UX across nine existing applications used for enterprise optimization, streamlining evaluation and consolidation of recommendations.

  • Developed workflows for data collection and validation through automated integration with Enterprise Digital Hub (EDH), OPC interfaces, and manual data entry.

  • Facilitated simulation and submission of recommendations for decision-making.

 

  • Predictive Revitalization of Instruments to Maximize Efficiency (PRIME):

 

  • Led a multidisciplinary team of IT and operations engineers on the PRIME project, a key data science initiative in Petronas' Digitization Roadmap. Focused on optimizing instrumentation integrity and safety while achieving cost efficiencies by integrating renowned DCS and PLC systems across 36 onshore and offshore platforms in Malaysia.

 

Key Systems Integrated:

 

  • Control Loop Performance & Tuning

  • Alarm Rationalization & Dashboard

  • Instrument Protective Functions (IPF) Management

  • Operation Parameters Deviations Management

 

  • Cyber Security Project – RTOT Deployment:

 

  • Spearheaded the Real-Time Operation Technology (RTOT) project, a critical component of Petronas' digitization strategy. Managed the deployment of AV Patch Management, Asset Management Tools, and Network Segmentation across all devices connected to the Petronas Network.

  • As the team leader, I oversaw Hypervisor Specifications, IP Management, Firewall Rules, and Equipment procurement, and provided support to vendors on technical documentation for control networks.

 

This experience underscores my ability to manage complex projects, lead diverse teams, and drive technical innovations in alignment with organizational goals.

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PROJECTS WITH PETRONAS CARIGALI SDN. BHD.

 

  • Miri Crude Oil Terminal – Effluent Discharge Quality (MCOT-EDQ – Approx. USD 21 MM)

Detailed Design Review, Overall Instrumentation Design & Selection, System Procurement, Technical Decisions, PTS and Procedural Compliance.

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  • Miri Crude Oil Terminal – H2S Analyzer Installation (MCOT – H2S Analyzer Approx. USD 2 MM)

Detailed Design Review, Overall Instrumentation Design & Selection, System Procurement, Technical Decisions, PTS and Procedural Compliance.

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  • Greater D18 Infill & Water Injection Wells – (Offshore WHP – Approx. USD 53 MM)

Detailed Design Review, Overall Instrumentation Design & Selection, System Procurement, Technical Decisions, PTS and Procedural Compliance. Total 21 production wells with new 04 Infill and 04 Water Injection Wells development on three platforms with “Bridged Platform” deployment for WI Facility

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  • Greater D18 Water Injection Wells HAZOP, HAZID & IPF Study (04 WI Wells)

HAZOP, HAZID & IPF Study to determine the SIL levels for newly developed Water Injection Facility, bridged and linked with existing D18 MP-A main process platform. WIF covers both new and OP to WI converted wells.

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  • Greater D18 WIF- HAZOP  (Vendor Packages)

HAZOP Study for Hazards and Operability Evaluation of the Design Packages including Power Generation, Communication Systems, Safety Systems, Process Control & Monitoring Systems and Fire & Gas Detection and Protection Systems for the newly developed Water Injection Facility, to be bridged and linked with existing D18 MP-A main process platform. WIF covers both new and OP to WI converted wells.

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  • Baronia Rejuvenation - PDMS 60% and Human Factor Engineering (HFE) for P1A

Review of the 60% Completion of the Plant Design Management System (PDMS) and Human Factor Engineering (HFE) Study for P1A to determine Technical Completion of the project and to review the close-out of 30% PDMS Technical Completion.

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  • Kinabalu KNDW-W Redevelopment Project SIL Assessment (20 Infill Wells, 15,000 bopd)

IPF Study to determine the SIL levels for new Kinabalu Wellhead Platform KNDW-D, bridged and linked with existing KNDP-A satellite platform. WHP consists conventional wellheads with Single and Dual completions.

