Resume - Reliability, Maintenance, Planning and Material Engineer- Mechanical

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Resume #84311

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Career Objective: Exploring for a role in Management with the Asset Integrity field as Mechanical engineer (Reliability, Maintenance, Planning or Material sections) in the Oil & Gas industry, however I will remain open for all offers, where my experience and qualifications can add value and contribute in achieving organization strategic objectives of long-term growth with enhanced reliability and availability of the plant equipments at reduced maintenance cost.

KEY ACCOUNTABILITIES:
-Improve availability and reliability of operation within design and operating limits through effective planning and mechanical maintenance.
-Develop maintenance procedures for Mechanical Stationary and Rotary Equipment.
-Maintenance KPI's analysis, identifying the areas of improvement, taking corrective actions accordingly, measure progress against targets.
-Monitor the integrity and reliability of the rotating and static equipments and identify areas of improvement.
-Provide technical support/ trip trouble shooting and problem solving service for maintenance regarding short/long term solutions to bad actors, difficulties or potential problems.
-Provide technical support, problem solving and trouble-shooting service for operations and maintenance Department regarding short/long term complex difficulties or potential problems/
-Developing and implementation of maintenance management system.
-Ability to carry out root cause analysis of failures of mechanical equipment.
-Development of Maintenance quality assurance formats (for stationery and Rotary equipments).
-Liaise with the Electrical, Instrument, inspection and Maintenance engineers to enable efficient scheduling of maintenance jobs.
-Focal point, department quality champion for preparation of department procedure and quality manuals, Maintenance procedures manuals.
-Periodically review daily/ emergency and monthly planning schedules and activities and ensure that work orders are planned and executed according to priorities and resources.
-Plan, supervise and inspect/control the quality of major overhaul activities of all major rotating and static equipment.
-Carry out technical review of all Plant Modifications, interface with Engineering & Projects teams.
-Prepare and control budget of major maintenance activities and implement capital schemes.
-Participate in teams to review procurement procedure, stock policies and spare parts interchangeability.
-Interface with vendors and/or outside consultants in the acquisition of hardware or technical support.
-Carry out Safety Audits, Behavioral Based Safety Audits.
-Assist in selection and training of new mechanical personnel and provides hands on guidance.
-Improve individual and Team competency by developing ongoing training and refresher courses with mechanical maintenance group.
-Inventory Optimization of all plant spares.

---Experience:

---March 2001 onwards: Saudi Arabian Fertilizer Company SAFCO2, SAFCO3, SAFCO4 and Ibn Al-Baytar, Al-Jubail, Saudi Arabia.
Maintenance Engineer SAFC04 Ammonia, Urea, Utilities and Product Handling areas. Hydro Agri Urea Granulator system, Titanium lined High Pressure Stripper/ Bi-metallic Zr. Lined Stripper, High speed centrifugal HP Ammonia & carbamate Pumps, CO2 Compressor/ Drive steam Turbine, Number of Steam Turbines, Fans, Blowers, Pumps & Big size ware houses with Reclaimers, automatic Bagging system, ship-loaders are the salient features of my routine maintenance activities),

Position: Reliability/ Maintenance Engineer (Ammonia, Utilities, Urea & Product Handling).

Responsibilities:

