senior engineer
east delta electricity production company
Total years of experience :14 years, 11 Months
Assisting the Head of maintenance department for scheduling all mechanical maintenance tasks in shutdowns with all departments according to safety instructions as well as contractors. Analyze abnormal conditions, troubleshoot issues, prepare Root Cause Analysis, and recommend remedial actions. Study and present technical solutions and upgrades for plant systems and provide engineering support to other disciplines. Coordinate work with other teams for the multi-discipline plant issues. Monitoring the installation and operation of equipment and systems to ensure that the plant is compliant with design specifications and safety codes, As necessary, contact suppliers to determine best methods of repairing equipment and for assistance in solving problems or to arrange services suppliers for shutdowns and turnarounds.
Main Equipment & duties :
Prepare the spare parts and tools list for units overhauling and shutdowns.
Preparation/approval of Technical Specifications and Data Sheets for Rotating Equipment and Packaged Equipment
Technical evaluation / clarification of rotating equipment vendor bids, plus the technical bid evaluation reports to support order placement
Changing the bearings of Gear Box Of startup/standby Boiler Feed Electrical Pump (Triveni HSG-400)
- Applying all bearings clearance.
- Making Laser and gauge alignment for Main pump and Gear box and Motor and Booster pump.
Changing Anti floating device for the Circulating discharge valve (KSB).
Changing the valve disc and making overall for deaerator control valve.
Checking HP heater no. 6, 7 and mixed flow heater no. 5, Plate heat exchanger.
- Dismantle and remove all clogging things. - plugging the damaged pipes.
Chemical cleaning for closed cooling water circuit plate heat exchanger.
Overhaul for steam condenser & debris filter which using seawater in condensing steam:
- Supervision on installation of cathodic protection system.
- Makeup the lost material, clogging of cracked tubes - Replace (Gears, bearings, oil seals & mesh)
Leading Al-Khorayef team in making assets evaluation and survey team for the SWCC (Saline Water Conversion Corporation) assets. Reviewing the Data Sheets, P&ID’s for any missing data. This project includes all SWCC assets including waste water treatment plants and pipeline, pumping stations, vent stations, line valves, chlorination plants, Water treatment, MSF ( Multi-stage flash distillation ), RO (Reverse Osmosis) and power plants, Tank farms. The asset assessment is following the BSRIA, CIBSE and ISO 55000. Al-khorayef technical report submitted to ATKINS with a technical advice to report to SWCC management in Riyadh. The project includes all SWCC assets around Saudi Arabia plants in Yanbu, Jeddah, Ras Ak Khair, Shuqaiq, Shouaibah, Alkhubar, Jubail. This project under supervision of ATKINS.
Field maintenance Supervision
*Supervising entire gamut of all Mechanical Maintenance activities coordinating with operation, Workshop, contractors, inspection teams.
*Coordinating with Planning team the Maintenance, repair works, equipment’s installation and testing of wide range of mechanical rotating equipments.
Ensuring the maintenance to be within cost & time norms, participating in maintenance review meetings for evaluating scheduled maintenance activities progress.
Monitoring & controlling all maintenance activities with respect to physical progress, time, and quality to ensure execution of activities within the set time as well as cost parameters.
Leading maintenance team to perform major overhauls for all steam turbines inside plant under Siemens supervision.
Identifying and quantifying critical and non-critical risk areas, mitigating & suggesting measures to minimize the impact of risk, monitoring status of risk throughout maintenance activities.
Anchoring on-site maintenance activities as per the given drawings to ensure completion of maintenance within the time & cost parameters and effective resource utilization to maximize the output.
Inspecting field sites to observe and evaluate condition and operability of facilities, along with collecting field survey data and measurements.
Maintaining the records of material requirements and material consumption as well as documentation about the (QA/QC), preparing daily, weekly and monthly reports.
Identify obsolete equipment and develop repair strategies for corrective action in coordination with Engineering & Technical Support Division.
Coordinating with workshop engineer for maintenance activities during periodical shutdowns or corrective maintenance.
Maintenance technical support
Following up spare parts procurement process beginning with ER, PR, then RFQ, BES, ending with PO, MIR.
Supporting field maintenance team with all field requirements like spare parts, technical DWG, to carry out maintenance activities efficiently without obstacles according to international codes and standards.
Provide a full technical support to plant modification projects coordinators as a maintenance representative, coordinating with project team in order to achieve a desired development.
