Sr. Machinery Commissioning Engineer
Air Products
مجموع سنوات الخبرة :14 years, 8 أشهر
Air Products - Secondment at JIGPC (Jazan IGCC - Saudi Aramco, ACWA and AP JV)
Jazan Integrated Gasification and Combined cycle power plant is the world’s largest IGCC complex, producing 4000MW electricity, 33, 000TPD steam, hydrogen, and nitrogen. Feedstock is vacuum residue from the refinery. Comprises of 15x Gasification, 4x Acid Gas Removal, 2x Hydrogen Recovery, 4x Soot &Ash Recovery, 3x Sulphur Recovery, and 5x Power Blocks.
1. Support in documents review, OTP, commissioning, and successful startup of machinery like large BB/ vertical pumps, reciprocating, centrifugal fans, inline compressors, Gas and Steam Turbines.
2. Troubleshooting of issues faced during the commissioning and providing forward plans,
3. Design data review and audits of turbomachinery and pumps etc.
4. Drafting initial plans of spares strategy, reliability, lubrication, and CM programs,
SADAF is SHELL and SABIC JV commissioned in 1984, Sadaf encompasses six world-scale petrochemical plants namely Ethylene, EB, Styrene, SP, EDC, Caustic and MTBE plants with a total output of more than 4 MMT/year.
Provide technical assistance to area supervisors to ensure that all rotating equipment were maintained, Improved and/or replaced to optimum plant availability to meet the plant integrity requirements in liaison with Operation, Planning, Major Maintenance and support functions.
Developed a monitoring sheet for ancillary systems on critical rotating equipment like lube, seal/ control oil systems, dry gas seal support, gland steam leak-off and mechanical seal systems (Plan 52, 53A, 53B and special plans for cryogenic pumps).
Planning Turn around jobs by developing scope of work, JSA, QA/ QC checklists and ordering spares.
Technical review of repair proposals for Rotors, Dry Gas seals and coupling, based on API and SES.
Generate inspection, RCFA and maintenance reports as necessary.
Spares working for all rotating machinery and perform technical clarifications with OEMs.
Coach and deliver trainings for maintenance staff.
Develop, improve and maintain SMPs (Standard maintenance procedures).
Performed various technical clarifications with OEM's like Elliott, Dresser-Rand, GE-NP etc.
As a subject matter expert in Technical organization my job is to enhance the reliability and availability of rotating equipment, play QA/QC role, and provide required technical support to maintenance, reliability, project and Major maintenance departments.
o Currently responsible for Vibration Analysis of more than 1400x rotating equipment at whole SADAF complex using Emerson AMS Machinery Health Manager® v5.61 and CSI 2140 analyzer.
o Provide Technical Support to Run and Maintain Team on any Complex/ Technical issues related to plant Machinery through eTSR system.
o Lead more than 10 RCA’s of selected machinery Bad actors (Through Defect elimination program) and creating Recommendations for resolution through Visaulsoft InnovBase® software.
o Identification of assets adolescence related issues using AMP (Asset Master planning) and assisting reliability engineers in further Growth and Weibull analysis.
o Part of team to define the criticality of all assets in complex using ACA methodology.
o Participated in Root Cause Failure Analysis (RCFA), Risk Assessment, HAZOP study and PHA sessions.
o Review of Major Special and Turnaround jobs/ repair Scope of Work for critical Turbo Machinery.
o Project proposal and documentation review for new Equipment installation.
o Proactive identification and registration of threats at process plants in web base MTA system and closing of assigned short term and long term recommendations generated.
o Diagnostics of Vibration related issues at Turbo Machinery using System 1.
o Technical Review of Rotor Repair proposals for Compressor and Steam Turbines with journal and Magnetic bearings at MTBE and EDC units as per API 687 requirements.
o Prepared SOW and supervised overhauling of M/s Elliott compressors, Turbines and M/s Peter Brotherhood positive displacement Net Gas (Hydrogen) compressors at MTBE unit.
o Technical Review of MOCs related to Rotating Equipment.
o Troubleshooting on DGS systems issues at Critical process compressors. Includes investigation of DGS leakage from product compressor at MTBE and Chlorine compressor at EDC.
o Supervised, planed, managed overhauling, routine maintenance and provided technical support of rotating equipment including Gas Turbines, Steam Turbines, Centrifugal, screw & reciprocating compressors, pumps, gearboxes, ID fans of GE-NP, Dresser Rand, MANTURBO, Elliott, Flowserve, AJAX Cameroon, Amarillo, Hudson, Atlas Copco, OMG, Milton Roy and KSB makes.
o Planned daily area jobs, carried out site visits, attended Operation and maintenance meeting in order to enhance plant reliability and promote safety & compliance to environmental standards
o Conducted root cause analysis (RCA) of equipment failures and un-scheduled shutdowns and recommend problem resolutions. Issued reports for each failure.
o Plan and prepare all the spares and special tools require for the planned maintenance activity.
o Prepared and maintained statistical maintenance and technical reports (daily job reports, machine history reports and material status) related to the routine and preventive maintenance activities.
o Performed various technical clarifications with OEM's like Dresser Rand, GE-NP, Elliott and Atlas Copco.
o Closed out all of reliability related actions and monthly updating of reliability master list.
o Planned Turn around overhauling job for Rotating Equipment by development of JSA, quality check and job cards having the details for all the activities, resources, manpower, consumables and spares required for Gas turbines and Turbo compressors.
o Prepared yearly maintenance Capital and Operating budgets, and monitor/control expenditure. Optimized budget preparation and consumption to control cost.
o Ensured that all maintenance activities are planned and carried out in line with the PPE, HSE control measures and requirements outlined by the company’s PTW system.
o Contributed to the evaluation of the capital projects and other modification projects. Reviewed and commented on all modifications of the concerned process units and facilities.
o Responsible for carrying out day to day maintenance by scheduling jobs on CMMS (Oracle).Ensured that all plant’s rotating equipment are maintained, Improved and/or replaced to optimum plant availability to meet the plant Integrity requirements.
o Lead team of 30 staff (permanent and contact employees) members.
o Developed 10 year plans for machinery overhaul through performance evaluations on the equipment and based on running hours to maintain high reliability & availability of the plant
B.E Mechanical Engineering from NUST, Pakistan.