reliability engineer
Saudi Petrochemical Company (SADAF)
Total years of experience :13 years, 8 Months
Responsible to plan and conduct Reliability Centered Maintenance studies for new and existing systems, Steward “Mitigating threat to availability (MTA)” program and ensure compliance of action plan, Monitor “Reliability Growth models” for high critical and high focus assets, Lead and conduct RCA investigations for Reliability incidents, Bad actors and Analyze and Improve candidates.
Team lead responsible to ensure integrity and sustained reliability of plant assets, develop reliability plans and specifications, conduct FMEA and RCM studies, monitor M&R KPIs and develop action plan for overall reliability improvement.
ROLES AND RESPONSIBILITIES:
Develop, implement and steward appropriate systems and plans to monitor and optimize asset failure modes, reliability, efficiency and service factor.
Optimize frequencies of preventive, predictive and condition monitoring regimes.
Use vibration analysis, lubricant oil analysis, DCS parameters review, trend analysis, online and offline condition monitoring and other diagnostics techniques for condition and performance monitoring of assets.
Conduct Root cause analysis of chronic and high consequence incidents and propose engineering solutions to prevent their re-occurance.
Develop equipment life extension, phase out replacement and obsolescence plans and advice senior managers to prioritize long term capital investments.
Select KPIs for metering asset / system reliability, compliance of implemented systems, planning and scheduling effectiveness, costs and labor performance.
Lead FMEA and RCM studies for existing and new plant systems.
Develop reliability specification with purchasing unit for new assets and revamps.
Ensure compliance to ISO9001, ISO14001 and OHSAS 18001 standards.
KEY ACHIEVEMENTS:
Increased annual production of Nitro-phosphate plant by 25, 550MT (7.6 MUSD) by overcoming key reliability challenges using Pareto analysis, RCFA, reliability modeling and PM Optimization techniques.
Proposed concept of Integrated preventive maintenance outages for N-Plants which resulted in production saving of above 3M USD per annum.
Improved ERP failure data quality by updating failure codes as per ISO 14224.
Implemented “Reliability incident reporting” program to ensure asset failures are properly investigated and corrective actions taken to prevent re-occurrence.
Conducted wrench time studies and improved average job start time by 23 minutes at all operating unit through better scheduling practices.
Responsible to meet business objectives by assuring availability and reliability of entire fleet of rotating equipment, supporting production unit in dynamic context, performing RCA investigations, monitoring machinery performance, overseeing repairs and FATs, optimizing and complying maintenance regimes, planning and scheduling routine tasks and shutdowns, controlling maintenance expense and spare part inventories. Developing and leading a highly competent team through training, mentoring and empowerment, conducting performance appraisals and instilling highest standards of safety, work efficiency and quality.
Key Achievements:
Improved rotary assets reliability at ammonia plant to increase daily plant production rate by 200MT.
Resolved inherent reliability issues of Urea CO2 compressor train to save downtime losses of 6.4MUSD per year.
Completed NG compressor (4.8M USD) installation and commissioning ahead of time as project manager
Slashed inventory cost by 1.7MUSD by standardizing rotary spares & implementing risk based spare philosophy
Reduced annual maintenance expense by 0.25MUSD through local / alternate development of expensive spares.
As core team member implemented DuPont PSM model and achieved level 4.0 in a record time of 3 year.
Coordinated successful compliance audits for ISO 9001, OHSAS18001 and ISO 14001 at department level.
ROLES AND RESPONSIBILITIES:
Develop maintenance strategies, procedures and plans for rotary equipment.
Collaborate with production department and other relevant units to ensure the integrity, availability, and sustainability of all the rotary equipment.
Plan daily maintenance work, carryout site visit and attend operation and maintenance meeting to ensure plant availability as per production plan.
Followup for quality assurance during PM and overhauling jobs on all rotary assets. Prepare quality assurance checklists and job reports for each activity.
Identify needs for overhaul of rotary assets based on online and offline condition monitoring data, efficiency and performance trends and Oracle histories.
Take measures to improve precision and quality of maintenance tasks.
Prepare job packages, resource plans and quality dossier for ATA jobs.
Correspondence with OEMs for clarification of technical issues.
Prepare yearly budget for capital and operating expenses and monitor/control expenditure. Optimize budget requirement and consumption to control cost.
Exceed cost saving targets through local and alternate development of costly spares and exploring options of quality refurbishments through qualified vendors.
Work with warehouse to improve inventory levels, storage quality, periodic maintenance and safeguarding of critical spares for rotary assets.
Lead a team of 31 staff employees (permanent and contractual).
Strengthen safety culture across the organization to ensure safe, healthy and accident free work environment and comply with local and international laws.
Performance testing of new and overhauled machine as per acceptance criteria.
Improve competency of staff employees through technical & soft skills training.
Define unit level objectives and conduct performance appraisals of reporting staff.
Maintain discipline and ensure compliance of enforced policies and procedures.
Member of project handling team responsible for installation, commissioning and handover of 1500MT capacity nitro-phosphate fertilizer plant. Reviewing datasheets, selecting equipment, corresponding with OEM for technical clarification, inspecting inbound material, monitoring contractor progress, verifying machinery installation as per package, ensuring precision alignment, conducting pre-startup safety reviews, approving machinery commissioning checklists and supervising startup activities. Consolidating technical documents, P&IDs, vendor manuals etc, safeguarding machinery spares, ERP coding and returning to inventory.
Key Achievements:
Installation & commissioning of 980T vapor compression refrigeration system with two compressor units.
Successful commissioning of three oil injected screw compressors packaged units ahead of time.
ERP inventory data compilation, safeguarding and storage of spares for more than 200 rotary assets.
I have completed four years bachelor's degree in mechanical engineering with honors and stood second among 154 students in mechanical engineering department.