Began in 1984 with the design, supervision and commissioning of the installation for a Bailey N90 DCS and field instrumentation to replace pneumatics on the R602A Dispersion Reactor and Monomer Charge project. Followed through in 1988/89 upgrading R503 Dispersion Reactor to electronic instrumentation and connect to the DCS. Over the years there continued further upgrades of smaller plants and equipment to be controlled from the DCS. In late 1994 and over three years, as a major project the two Styropor Reactors were converted to Dispersion Reactor and Feed Vessel which included a Deodorising Plant and upgrades to the Tank Farm and Utilities. The work entailed a significant expansion of the N90 DCS, adding new instrumentation and design of control room. The job was as Instrument Project Engineer with total responsibility for outcomes in design, construction, equipment selection, testing, scheduling, budgeting and quality.  The deodoriser plant included the responsibility for the electrical work. From 1997 to 2015 further upgrades on debottle-necking and enhancement projects have been implemented working with the process and maintenance groups on-site. Generally there was responsibility for the total design, implementation, purchasing of equipment and engaging contractors to complete the works in both instrumentation and electrical. BASF have decided to close Altona Plant In 2016.Hence the final task is to design, supply and install a standby effluent system for the period of de-contamination and demolition.

Started on the preliminary development of a Vapour Emission Combustion (VECS) project to draw hydrocarbon emissions from large storage vessels to a thermal oxidiser for combustion. The project is located at Coode Island and in 1991 there was a large explosion and fire that caused tremendous damage with local and city general community concern. The task included the contributions to a Hazop, recommendations to perform a SIL workshop and following through to implementation.

Recommendations for control system, design philosophy, specification of instruments and equipment, design of cabinets, circuits and testing. The position entailed the work as the instrument and electrical project engineer with a design team of engineers, draftsmen and PLC programmer to implement the project. The scope of work included the design of communication systems use fibre Ethernet between three land sites containing a control system in each and two control rooms. The thermal oxidisers supplied by GCD were commissioned in less than twelve months and the completion of all the vacuum ductwork with the ongoing instrumentation and PLC work for over 60 tanks went over another two years.

The responsibility continued as an IE project design engineer for the implementation of projects to install new truck Contrec loading arm facilities and incorporate the monitoring on the PLC control system. Two loading arm system facilities are involved, one a B West the other at C West involving 50 tanks. Design consideration is given to filling storage tanks from ships docked in the river.

The Melbourne Port Authority repossessed the Eastern portion of land from Quantem known then as Terminals Pty. Ltd.

The work involved the relocation of tanks from B & C East to B & C West land sites. The task here was to provide design and implementation of instrument/electrical work for tanks such as Phenol, Pygas and others and connect to the installed control system for VECs monitoring and Contrec truck loading.

Further design and implementation work involved the installation of eight Exxon tanks at B West with all its controls and truck loading. Also the same task involved to design and implement to completion in C West for twelve tanks. Implementation includes the supply of a design package for installation, specification and purchasing of instruments, design and supplying PLC, MCC and local control cabinets, co-ordination of contractors, PLC programming, testing and commissioning.

Project work continued south to the Corio site for the instrument and electrical work on the six Urea tanks and one large Avgas tank plus the truck loading systems. Currently engaged in designing IE systems for four new Bitumen tanks at Corio and Thermal Oxidiser at the Botany Bay Plant in NSW.

The project started in Mix Room 8 where 500L and 1500L process vessels were filled with Ethanol using 20L containers. The project entailed the design, supply of equipment, programming and supervision of installation for the installation of a bulk tank and the transfer of Ethanol to the 500L and 1500L process vessels. All work took into consideration hazardous area zones and hygienic application for hardware and installation.

Other projects were implemented such as the MR8 Bio- Isolator, MR8 Fume Cupboard, MR8 3000L tank with control panel CP-400 in the hygienic room, MR7 700L process vessel, CP-600 panel relocation, ethanol gas detector sensing aspirators on the air conditioning ducts, MR8 portable vessels with scales, purchase of spare parts for Mix Room 8.

