Productivity Leader for MEA Region
General Electric
Total years of experience :28 years, 4 Months
• Responsible for forecasting sales/billing/cost/margin, preparing budgets and monitoring actuals. This is done at contract, country, sub-region and region levels on quarterly and yearly basis.
• Monitor $4 billion cost backlog for Middle East & Africa region
• Lead regional initiatives to reduce cost and maximize productivity
• Liaison and provide regional support to Continuous Monitoring team in USA
• Take ownership of all regional cost Catalogs
• Coordinate with region operations team to issue and monitor cost out targets
• Prepare productivity pipeline for future years
• Work closely with regional repairs network, service directors, productivity teams, and shop operations to proactively drive cost and cycle management
• In charge of providing operation & maintenance (O&M) services to the Muridke Combined Cycle Power Plant of Sapphire Electric Company Ltd- Plant configuration: 2 GE 6FA GTs, 2 HRSGs & 1 ST with 225 MW Gross capacity - with P&L accountability for GE & client financial expectations (Mar 2011 to date)
• Assure achievement of maximum plant availability at lowest heat rate in a safe, reliable, economical & environmentally friendly manner.
• Hire, lead, mentor & motivate a team of 43 permanent employees - including 3 senior managers & 12 engineers - and a workforce of around 100 at the worksite eliciting superior performances.
• Understand & execute plant contractual requirements and deal with relations related to stakeholders including the owner, subcontractors, vendors & regulatory agencies.
• Formulate, implement and enforce systems, policies & procedures aligned to GE global framework assuring safe, reliable, cost effective operations compliant with regulatory requirements.
• Implement and assure adherence to GE EHS policies & procedures and GE integrity standards to safeguard GE’s worldwide reputation.
• Worked as Plant General Manager supervising O&M of the 225 MW Bhikki combined cycle power plant of Halmore Power Generation Company (Dec 2009 to Mar 2011)
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Mobilization Manager, Jun 2008 to Dec 2009
• Planned, executed, monitored and controlled mobilization of in-country contracts for providing O&M services to combined cycle power plants of various clients.
• Coordinated with the company HQ in Atlanta GA USA for securing required technical & logistic resources & support for successful mobilization.
• Established the Maintenance Management System and implemented the maintenance plan in each site.
• Supported the GE Country Operation Manager in hiring the management team for each site.
• Prepared & implemented various operational plans - operations, EHS & training as well as administrative procedures.
• Managed the contract budget & procurement.
• Coordinated with the site management team for smooth transition and signing -off.
Eastern Power Company Limited (EPCO) has got the approvals from the Government of Pakistan to Build, Own and Operate (BOO) used diesel engines based RFO fired 163 MW combined cycle power plant at Pasrur in the Sialkot District of Punjab, Pakistan on fast-track basis.
I am leading, along-with CEO, EPCO team to meet the challenging targets of achieving Financial Close by March 2008 and COD by May 2009. My current activities include:
• Initialized Implementation Agreement (IA) with PPIB
• Power Purchase Agreement (PPA) negotiations with WAPDA
• Settlement of tariff related issues with NEPRA
• O&M Agreement drafting and negotiations with Wartsila
• EPC contractor selection, agreement drafting and negotiations
• Fuel Supplier selection, FSA drafting and negotiations
• Site preparation activities
• Apprise the CEO and investors with ever changing project risks and returns
Technical:
