Head of Maintenance - Mechanical
ORYX GTL
Total years of experience :28 years, 9 Months
• Maintenance Management of Multi-Discipline Team ( Mechanical, Rotating, E&I, Civil)
• Maintenance Strategies (RCM, FMEA)
• Budgeting ( OPEX, CAPEX & Renewal)
• Shutdown and Turnaround Management
• Spares and Inventory Management
• RCA & Troubleshooting
• Management of Changes (MOC)
• Continuous Improvement - Brownfield Modification Implementation
• Greenfield Project Management
• Contracts and Contractor Management
• HSE & Quality Systems Management
• Incharge of SEA WATER DESALINATION PLANT OPERATION & MAINTENANCE
• Plan, design & oversee the Operation & Maintenance of following equipment
o Sea water pumping station ( KSB pumps ) with pretreatment facility
o MED (Multiple Evaporation Distillation ) - Alfa Laval make 475 m3/day
o Reverse Osmosis (RO) Desalination plant
First Stage : 1500 m3/day - 45000 ppm to 500 ppm (Industrial purpose)
Second Stage : 100 m3/day 500 ppm to 100 ppm ( Drinking water )
o Distillate water Re-mineralisation plant : 475 m3/day 10 ppm to 120 ~ 150 ppm (Drinking water)
o Exhaust Gas Boilers, Wartsila make, 3 TPH, 10.5 Bar ( 4 nos )
o Product water tanks ( 1000 m3, 500 m3 x 2nos, 100 m3 - Glass lined tanks GLS )
o Waste water treatment plant ( 750 m3/day )
o Sewage Treatment plant ( 500 m3/day )
o Brine discharge system
o HFO Storage tanks
o Fire Fighting system - Hydrant & Foam system
• Incharge of Utility Plant Maintenance ( SAP Plant Maintenance Module ) of Utilities plant
• Plan the Annual Shutdown activities & safe, timely execution
• Utilities units : LPG unloading, storage & transfer facility, Steam Boilers, Water Treatment plant, Cooling towers, Air Compressor units, Tank Farm units ( HFO, Diesel ), Sewage treatment plant & Effluent treatment plant.
• Plant operation & maintenance of Utilities equipment comprising of various types of centrifugal pumps handling raw water, DM water, Boiler feed water, sewage & effluent water, Acid/Caustic, Diesel, Liquid LPG, Gear pumps handling Furnace oil, Screw compressors (Process & Instrument air ), Boilers (furnace oil fired, fire tube), Water Treatment plant ( SAC & SBA ), Cooling towers ( cooling water treatment plant ), Fire fighting system (hydrant, foam, medium, medium velocity spray )
• Preparation of Safe Operating Procedures (SOP) & implementation
• Preparation of Emergency Response Plans - ON SITE & OFF SITE units
• Key member in implementation of ISO 14001
• Preparation of Preventive Maintenance schedules for the equipment in the Utilities plant
• Preparation of Maintenance schedules based on the condition monitoring reports ( Vibration & SPM values ) for Rotating equipment ( Condition monitoring )
• Periodic inspection of Static equipment
• Spares planning ( VIS analysis : Vital, Important, Secondary )
• Liaison with Statutory bodies such as Chief Controller of Explosives, State Pollution Control Board, Chief Boiler Inspectorate & ensure 100% compliance of the specified norms
• Costing system development in the Utilities plant
• Work includes Pre commissioning & Commissioning of Utility facilities (Water Treatment Plant, Air, Nitrogen Plant, Boiler, Hydrocarbon storage facilities)
• Preparation of Maintenance schedules for both ROTARY & STATIC equipment
• Preparation of schedules for Annual Turnaround activities which includes planning for Material, Equipment, manpower
• Involved in Piping Fabrication and Erection in Offsite & Utilities plant
• Review of Piping Plans, Piping Isometrics, Preparation of Material Take Off ( MTO )
• Follow - up of Fabrication, Hydrotesting, Erection of Piping jobs
• Responsible for the successful implementation of all mechanical maintenance work on both ROTARY & STATIC EQUIPMENT
• Interpretation of engineering drawing/documents and execute the job as per drawing/specification.
• Coordinate the maintenance work and manning of the maintenance team under my direction to plan, control and implement, in a timely and safe manner, all the requested work.
• Evaluate scope of assigned tasks and performs general work planning and preparation activities.
• Plan steps and procedures to accomplish assigned maintenance or repair work, including identifying materials and support equipment needed for the job.
• Coordinate with operating personnel regarding permits and clearances to initiate maintenance or repair activities. Support and coordinate all required maintenance activities with operating crew.
• Support the preparation and implementation of the various vendor test packages with respect to mechanical maintenance, by the subcontractors and take ownership of the integrity checks and completion of the equipment.
• Organize/implement predictive/preventive/breakdown maintenance of all equipment
• Maintain history record of equipment.
• Preparation of Refurbishment schedules of Rotary & Stationary Equipment in MS Project
• Complete Maintenance Refurbishment of Rotary Equipment such as Centrifugal pumps, Centrifugal compressors, Centrifugal fans, blowers, Reciprocating & Screw compressors in Ammonia and Urea Complex
• Complete Maintenance Refurbishment of Stationary Equipment such as Heat Exchangers, Reactors, Columns, Vessels etc. in Ammonia and Urea Complex
• Dismantling, Cleaning, Pneumatic Testing / Hydrotesting, boxing up, External Grit blasting and Painting in Stationary Equipment
• Preparation of Welding Fabrication Drawings for various Welding repair jobs in Stationary Equipment, Nozzle Replacement in Vessels
• Preparation of Refurbishment Reports using MS Excel and MS Access
• Supervision of Machine Shop & Fabrication shop jobs
• Fabrication of Low Pressure Vessels
• Structural Fabrication & Erection
• Design and Fabrication of Lifting Equipment Accessories such as Spreader and Lifting Bar
BACHELOR IN MECHANICAL ENGINEERING MARKS : 80% CLASS : FIRST CLASS WITH DISTINCTION