-Maintenance Engineer at SAFCO4/ Ibn- Al Baytar Ammonia, Urea, Utilities & All product handling areas of four urea plants and Solid Port facilities.
-Mechanical maintenance monitoring on a variety of makes & types of equipments and systems (Ammonia, Utilities, Urea plant and Product Handling).
-Rotating equipment spares review of Ammonia, Urea, Utilities & PH plants.
-Troubleshooting, maintenance/major overhauling/modifications, failure analysis, reliability improvement, critical spare part repairs/ planning, oil analysis.
-Provide technical guidance for reliability & maintenance data by assessing SAP data history for accuracy and compliance with reliability best practices.
-Endure that equipment are performing effectively and efficiently (current vs. design speed and capacity).
-Establish and monitors programs for critical equipment analysis and condition monitoring.
-Establish, in conjunction with maintenance supervisors, maintenance programs for critical equipment.
-Lead teams to handles and finds solution to equipment chronicle problems.
-Serve as the focal point for monitoring KPI's for maintenance and operation management teams.
-Evaluate plant and equipment unscheduled downtime proportions.
-Promote reliability best practices integration to plant operations.
-Promote and implement reliability & maintenance projects (RBI, RCM, etc)
-Coordinate identifying plant critical assets according to production targets.
-Updates equipment criticality list according to production business plan changes and targets.
-Coordinate critical spare parts reviews.
-Develop proactive RCA and analysis for critical equipment.
-Lead and facilitate failure investigation for critical equipment, generates reports, actions logs and follow-up in their closure.
-Monitor worldwide reliability and maintenance best practices concepts, techniques and tools (magazines, conferences, books, etc.).
-Develop learning logs from critical failures investigation and implement them for other equipments.
-Generate bad actors report and follows-up in gap closure.
-Organize reliability day to promote reliability practices, benefit and results.
-Performs cost/benefits analysis for technical solutions.
-Providing technical support to field supervisors and ensure quality and safety during Execution of different maintenance activities.
-Review SPIR (Spare parts and interchangeability records) for all Functional Locations installed.
-Provide maintenance material support to planning and execution team.
-Coordinate the development and implementation of a preservation program for critical maintenance materials.
-Assist Management in implementation of PMP and SMP (Preventive and Standard Maintenance Procedures).
-Coordination with all operating departments like Planning, Process, Operation and Engineering for any major modifications and improvements for shut down and Routine jobs.
-Coordination with O.E.M., vendors and contractors for improvement of the equipment performance when needed.

---June 1994- March 2001 PAK ARAB FERTILIZERS LTD., MULTAN, PAKISTAN (Joint venture of ADNOC and Pakistan)

Period: June-94 to March 2001. Position: (i) Area Engineer (Nitro Phosphate Fertilizer Plant); (ii) Area Engineer (Mechanical Workshops).

PAKARAB FERTILIZERS a fertilizer Complex in Pakistan and it consists of: Ammonia Plant (960 MTPD), Nitric Acid Plant (1380 MTPD) Calcium Ammonium Nitrate Plant (1100 MTPD), Nitro Phosphate Plant (900 MTPD), Urea Plant (300 MTBD) and a Power House of 27MW capacity.

Responsibilities:

-I was actively involved in planning and execution of maintenance activities, Proactive, preventive & breakdown maintenance of equipment's (rotary and static).
-Maintaining history of equipments and working on reliability issues, bad actors.
-Spare and inventory planning and management of equipments.
-Handling a team of Technicians and labors.
-I was also actively involved in various plant turn around & maintenance activity within the complex.
-Prepare and control budget of major maintenance activities and implement capital schemes.
-Routine maintenance activities, scheduling and execution of Annual Turn Around.
-Assistance to maintenance crew for maintenance of equipments, etc. development of drawings for local/ in-house manufacturing of some spares.
-Re-tubing heat exchangers and vacuum drum filters.
-Technical evaluation of bids, Budget preparation for maintenance department.
-Installation/Erection of machinery, piping, vacuum drum filters, vacuum pumps, Rotary Pumps, centrifuges and different kind of agitators relating to the machinery in Nitro-Phosphate Plant.
-Worked as Area Maintenance Engineer for two years, in Mechanical Workshop in maintenance, machining and fabrication shops.
-As a part of ISO requirement, I had been involved in preparation and review of department procedure and quality manuals, maintenance procedures manuals.
-Preparing risk assessment and analysis documents as per OHSAS guidelines.
-Actively participated in Quality Circles.
-Plan, supervise and inspect/control the quality of major overhaul activities of all major rotating and static equipment.
-Monitor the integrity and reliability of the rotating and static equipments and identify areas of improvement.
-Provide technical support/ trip trouble shooting and problem solving service for maintenance regarding short/long term solutions to bad actors, difficulties or potential problems.
-Carry out technical review of all Plant Modifications.
-Participate in teams to review procurement procedure, stock policies and spare parts interchangeability.
-Interface with vendors and/or outside consultants in the acquisition of hardware or technical support.

---Summary of Experience:

-As Reliability and Maintenance Engineer, followings are the highlights of my career.