Melbourne Museum has two storage rooms for containing specimens in glass jars filled with ethanol The jars are stacked on shelves. The task was to provide assistance to the contractor for a scope of work and a hazardous dossier following an assessment by Phil Marks. The endeavour was to comply with the assessment by removing all of the non-certified equipment within the envelope prescribed by Phil Marks. The only remaining items were the exit lamps and a row of emergency lights. 

Matrix manufacture buoyancy floats for drilling well shafts in the deep sea. The existing plant at Malinga WA was being phased out and a new $100m plant built in Henderson, south of Perth WA. The task was to design and drawings the instrumentation and electrical system for the plant. The design included Motor Control Centres, PLC Panels, PPC and RCP Remote PLC Distribution Panels, all the cabling throughout the Plant. The scope included commissioning with other contractors and the customer.

The scope included the provision for a site superintendent for the project for instrument, electrical, mechanical and civil as 2IC to the project manager.  

Started on the preliminary development of the Chlor-Alkali Plant 1 in Fitzgerald Road Laverton in 2009. Provided initial cost estimates, tendering the control system and specification of MCC and other main equipment. Prepared and issued an instrument and electrical design package and issued for tender. Reviewed tenders and instructed contractor on issues on site. The project involved drawings for Delta V control system, Main Incomer Distribution Board, Moeller 60 motor MCC, 7000 amp DC rectification system, various forms of instrumentation segregated into I.S., SIL and standard junction boxes, cabling and wiring systems.

Initiated the start-up and development of a new Chlor Alkali Plant 2, four times the capacity of Plant 1 and managed and monitored the instrument and electrical personnel in the execution of the design, programming Delta V and PLCs, purchasing of equipment. Instelec covered the instrument and electrical from concept in August 2009 to successful commissioning in May 2012.

The work entailed the design and supply of instrument and electrical hardware on various project at Coode Island in West Melbourne and the Altona Plants. Projects at ALtona include a new PLC control system for the 40 solvent tanks, controls for the six oil lube tanks, upgrade of controls for the hazardous and later the non-hazardous tanker loading pumps. Coode Island the scope of work included the Oxygen Analysers for  MMA Tank CD6/CD10 and BA Tank CD5, Corioils Flowmeters for BA and MMA at the tanker loading gantry, Air Compressors, Remote Access Server Hub with ability to remote into Citect Scada, Schneider PLC, Siemens Security Access Control and Wormald Fire Panel using laptops and smart phones. Work entails the upgrade of the Schneider PLC software and CPU as well as Combustor SIL PLC software and CPU and Communications. The tasks on site entails assistance with the running of the combustor.

The task involved the design, supply and installation of a shutdown control system for the sprinkler deluge system at Chemring Defence Countermeasure Ammunition Plant. The task is to initiate a deluge instantly by detonating an actuator to start the sprinkler system on detection of a minute flame in any of the production rooms. The installation also included overseeing the electrical installation was built to comply with hazardous areas.

The work entailed the design, supply and total rewiring of a dual fuel 32MW Gas Turbine installation and wiring of a Triconex System at Kwinana Power Station Western Australia. The design included the installation of the new gas fuel to the Turbine. The design developed a full set of loop drawings for the Gas-Diesel Turbine which is considered a first for such machinery which is consistent with adaption to SIL PLC installation rather than the old hardwired configuration.

The work entailed the design, supply and installation of cabling and instruments and the installation and wiring of a Triconex System at Murrin Murrin Nickel Plant in Western Australia. The work involved IE work on a $100m maintenance upgrade of a 200OC Sulphuric Acid Plant.

The work entailed the design, supply and installation of controls and wiring installation of two dual fuel gas turbines at Nifty in Western Australia (300km east of Port Headland). The turbines were upgraded to run on natural gas and the responsibility was to install the instrument and electrical equipment to hazardous standards and achieve start-up on gas fuel.