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  • PSR Review of Instrument & Control Systems PTS

Review the requirements of Project Safety Review (PSR) requirements of the existing PETRONAS Technical Standards (PTS). Total 47 I&C related PTS of SKG-14 I&C group reviewed and listed down 127 PSR Requirements for both the Green Field and Brown Filed projects. Evaluation covers the Implementation, Required Cost, Time & Resource (CTR) and ALARP implementation to PSR calls.

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  • JVM4 : SK-310 B15 Development Detailed Design HAZOP and SIL (Offshore WHP Development)

HAZOP & SIL Study to determine the SIL levels for new platform bridged and linked with existing “Sapura Kencana” main process platforms.

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  • Instrument Protective Functions (IPF) Studies

IPF studies to cover Green Field Projects. Both exSILentiaTM and purpose built Excel sheets used for SIL assessments in line with IEC 61508 & IEC 61511. Loop to Loop review of P&IDs to analyze all the possible Dangerous and Safe Failures with their respective Economic Loss conducted to determine the required Safety Integrity Levels (SIL) for the process plants.

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  • Alarm Rationalization and Periodic Bad Actors Assessments

Alarm Rationalization studies to cover Brown Fields and Green Field Projects under PETRONAS Carigali Sdn Bhd. AlarmPro software used for Alarm Rationalization. Loop to Loop review of P&IDs to analyze the periodic “Bad Actors” with respective Process Criticality, Frequency and Economic impacts conducted to determine the necessity of the Alarms and respective Priority for the process plants.

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PROJECTS WITH OMV (PAKISTAN):

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  • DCS Implementation Project from PLCs to Delta-V / Centum VP (Approx. USD 2.5 Million)

Scope of Requirement, Design Review, Concept & FEED Phase. System Selection, System Procurement, Technical and Procedural Compliance as well as Commercial Deliverables.

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  • GE Mark-V to Mark-VIe Upgrade Project (Migration USD 1.2 MM)

Scope of Requirement, Design Review, Concept & FEED Phase. System Selection, System Procurement, Technical and Procedural Compliance as well as Commercial coordination with GE M&C

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  • Solar Turbine Control System Upgrade Project from TT-2000 to TT-4000 (USD 850K)

System Selection, System Procurement, Technical Decisions, Procedural compliance & Commissioning with Solar FSR

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  • Power Generator’s F&G System Upgrade to EQP – SIL-2 Certified System (USD 165K)

Design, System selection & Replacement of Old SLC based system at Diesel Generators and SCADA package at Gas Generators. Both were obsolete and not SIL Certified. Systems upgraded to DetTronics Eagle Quantum Premier (EQP) – SIL2 Certified Systems. Field existing devices integration with new system at running plant was a big challenge.

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  • Simplex F&G System Upgrade to EQP – Integration with Mark-V at GE Turbine (USD 140K)

Design Phase, System selection & Replacement of Old 'System 4200' that was obsolete and non SIL certified. It was replaced with DetTronics Eagle Quantum Premier (EQP) – SIL2 Certified System. Field existing devices integration with new system at running plant was a big challenge.

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  • Omni Flow Computers Upgrade Project at Fiscal Metering

Design Phase, Procurement as well as Implementation of the project till Final Commissioning. Customer Witness and Approvals were the part of project. Multinational Joint Venture Partners and Government agencies were the stake holders of this critical project.

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  • Kadanwari Centralized Control System (USD 1.9 Million)

Upgrade and Integration the old PLC based control system of the Kadanwari Gas Plant to centralized Virtual DCS Environment, using server-client architecture on a common communication protocol in the new central control room building. This diversified project involved Hardware & Software upgrade, Fiber and Copper Ethernet network, New building construction with Electrical and Safety system installations. I played a role of Lead Design and Commissioning Engineer, involved not only in commissioning rather rectified all the post commissioning findings.

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  • ESD System Upgrade at Front End Compressors

Designed, Procured and Commissioned the upgrade project from old Relay based ESD Panel to PLC based system with dual communications capability over Ethernet as well as Serial communication protocol. Online bump less transfer from old to new control system and vice versa. First-out Logic, De-bounce Timers and Dead-band enabled logic configured.

