Lead Testing & Commissioning Engineer

Job Description

1. Position Purpose

The Lead Testing & Commissioning Engineer shall lead the complete pre-commissioning, commissioning, start-up, performance testing and handover of the Project. The primary process package is the instrument air and plant air compressor system; however, successful commissioning depends on extensive integration with electrical power systems, instrumentation, package PLC, DCS/ESD/F&G, mechanical and piping systems, utilities, brownfield tie-ins and offshore operations. The role is therefore multidisciplinary and shall coordinate all relevant disciplines, OEMs, subcontractors and Company representatives to achieve safe and timely system start-up.

2. Key Accountabilities

• Own and lead the overall testing and commissioning strategy, systemization, execution plan and handover process for the complete Project.
• Lead commissioning of compressor and dryer packages, including mechanical run-in, electrical energization, instrumentation calibration, logic validation, functional testing and performance testing.
• Act as the single focal point for commissioning interfaces among Engineering, Procurement, Construction, OEMs, subcontractors, ADNOC Offshore Operations and the project management team.
• Ensure all systems and subsystems are mechanically complete, safe, properly documented and ready before energization, introduction of utilities or start-up.
• Drive closure of punch items, technical queries, interface issues and commissioning constraints to meet project milestones.

3. Detailed Roles and Responsibilities

3.1 Commissioning Management and Planning

• Develop the overall Pre-Commissioning, Commissioning, Start-up and Performance Test Plan for the project.
• Define commissioning systems, subsystems, boundaries, priorities, turnover sequence and required completion milestones.
• Prepare and maintain the commissioning schedule, resource plan, vendor mobilization plan and offshore execution sequence in coordination with Planning and Construction.
• Establish commissioning readiness criteria, system handover requirements, Mechanical Completion (MC), Ready for Commissioning (RFC), Ready for Start-up (RFSU) and final acceptance requirements.
• Prepare and maintain the Commissioning Register, system/subsystem status tracker, punch list register, constraint register, interface register and vendor attendance schedule.
• Coordinate commissioning inputs for shutdown planning, brownfield tie-ins, SIMOPS, offshore campaigns and marine/logistics requirements.
• Conduct commissioning readiness reviews, daily coordination meetings and system walkdowns with all stakeholders.

3.2 Compressor and Mechanical Package Commissioning

• Lead pre-commissioning and commissioning of instrument air and plant air compressors, dryers, filters, receivers, after-coolers, drains and associated auxiliaries.
• Verify package installation, alignment, lubrication, cooling, ventilation, cleanliness, flushing, leak testing and readiness for initial start.
• Coordinate compressor OEM activities including preservation release, pre-start inspection, first start, no-load/load trials, vibration checks, capacity testing and reliability run.
• Validate compressor loading/unloading sequence, duty/standby operation, automatic changeover, pressure control, dryer regeneration and package operating philosophy.
• Coordinate piping blowdown, flushing, pressure/leak testing, reinstatement, line-up and introduction of air to the existing platform networks.
• Lead package performance testing against approved datasheets, guaranteed capacity, pressure, dew point, power consumption and other contractual performance criteria.
• Ensure safe interface with existing instrument air and plant air systems during cutover and transition.

3.3 Electrical Testing and Energization

• Lead testing, energization and functional checks for all electrical systems supporting the project package, including HV/LV switchgear, MCCs, VFDs, UPS/DC systems, distribution boards, transformers and control panels as applicable.
• Review and approve energization procedures, switching programs, electrical isolation plans, LOTO requirements and energization certificates.
• Ensure completion and acceptance of insulation resistance, continuity, earthing, contact resistance, primary/secondary injection, protection relay, functional and inter-trip tests.
• Verify protection settings, relay coordination, motor starting requirements, control power availability and interfaces with existing electrical systems.
• Lead motor solo runs, rotation checks, VFD tuning, current/vibration monitoring and load testing of compressor motors and auxiliaries.
• Coordinate electrical OEM support and resolve issues related to switchgear, MCC, VFD, ECMS/PMS and package power/control interfaces.

