Sphiwe Skosana

U031 Allen‑Bradley PLC‑5 Replacement to Honeywell Safe Manager

📅 September 2023

System: Allen‑Bradley PLC‑5 → Honeywell Safe Manager

• Facilitated replacement of U031 Allen‑Bradley PLC‑5 logic with Honeywell Safe Manager platform, ensuring seamless transition to modern system
• Conducted signal verification, loop testing, and trip logic validation, ensuring operational integrity of new safety system
• Participated in pre‑commissioning and commissioning activities during system cut-over, supporting successful integration of new platform
• Ensured correct integration of field instrumentation with the new safety system
• Supported safe start‑up and post‑commissioning verification

✅ Outcome: Successful migration from obsolete PLC‑5 system to modern safety platform, enhancing system reliability and maintainability

ESD System Replacement – Conlog to Honeywell Safe Manager

📅 July 2020 – September 2020

System: Honeywell Safe Manager (SIS)

• Upgraded Emergency Shutdown (ESD) system, replacing legacy Conlog system with Honeywell Safe Manager to enhance system reliability
• Executed trip testing, loop checks, and functional testing under operational and shutdown conditions to ensure system functionality
• Verified I/O and conducted system configuration checks
• Facilitated commissioning activities, ensuring ESD system integrity prior to handover to operations
• Coordinated closely with engineering, operations, and maintenance teams to facilitate safe execution

✅ Outcome: Improved plant safety integrity and reliability of critical shutdown systems

• Install, use, inspect, and maintain explosion-proof and intrinsically safe instrumentation in classified areas
• Perform calibration, loop checks, and fault finding on pressure, flow, level, and temperature instruments
• Assist with replacement of DCS cards and perform I/O configuration and signal verification
• Apply working knowledge of PLCs specific to the plant, supporting fault finding and system diagnostics
• Conduct trip testing during full process operation, ensuring reliability of safety-critical systems
• Maintain and verify ESD system integrity in line with plant safety standards
• Read and interpret area classification drawings to ensure compliance with hazardous area requirements
• Conduct QC inspections on new installations, ensuring compliance with engineering and safety standards
• Read and interpret instrument documentation, including:Loop diagramsLogic diagramsCause & Effect diagramsMFDsP&IDsDatasheets
• Interpret system-related and process-related alarms, performing root cause analysis to prevent recurrence
• Explained basic operation and application of field instruments to junior artisans and operations personnel, fostering knowledge transfer and skill development
• Utilised SAP PM systems to capture defects, create notifications, execute work orders, and provide feedback, streamlining maintenance processes
• Execute shutdown activities according to approved plans and schedules
• Read and interpret instrument documentation, including:Loop diagrams
  Logic diagrams
  Cause & Effect diagrams
  MFDs
  P&IDs
  Datasheets
  
• Applied knowledge of emergency procedures, participating in plant safety response initiatives to enhance overall safety readiness
• First Aid trained, supporting on-site emergency preparedness
• Maintained readiness to perform standby duties, responding to breakdowns and plant emergencies.