-Successful completion of "Inventory Optimization Project" as team member (reviewed around 12000 spare parts of rotary and stationery equipments).
-Assisted number of times in overhauling and trouble shooting of high pressure Ammonia and Carbamate centrifugal pumps (disch. Press: 160 Kg/cm2) and number of rotary and stationery equipments in plant area.
-Successful completion on assignments on rotating equipment spares review of Ammonia, Urea, Utilities & plants.
-Rich experience in troubleshooting, maintenance/major overhauling/modifications, failure analysis, reliability improvement, critical spare part repairs/ planning.
-Repairs and replacement of Bimetal and Titanium tube Urea HP-Stripper.
-Retubing of HP-Carbamate Condenser with expertise from FBM Hudson. In addition, a number of Shell & tube, air cooled heat exchangers replacement on my account.
-Relining and trays replacement of HP Urea Reactor.
-Actively participated, as a team member, for PHA/ HAZOP study to handle critical situations and all MOC's in process.
-As quality champion of Maintenance Department, successfully completed the assignments on review of "Maintenance Department Quality Manual", "Maintenance Department Procedures manual" and "Standard Maintenance Procedures", review as per defined frequencies.
-Using SAP module, continual analysis done with recommendation and presentations to management, the effective use of maintenance activities with Supervisor work load analysis highlighting cost reduction and improvement areas of work/ re-work, material and services management.
-Actively participated for Maintenance department Internal and DNV audits and resolved all audit findings.
-Conducted Job Safety Analysis (JSA) for all critical equipments (stationery and rotating).
-Identified chronic problems (bad actors) in the area of work and followed-up with concerned departments like engineering (Technical Support), operations and Process department for trouble shoot.
-Conducted Pre Start-up Safety Review (PSSR) for all implemented MOC's.
-Actively participated in preparation of department maintenance objectives, Maintenance Budgets (expanse or capital) and follow-up for 100% compliance.
-Reviewed and analyzed the backlog, Maintenance KPI's and support maintenance supervisor for improvement while ensuring high PM compliance. A number of presentations done on awareness, analysis and recommendations for improvement.
-Shared with power point presentations on PSM (Process Safety Management) Elements and SWP (Safe Work Procedures) for employee's assistance/ awareness and improvement.
-Planning all emergency and routine maintenance Notifications utilizing SAP system PM and MM modules.
-Certified Train the Trainer for Occupational Health And Safety Hazards Identification & Risk Assessment (OHSAS 18001 ) from SABIC Environmental Consulting Bureau at Al-Jubail.
-Certified end user of Meridium software for RBI methodologies (total four weeks training by Meridium US experts, Training conducted by SABIC).
-Raised a number of Idea proposals through Idea Proposal System and implemented them resulting in reliable equipments and maintenance cost reduction.
-Prepared a number of RCA reports and, as team member, utilized the Tap Root methodology, 5 Whys, Fault tree analysis on some cases.
-Equipment and work processes reliability assessment and monitoring of all reliability improvement plans implementation.
-Technical guidance for reliability & maintenance data by assessing SAP data history for accuracy and compliance with reliability best practices.
-Establish and monitor programs for critical equipment analysis.
-Participation in developing the Safe Work Practices Procedures as team member.

-As Maintenance Planner, followings are the highlights of my career.

-participated in around Eight major Turnarounds and number of emergency /unplanned shutdowns in SAFCO (Saudi Arabia) and Pak Arab Fertilizers (Pakistan) Ammonia/ Urea/ Utilities and Nitro-phosphate including product Handling areas, Following are the job responsibilities.
-Periodically review daily/ emergency and monthly planning schedules and activities and ensure that work orders are planned and executed according to priorities and resource availabilities.
-Identify and recommend requirements for specialized contractor work and monitor/ record contractor's performance and quality of services.
-Monitor and ensure on time planning and execution of maintenance and Inspection programs.
-Monitor and continual analysis and presentations to management, the effective use of maintenance activities with Supervisor work load analysis highlighting cost reduction and improvement areas of work/ re-work, material and services management.
-Review and analyze the backlog, Maintenance KPI's and support maintenance supervisor for improvement while ensuring high PM compliance. A number of presentations done on awareness, analysis and recommendations for improvement.
-Participation as team member to define T/A or S/D detailed job plans utilizing SAP system, MERIDIUM (for Inspection Tasks).
-Participation as execution team member in T/A as per the roles and responsibilities.
-Conducting meetings among Maintenance, planning, Operations, Process, Inspection, Technical Support/ Engineering departments etc., to verify job scope, action plans and responsibilities and follow-up.
-As team member of PHA, Finalizing the MOC's list with operations and technical support departments.
-Arranging material and resources as per the job list..
-Ensuring availability of critical stock items in warehouse (developed an automated programming utilizing SAP, excel VBA coding to extract the critical stock items below maximum stock levels from SAP system. The software can be run periodically for close follow-up of the critical spare parts).
-Preparing the list of zero stock items and the stock items below maximum defined levels, on monthly basis, communicating them to material and purchase section and follow-up.
-Attending meeting and finalizing the job scope with Planning/ operations/ Maintenance / Process and Inspection on regular basis.
-Creation of direct charge purchase requests for services and materials for routine, emergency and call-out activities (utilizing SAP).
-Interaction with local and foreign contractors for services and finalizing the contracts.
-Scheduling and follow up of the activities as per the Inspection/ Process findings and recommendations ensuring timely execution of jobs. Accommodate the Inspection and process findings in the job plans and adjust daily schedules.
-Maintaining detailed histories in related equipment maintenance orders utilizing SAP system.
-Providing input to Post T/A critique and for the preparation of the follow-up lists to implement in next available opportunity.