3.4 Instrumentation, Control and ICSS Integration

• Lead calibration, loop checking and functional testing of pressure, temperature, flow, dew point, vibration and other package/process instruments.
• Ensure completion of instrument installation checks, impulse line verification, tubing leak tests, instrument air connections, range/settings verification and calibration records.
• Review and validate I/O lists, loop diagrams, instrument index, alarm and trip set points, control narratives, Cause & Effect matrices and shutdown philosophy.
• Lead package PLC, DCS, ESD, F&G, ECMS/PMS and other ICSS interface testing, including hardwired and communication signals.
• Coordinate Factory Acceptance Tests (FAT), Integrated FAT, Site Acceptance Tests (SAT), loop tests, logic tests and end-to-end functional tests.
• Validate compressor start permissive, trips, alarms, sequencing, duty/standby changeover, remote/local operation and emergency shutdown response.
• Coordinate DCS graphics, alarm displays, trends, historian points and operator interface validation with ADNOC Operations.

3.5 Engineering, Construction and Vendor Interface

• Review engineering deliverables from a commissioning and operability perspective, including P&IDs, SLDs, layouts, cable schedules, loop drawings, logic diagrams, Cause & Effect, datasheets and vendor documents.
• Identify commissioning requirements early and ensure they are incorporated into design, procurement, construction and vendor scope.
• Provide input to constructability, operability, maintainability, HAZOP/PHA, design reviews, 3D model reviews and shutdown/tie-in studies.
• Coordinate resolution of design changes, field changes, technical queries, NCRs, interface gaps and vendor deviations affecting commissioning.
• Confirm preservation, storage, installation and pre-commissioning requirements for vendor packages and long-lead equipment.
• Ensure adequate availability of commissioning spares, consumables, temporary facilities, test equipment, special tools and vendor specialists.

3.6 Offshore Brownfield, SIMOPS and Start-up Coordination

• Plan and coordinate offshore commissioning activities in live operating facilities with minimum disruption to existing operations.
• Prepare detailed tie-in, cutover, isolation, de-isolation, reinstatement and start-up sequences in coordination with ADNOC Operations.
• Ensure compliance with PTW, SIMOPS, LOTO, energy isolation, electrical safety rules and offshore work control requirements.
• Participate in job safety analysis, task risk assessments, toolbox talks, pre-start-up safety reviews and operational readiness reviews.
• Coordinate offshore manpower, rotation, access, logistics, material movement and vendor/OEM attendance for commissioning campaigns.
• Provide immediate technical leadership for troubleshooting and safe recovery from failed tests, trips or start-up issues.

3.7 Documentation, Completion and Handover

• Prepare, review and obtain approval for pre-commissioning, commissioning, energization, functional test, start-up and performance test procedures.
• Ensure complete and accurate ITRs, check sheets, loop folders, FAT/SAT reports, test certificates, calibration records and commissioning dossiers.
• Manage MC, RFC, RFSU, System Completion and final handover dossiers in accordance with project and ADNOC requirements.
• Coordinate red-line markups, as-built drawings, O&M manuals, spare parts records, vendor data books and final turnover documentation.
• Lead punch categorization and closure, ensuring no safety-critical or start-up-blocking punch remains open before commissioning.
• Prepare daily, weekly and monthly commissioning reports, progress curves, look-ahead plans, risk/constraint reports and management updates.
• Coordinate training, familiarization and final handover to ADNOC Operations and Maintenance teams.

4. HSE and Quality Responsibilities

• Demonstrate visible HSE leadership and stop any unsafe testing, energization or start-up activity.
• Ensure all commissioning works comply with ADNOC HSE requirements, Electrical Safety Rules, PTW, LOTO, SIMOPS and project procedures.
• Confirm calibrated and certified test equipment is used and all test records are traceable.
• Ensure commissioning activities comply with approved Inspection and Test Plans, method statements and quality requirements.
• Lead incident/near-miss reporting, technical investigation and corrective action for commissioning-related events.