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  • Minerva – 80 to Minerva – 4000 Camp Fire System Upgrade

Design Phase, System Selection and Final Commissioning. Old system Minerva-80 was obsolete one and replaced with Minerva – 4000. Using existing camp cabling with new addressable devices with provision of future expansions was a big challenge.

 

  • Front End Compression and Wellhead Compression Projects (05 Nos.)

Kadanwari and Miano concessions have low pressure wells and require wellhead compression. Projects involved HAZOP study, C&E Development and Interface Loops between wellhead RTUs, Compressor Controls and Centralized Control Network of 4 wellhead compressors (2 Miano + 2 Kadanwari) and 1 Front End Compression Project at Miano.

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  • Wellhead Development Projects (13 Nos.)

To achieve the production targets and balance the depletion from other wells, addition of new wells and integration with existing system is a continued process at oil & gas fields. Projects involve complete PLC and Hydraulic Control based RTUs Commissioning and Integration with Centralized Control Network. So far we have been a part of almost 15 well development projects.

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  • Voice Over IP Telephony Implementation

FEED & Final Commissioning of the VoIP Telephone upgrade project. Coordinated with IT-Team for the replacement of old conventional Analog Exchange with State of the art IP telephone system, fully integrated with remote wellheads, process plant, camps, internal and external exchanges and Main Exchange at the head office.

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  • VHF Communication Upgrade Project

FEED & Final Commissioning of the VHF Radio Communication upgrade project. Coordinated with IT-Team for the installation of Digital Repeaters at Remote locations and at Central facility to cover Communication range at the diameter of more than 100 Kilometers. Fully integrated with remote wellheads, process plant, Country Side Roads and Desert Ways.

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  • Maximo & SAP Implementation Project

Review, Addition, Deletion and Modification of existing Equipment, PM Plans, Spares and Inventory rationalization in Maximo CMMS in year 2004 – 2005 and later conversion from Maximo to SAP in year 2011. Developed, presented and got appreciation on successful implementation of Process flow of Maintenance Work-Order system for Corrective jobs as well as S-RCM based PM plans.

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PROJECTS WITH ENI (PAKISTAN):

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  • Wellhead Compression Projects (02 Nos.)

Project involved HAZOP study, C&E Development and Interface of Loops between wellhead RTUs, Compressor Controls and Centralized Control Network.

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  • Wellhead RTU Upgrade Projects (10 Nos.)

To upgrade and integrate the old Modicon Micro PLC based RTUs of the Kadanwari wellheads to more advance Modicon Momentum PLCs. Project involved Hardware & Software upgrade, Fiber and Copper Ethernet network, Integration with Centralized Control Network. I played a role of Lead Design and Commissioning Engineer, involved not only in commissioning rather rectified all the post commissioning findings.

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PROJECTS WITH INTECH PROCESS AUTOMATION:

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  • Kadanwari Upgrade and Miano Field Development Project

Commissioning, Dry Cycling and Startup of Memguard System, a propriety system of Universal Oil Products (UOP) based on Allen Bradley programmable logic controller PLC 5/80 C, with HMI interface of Wonderware Intouch, using DH+ & ControlNet as a communication protocol. Communications b/w Heater Panels, Eurotherm VFDs and Multi Speed Motors at Coolers, ABB Gas Chromatograph are the part of complete system integration.

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  • Chevron Abiteye Water Injection Facility, System Integration Project, Nigeria

Development & Commissioning of Control Systems for OML100 Project at Total-Fina-ELF Offshore site in Nigeria. System consisted of Elsag Bailey’s Infi-90 DCS

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  • OML100 Infi - 90 Upgrade Project Total-Fina-Elf (Offshore Site), Nigeria

Upgrade involved Intellution Dynamics iFix 2.1 as HMI and OpsCon as an OPC server, to establish the link b/w Infi-90 and WinNT based PC. Remote Data Acquisition of Alarms History from Offshore site to main head office via existing radio link using MS Query and Visual Basic scripts were also the part of the project

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  • Cabinda Gulf Oil Company (CABGOC) Control System Project, Angola

Development of Vendor Requirements Package and HMI screens.

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