1. Combined Cycle Power Plants (Siemens & GE) - 6 week course at ESB Generation Training Center Dublin, Ireland.
2. Speedtronic Mark V - by General Electric USA at Uch Power Plant.
3. Gas Turbine and Steam Turbine Overview - by GE USA at Uch Power Plant.
4. STAG Unit Operations and BOP Systems - by GE USA at Uch Power Plant.
5. Generator Excitation - by GE USA at Uch Power Plant.
6. MAX1000 DCS - by Max Controls USA at Uch Power Plant.
7. Predictive Maintenance - by General Physics USA at Uch Power Plant.
8. Instrumentation & Control - NFC Institute of Engineering & Technology Multan.
9. Preventive Maintenance - by Petroman at NED Engineering University Pakistan.
10. Fuel Gas Supply System for Gas Turbine based Thermal Power Plants - Siemens Power Generation / Rotring Engineering
11. Chromatograph and Flow Computer - Siemens Power Generation / Rotring Engineering
12. Vibration Analysis 1 - Western International Lahore
13. Vibration Analysis 2 - conducted by CSI USA in Lahore
Health & Safety:
1. Basic First Aid - The British Association of Emergency Medical Technicians.
2. Electrical Safety, Hearing Protection, Risk Assessment, Basic Fire Fighting - Eurolink Safety Services.
3. First Aid and Basic Life Support - Agha Khan University Hospital.
4. Basic Fire Fighting - Professional Maritime Education & Training Institute.
5. Competent Person (ESBI Safety Systems) - ESBI Uch Power Plant Pakistan.
6. Operations & Maintenance of Breathing Apparatus - Maritime Education & Training Institute.
7. Basic First Aid and Life Support - Maritime Education & Training Institute.
Others:
1. Contribution Certificate for ISO 9002 Achievement - ESBI Rousch Power Plant.
2. ISO 9001:2000 Certification Course for Internal Auditors - Lloyd’s U.K, Certification No. 02/5160.
3. Achievement Certificate for ISO 9001:2000 - ESBI Rousch Power Plant.
4. Basics of Business English - Pakistan Institute of Management Karachi.
PPIB provides support by the Government of Pakistan (GOP) to the private power sector in implementing power projects and provides “One-Window” facility to investors on behalf of all ministries, departments and agencies of the GOP. PPIB negotiates the IA and provides support in negotiating PPA, GSA, FSA and other related agreements. PPIB also assists the regulatory authority (NEPRA) in determining and approving tariff for new private power projects.
• I was responsible for the project management of following Independent Power Projects:
1. 1000-1200 MW Imported Coal Based Integrated Power Project near Karachi sponsored by AES
2. 1000-1200 MW Imported Coal Based Integrated Power Project near Karachi sponsored by Mitsui
3. 120 MW Combined Cycle Power Project on low BTU Kandra Gas at Sukkur
The activities included:
Pre-Qualifications and selection of Bidders
Preparation of terms of reference, monitoring & review of feasibility studies
Issuance of LOI/LOS
Contract administration and related issues
Handling technical and financial matters related to the project
Financial and tariff analysis
Participation in various project development activities
Preparations of presentations, project briefs, working papers and progress reports
• Coordinated with WAPDA, NEPRA, Ministry of Water & Power, Ministry of Petroleum & Natural Resources, SSGC, PSO, Shell, Multinational Consultant, IPPs and other relevant entities.
• Prepared framework for Fuel Oil Supply Agreements and Competitive Fuel Pricing Framework for IPPs under Power Policy 2002. Reviewed FSA for ICB Projects.
• Finalized new tariff structure and bid evaluation methodology for ICB projects in collaboration with PPIB consultants. Analyzed tariff for the Fast Track IPP Expansion and Leading Business Houses proposals for setting up new power projects.
ADWEC, a wholly owned subsidiary of ADWEA, is single buyer, seller and planner of water and electricity in the Emirates of Abu Dhabi.
Working for ADWEC with German and Australian management in PCD (Procurement & Contracts Department) my responsibilities include:
• Developing and implementing contractual agreements including PWPA and GSA
• Reviewing and finalizing performance testing procedures for IWPPs
• Technical evaluation and verification of compliance with the signed documents of capacity/energy payment invoices submitted by IWPPs and fuel invoices submitted by Gas Suppliers
• Initial and annual performance testing of IWPPs
• Projects follow-up and to witness commissioning tests
• Evaluating bid proposals for new IWPPs
• Fuel Demand modeling of IWPPs and to finalize PWPA schedules
• Operate heat-cycle software and analyze IWPPs’ performance
• Perform statistical analysis of Power/Water production and fuel consumption
• Supervise gas, distillate, and water meter calibration
• Prepare management reports
For eight years I worked for the multinational ESBI (Electric Supply Board International), a subsidiary of ESB the National Electric Power Company of Ireland. Initially I was appointed at Uch Power Plant Pakistan and later on transferred to Rousch Power Plant Pakistan. ESBI is O&M Contractor of these two plants.