5. Team Leadership

• Lead and coordinate commissioning engineers, discipline engineers, supervisors, technicians, vendors, OEM specialists and subcontractor personnel.
• Allocate responsibilities by system and discipline and ensure clear ownership of commissioning deliverables and field activities.
• Mentor team members, provide technical guidance and maintain effective communication between office, yard and offshore teams.
• Forecast manpower and specialist requirements and support timely mobilization, offshore certification and competency verification.
• Promote collaborative working with ADNOC representatives while protecting project scope, schedule, quality and contractual requirements.

4. Key Deliverables

• Approved Commissioning Execution Plan and system/subsystem breakdown.
• Commissioning procedures, energization plans, test packs and performance test procedures.
• Commissioning schedule, resource/vendor mobilization plan and readiness tracker.
• MC/RFC/RFSU/System Completion dossiers and punch-list closeout records.
• Daily/weekly/monthly progress reports and commissioning risk/constraint registers.
• Final handover dossiers, as-built documentation, operating records and training completion.

Qualifications

Minimum Qualification and Experience:

• Bachelor's degree in Electrical Engineering, Instrumentation & Control Engineering, Mechanical Engineering or equivalent. An Electrical or Instrumentation background with strong compressor/mechanical package commissioning experience is preferred.
• Minimum 16 years of experience in Oil & Gas EPC projects, with at least 8 years in testing, commissioning and start-up leadership roles.
• Demonstrated experience in commissioning compressor packages and associated electrical, instrumentation, control and utility systems.
• Substantial offshore brownfield experience, including live-plant tie-ins, shutdowns, SIMOPS and start-up activities.
• Experience with ADNOC Offshore or similar major operating companies is strongly preferred.
• Proven experience coordinating package OEMs, electrical vendors, ICSS vendors, construction teams and operations personnel.
• Ability to independently lead multidisciplinary commissioning from engineering review through final handover.

Required Technical Competencies:

• Compressor package operation and commissioning, including rotary screw/centrifugal compressor systems, dryers and air treatment equipment.
• HV/LV electrical systems, switchgear, MCCs, VFDs, motors, UPS/DC systems, protection and energization.
• Instrumentation calibration, loop checking, package PLC, DCS/ESD/F&G integration, Cause & Effect and functional testing.
• Mechanical completion, systemization, commissioning dossiers, punch management and turnover processes.
• Brownfield tie-ins, isolation philosophy, cutover planning, SIMOPS and offshore commissioning execution.
• Ability to read and interpret P&IDs, SLDs, schematics, wiring diagrams, loop drawings, logic diagrams and vendor documentation.
• Knowledge of ADNOC standards, IEC, ISA, API, NFPA and applicable hazardous-area requirements.

Software and Tools:

• MS Office, advanced Excel-based trackers and commissioning reporting tools.
• EDMS/Aconex/Wrench or similar document management systems.
• Commissioning management or completion systems such as WinPCS, ICAPS, Zenator, CoConsole or equivalent.
• ETAP and electrical testing tools such as Omicron, Megger and Fluke are desirable.
• PLC/DCS diagnostic and configuration exposure relevant to ABB, Siemens, Schneider, Rockwell or other project systems is desirable.
• AVEVA E3D/PDMS, Navisworks or similar model review tools are desirable.

Additional Information

Personal Attributes:

• Strong leadership, ownership and decision-making capability in high-pressure site and offshore environments.
• Excellent multidisciplinary coordination, communication, reporting and stakeholder-management skills.
• Systematic approach to safety, quality, documentation, troubleshooting and closeout.
• Ability to work across engineering, construction, commissioning and operations teams and manage multiple vendors simultaneously.
• Willingness and medical fitness to travel and work offshore as required.