Performed as project instrument engineer in three major projects at the Altona Plant for the installation of an Emergency Shutdown System using a Triconex (Triple Redundancy) System. The plants worked on were 3CDU/NFU, 2PtR and 3PtR over the years 1997, 1998 and 1999 respectively. The responsibility included the supply of design, drawings, co-ordination, supervision, testing and commissioning of the instrument and electrical works. Work included the design of solenoid valve test panels, local heater control panels, cabling and instrument specifications. Progressively improved the heater shutdown times from ten days down to three days on the last project. Work involved in the liaison with Triconex Singapore Software/Hardware Engineers and Mobil Reliability, Maintenance and Operations Group and the Mobil “Alliance Contractor”. In 3PtR the work extended to the responsibility for the supply of instruments, panels, valves and materials.

In 1999, the work at Mobil included the design, purchase, assembly and supply for a new Rosemount Delta V DCS cabinets at the Yarraville Terminal. The work was done for the Fisher-Rosemount group to replace the existing Foxboro system on-site. Four DCS cabinets were supplied for locations at the Main Control Room, Sub1, Sub2 and Holden Dock. Responsibility also included site work by providing loop design and drawings and supervision of physical changeover of panels with tie in of wiring and assist in testing.

In 1997, the work at Mobil included the preparation of all the loop drawings and rationalisation of Honeywell DCS hardware for the shutdown on the Unsaturated Gas Plant. The work coincided with Mobil bringing on-line its new FCC unit and the tie-ins were critical to minimise the shutdown duration. The work entailed the supervision of the changeover in the No.2 Equipment Room and in the field as instruments and marshalling boxes were removed or rewired.

Worked over three years on a new $(A’1991)250m Plasma Products Facility project. Started initially on preparation and development of conduit design technique, instrument installation details and construction drawings unique to hygienically sterile areas. Tasks followed through with writing of specification and issue of instrument installation tender documents, review of tender submissions and letting of contract. Upgraded to position of Package Co-ordinator providing monitoring and reporting of construction design concepts to the contractor and CSL management. Promoted to the position of Instrument Installation Group Manager being in control of the implementation, scheduling, administration and supervision of the installation contract. The Group, peaking at ten people, included designers, supervisors, and Cad operators providing design, supervision of instrument contractor and co-ordination with other project and group managers, departments and various contractors. The work was on the process and utilities section of the plant that had around twelve thousand process I/O (not including air handling) involving both field instruments, cables and cabinets. Also the work focussed on major video cabling installation to connect remote portable CRTs and the cabling of ethernet and other communications cabling for PCs and PLCs.

Provided designs on small projects. [1995 to 2009]

Prepared design and drawings for installation and implementation of gas regulator metering station and take off skid at Nifty in Western Australia for Gasnet.

Prepared design and drawings for installation and implementation of gas regulator metering station at Tipton in Queensland for Power Station.

Provided design and drawing installation tender package for installation of instrumentation and electrics for the SO2 Plant in Sunshine, Argon Vessel in Altona and various documentation updates for the general plant in Altona. Provided assistance on Plant upgrades and maintenance at Sunshine. Updated a section of electrical documents for Adelaide.

The work entailed instrument and electrical design and drawings for the pharmaceutical industries on projects for Gradipore, an R&D blood plasma portable skid; MDA, an instant relief for burns; Gropep, growing cultures for research. Involved with the assembly and design support for the supply of three gas analyser shelters and twelve analyser racks for Curtis Island in Queensland.

The work entailed design and drawings for implementation of various projects such as the XPF Plant, warm rooms, PLC panel rewiring.

Began initially invited in to provide recommendations to ensure the Acrilico Plant in Cooloroo was built to Australian Standards for Explosive Hazardous Areas. Following a survey and the advice from a hazardous consultant, the client was advised the Plant did seriously not comply to the requirements of the Standards, the Office of Chief Electrical Inspector and Workcover. A hazardous Area drawing was prepared and recommendations to rectify the condition. The work followed with providing a total design of the electrical and instrumentation upgrade. Included in the design and drawing package was the relocation of the control room and its PLC control system out of the hazardous location, the existing electrical wiring to be totally replaced, and all instrument wiring set to I.S. type installation. Finally, the plant was commissioned and passed by Electrical Inspector and Workcover.

The work involved the preparation of design and drawings for the computer batch control system to provide loss of weight on drum emptying on hot melted cream products. The design included a PC control with relay interface in a custom built panel to be inbuilt into the clean room wall. The task included liaison with the client to discuss the requirements, develop the design, purchase the materials, supply the control panel, and supervise the construction and commissioning.