Well familiar with ISO, ASME, API, DIN, ASTM & OSHA standards.

ACHIEVEMENTS:

-Successfully refurbished the conventional plain bearing arrangements, that have the failure history due to unpredictable axial displacement phenomena, with unique combination of CARB toroidal roller bearing and spherical roller bearing. This methodology was applied to some fan rotors in Ibn Al Baytar Urea plant to review the design of plain bearing arrangements and gained results were excellent. Thus saved the unplanned S/D of the machines saving the production loss too.

-Designed and manufactured a special tool for removal of granulator nozzles without dismantling the nozzle caps, resulted in to recover 3 hrs of production loss for a planned granulation wash activities after every 30 days in three Urea plants. So the cost saving per year= 3(Urea Plants) X 3 (hrs saved time) X 62.5 (MT urea/hour) X 12 (for one year based on one washing per year) X 150 (average cost of urea in $) = 1.01 million $.

-Locally manufactured the Repair Kits for LP and HP Hydraulic cylinders for steam Turbine for CO2 compressor during the course of emergency S/D of the plant and saved 10 days production loss what needed for the procurement purpose from O.E.M.

-Developed the spares interchangeability of Syndyne centrifugal high rpm pumps installed in 04 number of urea plants and thus reduced the overall inventory cost by 0.5 million $. Equipment availability also increased by knowing the interchangeability of the spares.

-Successfully completed an assignment of review of rotary and stationary equipment spares, their interchangeability, deletion of obsolete spares, merging duplicate spare parts and optimize the min/ max stock levels (total spared reviewed= more than 11000). Cost saving= 5.0 million $.

-Proposed an idea and developed a special attachment for machining purpose to machine and polish the used lens type gaskets to reuse them on high pressure piping in urea plants. Total spare parts cost saving per year= 2 million $ (for 04 urea plants).

-Successfully completed the assignment and developed Isometrics drawings for installation/ Erection of machinery, piping, vacuum drum filters, vacuum pumps, Rotary Pumps, centrifuges and different kind of agitators relating to the machinery in Nitro-Phosphate Plant, resulted in plant production increase from 100% to 120% (Pak Arab Fertilizers In Pakistan).

-developed an automated programming utilizing SAP, excel VBA coding to extract the critical stock items below maximum stock levels from SAP system. The software can be run periodically for close follow-up of the critical spare parts).

---System Knowledge and Certification:

Certification:
-Certified End user of SAP PM (Plant maintenance) module (Trainings by SABIC with certificates).
-Certified end user of MERIDIUM (RBI methodologies, Training by MERIDIUM consultants arranged by SABIC).
-Total Plant PHA of entire SAFCO complex (training and certification by US expert arranged by SABIC).
-Certified Train the Trainer for Occupational Health and Safety Hazards Identification & Risk Assessment (OHSAS 18001), from SABIC Environmental Consulting Bureau at Al-Jubail.
-MS Office, Windows 98/2000/XP, AS/400 (PRISM), RAMIS, Ultra-pipe, ATC, EDMS (Electronic Data Management System) etc.

Contacts:
Available if required.

With this resume, I am looking forward for a position in your company that fits with my experience background as summarized above.

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