Antony Smith

I am working as a Senior Mechanical Engineer for Sadara world largest chemical plant in ISO Cyanides Maintenance Department.

 Resolved FAM Centrifuge oil leakage issue, root cause analysis, and design modification implemented, Overhauling of Centrifuge and re installation done.
 Resolved steam trap steam leakage issue
 Resolved Dresser PSV nozzle stuckup issue, due to construction error in eccentric reducer orientation
 Cataloguing of Spare parts for 300 pumps, 200 PSVs, and stock quantity finalization, BOM list maintained, to ensure sufficient spare parts available with proper quantity for quick overhauling, repair of pumps
 Resolved sealess AES magnetic pump issue, and overhauling done
 Design modification solution to Fraitec Hydrochloric Acid pumps seal leakage, seal plan modified from 53A to Seal Plan 54
 Flowserve pumps impeller, backplate chemical erosion issue resolved
 200 meter conveyor belt issue resolved, spare belts list creation and stock quantity planning done
 Having experience in troubleshooting failures, repairs, restoring defective equipment and providing input to facility and equipment strategies.
 Good experience as a subject-matter expert in equipment failures and repair techniques during root-cause investigations.
 Resolved plant issues impacting production over a short period of time.
 Trained plant personnel on troubleshooting failures, repairs, and evaluate equipment’s durability and conditions.
 Alignment of Nuovo Pignone Gas Compressor & Centrifugal pump, including the removal of rotors complete with impellers to change out for re-staged impellers and new rotor.
 participated in performing Condition Monitoring of Rotating equipment and advice on the maintenance schedule based on the analysis & update the equipment data, history & Maintain records in the system
 Repair & clean different types of valves, Gate valves, globe valves, butterfly valves, shut-down valves, motor operated valves, control valves and safety valves, after completion of cleaning activities install them in respective positions. Testing & recertification of PSV’s done in the workshop
 Ensured that requests for equipment critical to work process include engineering input on repair details such as clearances, tolerances, materials of construction, welding procedures, etc., and if necessary provide onsite/offsite technical support for deviations from this data
 Ensured that repairs, repair techniques, equipment specific training, are documented and accessible
 Supported the PPM coordinator as required in reviewing spare parts’ list for existing equipment
 Participated in developing the maintenance budget to support the maintenance strategy

I worked as a Senior Rotating Equipment Engineer for Atmospheric Residue De Sulfurification unit, Naphtha Hydrotreater unit complex of Oil Refinery.

 Written More than 40 pre commissioning, commissioning procedures of pumps, compressors, Steam turbines.
 Complete loop GE BB5 Recycle Gas Compressor MRT procedure completed.
 Written Mechanical Run Test procedure preparation for Dresser Rand Steam Turbines
 Written Lube Oil flushing procedure for steam turbines, pumps, and compressor
 Seal oil flushing procedure preparation for pumps completed
 Selection of lube oil flushing agency, more than 60 equipments lube oil flushing done.
 Solo run test done for all motors in these units Atmospheric Residue De Sulfurification unit, Naphtha Hydrotreater unit
 Fin Fan Mechanical Run Test completed for around 200 fin fans.
 Follow up the equipment pre-installation procedures and foundation checked, anchor bolts check against the civil drawings in correlation with equipment vendor drawings
 Carefully comply with equipment installation procedures and make sure the jobs performed by subcontractors are done accordingly to the vendor’s installation manuals wherever vendors are not onsite to assist them for the equipment installation and also ensure all the installation jobs to be performed in a safety manner.
 Record all rotating equipment activities done by the subcontractors and update the work progress, compare the actual work progress with planned schedule and see if there is any delay in the planned activities and require subcontractors to increase their workforce and/or resources that so to come back in the schedule mostly for the critical route activities.
 Communicate and be in touch with vendor’s representative while installing the equipment and make sure there were no significant differences between project specifications and vendors installation/erection procedures.
 Answer to Technical Queries and elaborate Site Instruction in the event of discrepancies between vendor and project documents. Also comply with company call off materials and hotshot accidentally breakdown spare parts.