Troubleshooting electrical control on Plant machines at various times particularly the Killian Tablet Machine. Also includes organising and supervision of electricians in wiring looms and cables issued with machines from Germany being assembled in Australia, particularly the Becomix Cream Plant.

2003, The design, drawings and assembly of a pneumatic controlled drum lift and rotate ram for the drum washing station.

Prepared design and drawings for tender on the Effluent to Polyphos project. The design and implementation of a magnetic roller to trap metals in food grade powder. Other tasks were to manage various small request for advice on various valve sizing, orifice plate sizing, project concepts and drafting services.

Preparation of design and supply of a No.4 and 5 Plug Mill Flow metering Panel for Glucose addition to the process. Assistance provided to monitor the inspector for machine safety after a near incident where an electrician was nearly crushed.

Initially invited over to Singapore and subsequently to Dumai Sumatra Indonesia at its crude refinery. The task was to provide advice on instrument and mechanical interface connection to high pressure/temperature crude oil pipelines. The work also included the investigation of flowmeters for air intake on four large compressors. The application was difficult due to the mechanical access, process conditions and costs. Finally the solution was simply to utilise annubars. Back in Melbourne Instelec Office the task was to prepare instrument installation details for mechanical welding, piping and tubing of pressure, temperature and flow devices. The package was issued to the refinery and installed. Due to political tensions between Australia and Indonesia after 9/11 the remainder of assistance was communicated through email and phone lines.

2006                       The management of preparing P&IDs for the Cheltenham (Vic), Whyalla (S.A, and Hutt Lagoon (WA) Plant

2001                       The work included the co-ordination of mechanical design, drawing and scheduling tasks for the installation of a new cooling tower and 200mm cooling water pipelines.

2001/3                  Co-ordination of various tasks including establishing, plant equipment and instrument numbers, P&IDs and plant improvements particularly for the Whyalla Plant.

2014                       The design and supply of instruments for the Cheltenham KOH Tank. The design, supply and installation of the gas detectors after Phil Marks hazardous assessment.

1999                       Instrument and Electrical design for the Continuous Formulation Project.

1998                       Electrical control design for the Glysophate Powder automatic bag filling station.

Gladstone Chemical

1997                       Design and construction for flow metering and filling solvents to Bulk Road Tankers.

Australian Synthetic Rubber Co. Ltd. (now part of Qenos)

1992                       Design and supervision of flowmeter and levels in treatment plant.

1990                       Writing of Instrumentation Standards and Equipment Specifications.

1989/90                Design loop connections and testing of instruments for C-Line Incinerator.

1989                       Re-establish instrumentation and electrics after D1 Drums fire damage.

1988/89                Re-establish instrumentation and electrics after C-Line MCC fire damage.

1988                       Procurement of instruments on the High Solids Latex project.

1988                       Design and construction for Austraflex project (postponed mid-phase)

1984                       Design package for Re-instrumentation Stage 2 on BR-Plant project.

1986                       Specification of field instruments on BP Kwinana new Cat. Poly project.

1983                       Specification of field instruments on the OK Tedi Gold Mining project.

1980/81                Specification and procurement of instruments, development and issue of design drawings, testing of DCS control panels for Gladstone Aluminium Smelter project.

Altona Petrochemical Co. Ltd. (now part of Qenos)

1995                       Instrument design for SCAL 2 Tar Disposal.

1984/86                Preparation of capital expenditure proposals and design work for SCAL 1 & SCAL 2  Turnarounds. Investigate compliances to hazardous area standards.

1991/93                Design of Lighting and Power in Buildings at Mt. Piper Power Station (NSW).

1982/83                Project engineering for Bayswater Power Station on Power and Lighting (NSW).

1983                       Project engineering for MMBW Thomson Dam instrument/electrical works (Victoria).

1980/81                Project engineering for Fiji Nadi-Latouka Water Treatment Plant.

1980/93                Estimating, design and procurement for numerous large and minor works including power and lighting in underground tunnels, mobile rock crushing plants, power and lighting in large construction camp sites and MCC and control panels for Government Instrumentalities.