Sr Engineer Mechanical
Maaden Phosphate Company
Total years of experience :25 years, 3 Months
Growth Path / Delegations
Jan’14 - Till date Sr. Mechanical Engineer ( Maintenance Support Service)
• Accountable for managing contract for full time on site support service contractor for Static equipment, piping maintenance & all fabrication work, Rotary Equipment Maintenance in central work shop, Rubber lining & Acid proof tiles lining, FRP piping, Scaffolding, Corrosion Protection, Insulation & Lagging, Testing and Calibration of Pressure relief valve, Annual Inspection, Statuary load testing & maintenance of lifting overhead carne & hoists, Mobile crane, boom truck, man lift and forklift service etc.
All above service are provided to whole Maa’den Ras Al Kahir Complex which include 3x 4500 MTD Sulphuric acid Plant, 3X1400MTD Phosphoric acid Plant, 4X 2250 Di-ammonium Phosphate plant, 1x3300 Ammonia Plant,
2x85 M WAT Power plant and Utility.
• Accountable for scope preparation, Tender, technical evaluation of bid and timely renewal for service contract.
• Ensure timely repair of rotary equipment and process vessel so that operation can achieves maximum production.
• Provide technical support and lead in RCA to improve the equipment reliability.
• Assist in execution of operation initiated modification to achieve maximum production and efficiency.
• Assist in annual turn around planning and execution to minimize the cost with available regular resources.
• In house drawing development and fabrication of spares to reduce the maintenance cost.
• Development of Standard Maintenance Procedure (SMP) for improve the quality of service.
• Preparation and Implementations of SHEQ, SOP, SMP.
• ISO9001, 14001, TPM, WCM, OSHA management work
• Implementation of capital project within estimated time & Budget.
Growth Path / Delegations:
Feb’08-Aug’09 Maintenance Engineer (Mechanical) Engineering Services
Sep’09-Jul’10 Maintenance Engineer (Mechanical) Sulphuric Acid Plant
Aug’10- July’13 Project Engineer (Mechanical)
Key Result Areas:
As Project Engineer (Mechanical):
• Accountable for the planning and execution of capital and equipment repair projects for Sulphuric Acid and Phosphoric Acid plant for equipments replacement for productivity improvement, debottlenecking which mostly includes time based replacement /refurbishment of static equipment like Bulk Phosphoric acid and Sulphuric acid storage tanks, Cold and Hot Interpass heat exchanger, acid coolers, Economizer, Super heater, Waste heat recovery boiler, Absorbing towers for Sulphuric acid plant, Graphite heat exchanger, Evaporator vessel, Flash cooler for Phosphoric acid plant etc.
• Initiation, cost estimation, capital fund approval, tender documentation, tender evaluation, contractual agreement (FIDIC Based), concept design, detail design, construction, etc.
As Maintenance Engineer (Mechanical) Sulphuric Acid Plant:
• Managed 3 off Sulphuric Acid Plants and utilities plant which includes demin water treatment plant, 25 MW captive power plant, Auxiliary gas fired boiler, Process and instrumentation air compressor units.
• Carried out the repair operations of various machines equipments.
• Ascertained the maintenance of various blowers, and pumps at central workshop.
• Deftly recruited and appointed team members, thereby motivated them for achieving set targets.
• Adroitly monitored and prepared performance reports of team members for improving efficiency level.
As Maintenance Engineer (Mechanical) Engineering Services:
• Single-handedly managed heavy earth mover, cranes and loco workshop, central main workshop for maintenance of all rotary equipments, fabrication and rubber lining workshop and condition monitoring services
• Monitored spare planning, budgeting, and annual rate contract for all suppliers held stock items like Bearing, V Belt, Oil Seal, Mechanical Seal, etc. to reduce the inventory cost, manpower training and skill development
• Deftly ensured enhancement in operational efficiency in adherence to quality standards, 5S’, Kizen, WCM Practices
Major Equipments Handled:
• Turbo Blower (GE/Dresser Rand)
• Air compressor ( AtlasCopco, Ingersoll Rand)
• Multi Stage Boiler Feed Pump (KSB, Sulzer)
• Gear Box (Hansen, Siemens)
• Waste heat recovery boiler.
• Auxiliary gas fired boiler(Johnson)
• Sulphuric Acid Circulation & Molten Sulphur Pump (Chas Lewis)
• Sulphuric acid shell and tube anodic protected acid cooler.
• Payloders ( Cats, Kawasaki)
• Forklift ( Toyota )
• Tyre mounted Mobile crane ( Manitowoc Grove)
• Phosphoric Acid Plant Attack Tank Agitator (Profile/Prayon)
• Phosphoric Acid Circulation Pump for Concentrator (Ensival)
• Water Ring Vacuum Pump (Nash and Hibon)
• Plate Heat Exchanger (Tranter)
• Horizontal Belt Filter (Delkor )
• Graphite shell and tube heat exchanger( Mersen, SGL)
Key Result Areas:
• Skilfully monitored the budgeting, planning, execution of major plant equipment revamping projects, annual shut down as well as the spares inventory control
Major Equipment’s Handled:
• Water Ring Vacuum Pump (Nash)
• Phosphoric Acid Circulation Pump for Concentrator (Ensival & Fritech)
• Horizontal Belt Filter (Delkor & Gaudfrin)
• Phosphoric Acid Plant Attack Tank Agitator (Profile/Prayon)
• Non Metallic Pump for Transfer of Hyrdoflusilic Acid (Fritech & Wernet)
• Pre Vulcanized and Pressurized Steam Curing Rubber Lining of Vessels
• Refurbishment cooling tower of Phosphoric Acid Plant
• Refurbishment of 3 off Phosphoric acid storage tank which includes Metal repair, re rubber lining, carbon brick lining.
• Refurbishment of concentration unit vessels Evaporators, P205Seperators, condenser etc which includes Metal repair, re rubber lining, carbon brick lining.
Growth Path:
Sep’98-Sep’99 Graduate Engineer Trainee
Oct’99-Dec’01 Project Engineer (Mechanical)
Jan’02-Dec’02 Engineer (Maintenance)
Jan’03-Dec’04 Sr. Engineer (Maintenance)
Key Result Areas:
As Graduate Engineer trainee & Project Engineer, Mechanical (DAP plant)
• Involve in inspection during fabrication and erection of Equipment, Vessels, Tanks, Piping, Belt Conveyor, bucket elevators, as per approved Drawing and quality procedures and Successful Pre commissioning and commissioning of DAP (Capacity-140tph) units
As Engineer, & Sr. Engineer Maintenance (DAP plant)
• Infrastructure set up for maintenance of DAP plants & Bagging plants. Spares planning, indenting, budgeting, manpower recruitment, training etc.
• Co-ordination with Vendors, Consultants and Suppliers to make Technical documentation and equipment master file, stores stock item generation.
• Preventive and planned maintenance of equipments, vessels, Spare planning, Annual budgeting etc.
• Recruiting and appointing team members and motivating them for achieving set targets.
• Monitoring and preparing performance reports of team members for improving efficiency level.
Major Equipments Handled:
• Di-ammonium Phosphate Slurry transfer pump with dry-mech Seal (AR Wilfly),
• Rotary Drum Granulator and Dryer
• Oil Fired Combustion System
• Fluidized bed product cooler
• Bucket Elevator, Belt Conveyor
• Air Blower
• Heat recovery shell and tube heat exchanger for Ammonia vaporization
• B.Sc. Production Engineering ( Mechanical) from B.I.T Sindri, India in 1998 with77%