Rotating Equipment Engineer- Completions & Commissioning (Mar 16 - Nov 17 )
PetroRabigh, Saudi Arabia Phase II -Polymer, Monomer, Fire Water System, Portable Water System
Cooling Water System, Steam Condensate, Compressed Air System, Fuel Gas System

 Provided necessary project engineering interface with all yard project activities to ensure construction and commissioning activities proceed in accordance with project requirements and to ensure that these activities are carried out in accordance with the guidelines of the company.
 Completed more than 200 numbers of centrifugal pumps pre alignment, final alignment done which are from tank form, process pumps, feed pumps, suction pumps, transfer pumps.
 Completed more than 100 numbers of centrifugal pumps mechanical run test done, verifying temperature, vibration, pressure
 Pipelines walkthrough, more than 2000 punch items handled, all technical issues, critical & non-critical issues identified.
 Main air compressor unit : Vendor Air Products, Capacity 22179 Nm3/hr,
 Instrumental Air compressor Unit: Ingersoll Rand, Rated Flow 13000 Nm3/hr,
Hands on experience in Walkthrough & punch items, verify completions according to P&ID, Root cause analysis of trips during unload test, Solo run of motor, Lube oil flushing of centrifugal compressor, Trend and performance analysis in system 1 vibration, Magnetic centre finding of motor, Mechanical Run Test of compressor
 Cooling Water system: API 610 centrifugal pumps 6500 m3/hr rated flow
 Wastewater treatment plant: Hands on experience in Air blowing, chemical cleaning, steam blowing activities.
 Product tank feed storage: Tank, Vessel closure inspections done, Fire water system inspection completed.
GE Frame 7FA Turbo-Generator
 Having experience in GE Fin Fan Cooler installation and commissioning.
 GE Cooling water pumps skid testing and flushing procedure for the system.
 Lube/Hydraulic oil system, motors rotation checks with the required system flashing.
 Exhaust stacks installation, insulation, welding, and barrier wall cladding fabrication.
 Generator and Turbine Cooling Water CS supply and return pipe lines, with the required orifices installation for cooling water flow rate adjustment as per GE design/drawing
 GE turbine compartments Fire Fighting CO2 pipe lines connection with F.F.LP CO2 tank. With respecting to puff and concentration test.
 LP co2 tank installation, interconnecting piping with the turbine at 3 zones
 Vent fan installation alignment and motor rotation check
 Lube and hydro oil piping installation and hydro test
 Exhaust stacks installation, insulation, welding, and barrier wall cladding fabrication.
 Turbine Over head crane (35 ton) installation, and rail way beam alignment.( ital crane).