*Monitoring all Maintenance Work Orders for all areas of responsibility preparing reports showing outstanding WO’s keeping open orders within certain limit.
Responsibilities
*Supervising Preventive, corrective, Predictive maintenance and troubleshooting of rotating equipment’s, including a variety of pumps & compressor (centrifugal &reciprocating), Steam turbines …..Etc.
Supervising the major overhauls for steam turbines under Siemens witness according to planned time schedule with no injuries following safety rules, including thermal shield disassembly / assembly, outer/ inner casing of IP, LP turbines, HP turbine barrel, turbine shaft, Shaft seals and gearbox clutch Disassembly & replacing, turbine bearing disassembly, bearing replacing, witness of NDT & OSM (On Site Machining) for the main steam valves externals and internals such as (casing, stem, seats..etc), turbines blades replacement.
*Following up all preparations prior to any overhauls like (spare parts availability, relevant tools, enough technicians, raised work orders, required work permits….etc), making sure of enough material stocking and reservation, monitoring overhaul progress, preparing daily progress reports for running overhauls.
*Supervising overhauls of multistage centrifugal air compressors (Ingersoll Rand air compressor), multistage reciprocating hydrogen compressors (flatiron compressor), following up replacement of compressor parts according to overhaul plan such as (Shaft, impeller, diffuser, mechanical seal, diaphragms ..etc) .
Assisting planning engineer in preparing overall estimates of shutdown period as required, and helps for any network plans for such work.
Preparing details of work completed, used materials, up-to-date estimates of projected use of tools and equipment and expected date of completion.
To review and prepare MTO (material take off) from equipment’s design DWG’s, MR (material requests), PR (purchase request), PE (purchase Enquiry), to follow up PO (purchase orders), to evaluate MTC (material test certificate), MIR (material inspection request), to prepare FR (fabrication request)for equipment components fabrication, RFI (request for inspection), in addition all other system documents.
Fully conversant with engineering drawings, schematic diagrams, engineering standards specs, Plot Plans and P&ID’s, weld map drawings, PFD, assembly drawings, general arrangements DWG.
To ensure all maintenance work-forces are comply with planning compliance in order to maintain excellent KPI and in-line with Strategic Planning, Company’s Maintenance Policies and Procedures & HSE.
To verify daily maintenance schedules, to implement weekly rolling plan. To generate and follow up monthly PM.
To provide Reliability / Maintenance expertise for maintenance of Plant equipment’s Facilities & Utilities including Major Turn-rounds, Shutdowns and associated maintenance Projects. To maintain continuous improvement in reliability procedures and new technologies available in market.
To maintain and improve efficiency of the Plant by a timely and consistently planning/scheduling to avoid any unforeseen breakdown of Plant Equipment and keep the Plant running in a safe manner.
To follow up on relevant technical queries, inspection, delivery, arrangement of the logistics of all extra resources.
Reviewing job work orders issuing to record equipment history over CMMS system, assisting with any technical adjustment, verifying bill of materials as per design DWG and international codes.
Assisting planning for preparing annual & monthly maintenance schedules.
Responsible for making annual mechanical maintenance budget including field and maintenance support.
Ensuring that all maintenance support services are provided in accordance with internationally recognized engineering standards (API, ASME, ASTM, ANSI, NACE, DIN, BS, EN...).
Reviewing requirements for mechanical materials, spare parts and equipment, advice on stock levels and material descriptions, and provide suggestions for alternatives or interchangeability of parts and inspection of expensive/critical items.
Providing field support for work execution in critical equipment’s.
Reviewing contractors' regular reports, assessing their performance and providing advice as necessary.
Taking part in the coordination meetings with Operations for following up of critical equipment’s.
Technically evaluate bids related to direct capital and operating budget purchase requisitions.
Proactively plan, prepare and schedule future maintenance activities ensuring the required level of equipment integrity and reliability within areas of responsibility.
Proactively coordinate maintenance activities including vendor management within areas of responsibilities.
Attend and assist supervising major, important and/or critical breakdown jobs.
Provide inputs for shut down planning activities within areas of responsibility.
Prepare inputs to the yearly Integrity & Reliability reports within areas of responsibility.
Ensure that Company procedures, International as well as Local standards and legislation within areas of responsibility are adhered to.
Ensure day to day improvements.
Present results of analysis to management.