Senior Reliability Engineer Mechanical
SHARQ Eastern Petrochemical Company
Total years of experience :16 years, 9 Months
Working as Focal point Reliability Engineer from November 2006 till date with SHARQ (Eastern Petrochemical Company) an affiliate of Saudi Arabia Basic Industries Corporation (SABIC)
-Performing / facilitation of RCM, RCA workshops, coordinating for RBI, SIS workshops.
-Prepare and present monthly KPIs like major systems MTBF, Overall Equipment Availability, Utilize all modules of MERIDIUM software like system models, Growth, Equipment availability etc.
-Analyze bad actors and solve the technical problems.
-Carry out criticality assessment of plant systems and equipment's
and implement umbrella strategy to cover 100% plant assets.
-Prepare annual Plan & establish workshops for RCM, SIS, RBI analyses.Prepare economical models for completed RCM and RCA analyses.
-Implement recommendations in SAP, SMPs, SOP's, Operator log sheets, design changes basic concept development to final project approval, etc.
- Ensure the RCM compliance with international standard of RCM, JA1011/1012.
- Coordinate and facilitate RCA workshops and check the quality of RCA in MERIDIUM PROACT software.
- Improve the Management process of SAP utilization in Plant O&M.
- Improve / customize MERIDIUM APM software for the particular business needs of petrochemical plants with special emphasis on production, RCM, RCA, RBI and SIS for users and Management reporting. I am member of SABIC MCE committee for Reliability improvement.
- Improved technical skills of RCM plant teams to carryout RCM and RCA analyses and support the sustainability of the project by planning trainings, facilitation, surveys, conferences and presentations.
- Worked as permanent agent of continuous sustainability of Reliability culture in SHARQ for Engineering (Design Management Department), plant Operations & Maintenance. Confident to establish the reliability procedures, practices, monitoring and sustainability in any process industry, Oil and Gas from grass root level to International standards.
Worked for Machine Shops O&M & Spares development from December 1999 to November 2003.
- Experienced for the repair of most complicated spares of plant machinery and equipment using manual machine tools like lathe, milling, drilling, Universal boring and balancing machines.
- Major repairs & overhauling containing repair of Turbine rotor 25 MW turbo generator (ABB which is GE now), overhauling of various gear boxes of Flender & other make, parts for various pumps from small up to 100 m3/hr capacity, small turbines up to 1.8MW, Control valves, pressure safety valves, Gate & Globe valves of 16” and above size, Hand operated, pneumatic operated and motor operated valves.
- Local manufacturing of various simple and intricate spares for rotating and stationery equipment considering all technicalities, with detailed procedures of developing the spares.
- Health check of all tools utilized for plant maintenance and their maintenance. Feasibility of tools discard on the basis of condition.
Worked for field rotating equipment maintenance from December 2003 to October 2006.
- Experience of trouble shooting and complete overhauling of high speed (8400 rpm - 14600 rpm) machinery at Ammonia Urea Complex like Synthesis gas Compressor of Nuovo Pignone, Air compressor of BORSIG, High power turbines of AEG KANNIS (25 - 35 MW), CO2 compressor of Nuovo Pignone, Electric Generator of SIEMENS (Now GE).
- Vendor communication, planning, arrangements of spares, manpower, logistics, Vendor specialist of Machine (VSM), for major critical machines overhauling carried out.
- Supervision of maintenance work, machinery performance monitoring of major critical machinery carried out to solve the current and most pressing technical issues.
- Spares review, useful shelf life of spares, storage procedure, spares discard and particular problem solving techniques to remain ready to manage consequences of failure of major critical machine or plan for overhauling activity.
- Performed Non Destructive testing methods like Visual inspections, Dye Penetrating testing, Magnetic particle testing, Radiographic Testing, Ultrasonic Testing, Ammonia leak testing, Hydrostatic pressure testing, Pneumatic leak testing, Material Analyses / identification, Holidays detection of rubber lining.
- Major equipment inspected include Bimetallic tube Urea Stripper, 25/22/2 Material sheets lined Urea reactor, SS lined Carbonate Separator, Ammonia pressure vessels, CO2 Stripper column, CO2 absorber column, Methane Cracking furnace / tubes, Synthesis gas Reactor, High and low temperature shift converters, Main and auxiliary boilers, Steam drums and super heaters, Various Heat exchangers, Various vessels, Storage tanks rubber linings, Cross country pipe line inspection, monitoring and maintenance of Cathodic protection for underground piping.
- Qualified Radiographic testing level 1, Ultrasonic testing level 1 from Pakistan Atomic Energy Commission, Islamabad, Pakistan.
- Carried out identification / analyses of materials with Alloy Analyzer model 9266 of Texas Nuclear, USA for inspection of materials, preparation of welding procedures and various plant maintenance, operation & project related requirements.
- Practiced identification of ferrite content testing after repair / maintenance of Urea reactor internal lining weld seams with ferrite meter.
- Hydro static pressure testing / pneumatic leak detection / Ammonia leak printing carried out for various types of Heat exchangers, pressure vessels, columns and process piping.
- Refractory inspection inside furnace, flue gas ducts, affluent exhaust gas lines, High temperature / Low temperature shift convertors etc. for cracks, disbandment, weaknesses etc.
- Performed QA/QC of weld joints (Visual, PT, MPT, RT & UT), layout, installation of 48” to 76”piping for cooling tower and Urea plant cooling circuit piping.
- Installation, commissioning and monitoring of sacrificial anode Cathodic protection system.
Secured Destinctive position through out the educational career. Secured Third position in the University in Final Year Engineering. Post graduate qualification of RT and UT level 1 Various certifications / courses acquired on job. Special trainings related to RCM received through MERIDIUM Inc. USA by internationally recognized Reliability Professionals.