 Perform/Plan/Supervise Maintenance & troubleshooting for pumps, compressor, mixers, gear boxes, Blowers, turbines, Turbo-Expander, all rotating equipment and Auxiliaries' System .
 Reviewed daily casing vibration trends of Plant machinery equipment i.e. Compressors, Turbines, Motors, Pumps, Fans, Gear Boxes, etc. as company follows predictive maintenance program.
 Having experience in Oil analysis reviewing, maintaining all oil analysis reports, oil analysis plan and sampling.
 Preparation of Technical study report, failure reports (RCFA) and corrective action to improve the reliability, availability of the equipment.
 Plan and support repairs/upgrades to major rotating equipment for safe, reliable, and cost effective operations according to applicable OEM & company requirements and specifications.
 Troubleshoot and resolved steam turbine radial bearing high temperature problem. The problem was observed since turbine commissioning by vendor. Troubleshoot and identified cause of air compressor 2nd stage thrust bearing damaged.
 Troubleshoot and resolved bearing housing high temperature problem on 4 units' general purpose steam turbine by retrofitting new cooling water line to bearing housing. Bearing temperature was successfully reduced from 120degC to 80degC.
 Hands on Experience for the maintenance of single casing multi-stage (Total 36 Reaction stages) condensing type steam turbine. Installation of Bearings (Thrust & Journal) Overall Assembly including Lower Casing half, Glands/Labyrinth Seal, Turbine Rotor, Inner casing parts, Upper casing half, Measurement of clearances (axial and radial), checking of rotor movement, overall centering, Tightening of bolts, Installation of main stop valve, admission and control valves, Grouting and Turbine Generator Alignment by Dial Indicator method.
 Having experience in Troubleshoot and resolved integrally geared air compressor repetitive 3rd stage high speed rotor high vibration problem
 Led RCA team to resolve plant bad actor mechanical seal coolers high temperature problem on 6 pumps. Led RCA team to troubleshoot Hitachi reciprocating compressor cylinder discharge high temperature. Problem solved after replacement of passing valve plate which caused re- compression of the gas.
 Carry out root cause analysis of failures of mechanical equipment by use of scientific technique like Why tree analysis
 Hands on experience in Maintenance of GE Gas Turbine Generator set (Frame 9E Model MS9001E), mainly low BTU gas firing, with high speed diesel as back up. GT is capable of operating in open cycle via bypass stack with necessary isolating devices, hands on experience for the maintenance of gas turbine auxiliaries.
 Hands on experience in Maintenance and overhauling of Reciprocating & Centrifugal Compressors.
 Hands on experience in Maintenance of Diesel Engine Make: Caterpillar, Waukesha, GMWA -Cooper Bessemer
 Hands on experience in Overhauling of ID/FD Fans. General Maintenance Activities relating plant shutdown requirement
 Hands on experience in Centrifugal Gas Compressors- Make: Thermo dyne, Dresser Clark and Atlas Copco. Dry gas seal, separation (barrier) seal removal & re install. Dismantling and assembling of diaphragms. Bearing inspection and rotor axial centering. Coupling alignment checking and correction.

Pre-Commissioning & Commissioning activities carried out as follow:
Overhauling, Solo run, Over speed trip tests and lube oil flushing of the following Rotary Equipment in collaboration of respective vendor specialists:

 Induced Draft fan Turbine (A/101-BJIT) of 340 KW
 Forced Draft fan Turbine (A-101-BJ2T) of 340 KW
 Air Compressor and Turbine (A-101J/JT) of 6 MW
 Supervised 15 technicians in the performance of maintenance, Trouble shooting and repair of all types of pumps, Compressors and Steam Turbines.
 Also planning & scheduling of preventive maintenance and shutdown preparation.
 Providing formal and on-the-job training on operation and maintenance of Mechanical system.
 Planning of two years spare parts of rotary equipment

 Overhauling of Frame V GE gas turbines & sagging problem of steam turbine rotor.
 Managed all the plant maintenance activities including condition monitoring and vibration analysis of rotating equipments.
 Responsible for the planning and execution of major overhauls on Turbines, Compressors, Pumps and other plant rotating equipment. Inspection of various parameters such as Vibration, Bearing temperature, Sound, RPM, and Alignment Checks.
 Experience in Siemens Steam turbine, Ebarra compressors, GE 23 MW gas turbines, Expander compressors, Flowserve, Sundyne, Dresser pumps, cold box, cracking furnace and boiler.
 Root Cause Analysis, trouble shooting of mechanical equipment & performance monitoring
 Monitor and track to ensure timely and quality delivery of spare parts
 Planned and executed five shutdown and major turnaround maintenance at Gas processing Plant. Prepared scope of work, schedules, arranged spare parts, tools.
 Planning, scheduling and executing of maintenance, breakdown and preventive maintenance and tracking of history using SAP.
 Carried out maintenance of heat exchangers, overhauling of Gas turbine, steam turbines, pumps, compressors, valves, PSVs, pipe line maintenance, welding repairs, refractory repairs, boiler and furnace maintenance.
 Experience in the development of maintenance strategies and procedures for rotating & static equipment
 Experience in Various API Standards and Recommended practices like API TEMA, ASME etc