Working with expat. (European) management, following were the details of my work.
2000 - 2005 PERFORMANCE ENGINEER ESB INTERNATIONAL ROUSCH POWER PLANT
Rousch Power Plant is a 450 MW Combined Cycle Power Plant having two Siemens Gas Turbines V94.2 and one ST. In 2004 the plant was converted to burn fuel gas instead of RFO.
Major Accomplishments
• Conducted ADC tests with WAPDA in years 2001, 2002, 2003, 2004 and 2005. After plant gas conversion conducted Plant Performance Tests with Siemens in year 2004.
• After gas conversion, preparation and finalization of PPA amendments and PPA/GSA related working procedures in collaboration with the owner representatives.
• Gave a presentation during Siemens V94.2 User Conference 2003 in Istanbul Turkey covering my earlier report “AP128 (Vanadium Inhibitor Chemical) impact on Gas Turbine performance” giving detailed analysis and recommendations.
• Established a Microsoft Excel & Word 97 based structure to generate monthly performance reports for higher management (ESB Dublin head-office), owners and lenders. Advanced functions and formulae as well as VBA scripts have been used in the templates to generate daily, monthly and yearly statistics as well as informative tables and different types of charts.
• Established Microsoft Excel based system for plant performance monitoring. It includes gathering of plant data, calculating key plant performance parameters as well as reporting and charting these to plant management. Periodic performance tests as well as daily performance monitoring is carried out using these templates.
(Max character limit reached cont. under next job)
Responsibilities
• Implementation of contractual agreements including O&M, PPA and GSA.
• Interface with WAPDA and SNGPL to support owner interests.
• Calculations of Capacity and FADL LD’s and negotiation with WAPDA.
• Make strategies to minimize LD’s or reduce their commercial impact.
• Conduct Dependable Capacity and Heat Rate tests and issue reports to meet requirements of EPC, PPA and O&M Agreement.
• Plant performance monitoring & optimization.
• Prepare monthly performance reports for owner and lenders. These reports cover a wide range of plant data and key performance parameters in addition to PPA related figures. Fuel, chemical consumption as well as safety & environment related data and issues are also part of these reports.
• Write ISO 9001:2000 compliant procedures for Performance Section.
• To keep record of all outages as well as to segregate those applicable to the company (ESBI) for the purpose of calculating ESBI FOF (Forced Outage Factor).
• Discussions with owners to finalize ESBI FOF and thus ESBI Performance Bonus.
• Using Gas Turbine Diagnostic System for Gas Turbine performance monitoring & optimization.
• Compressor online/offline washing system performance monitoring.
• To give plant performance presentations during monthly performance meeting with owner.
• Perform investigations to establish root cause of plant failures or potential reductions in plant availability or increase in heat rate.
• Highlight risk areas which may impact upon short and long term plant availability and heat rate.
• Reporting of health, safety and environmental data.
• Assist in the preparation of Operations Department budget.
• Prepare templates for performance monitoring and reporting of the Complex.
• Being a certified internal auditor, carry out internal audits for ISO 9001-2000
(Cont. under next job position)
1997 - 2000 CONTROL & INSTRUMENTATION ENGINEER ESB INTERNATIONAL UCH POWER PLANT
Uch Power Plant is a 586 MW Combined Cycle Power Plant located in Balochistan Pakistan. The generating plant consists of three General Electric Frame 9E Gas Turbines, three Heat Recovery Steam Generators and one GE Steam Turbine. The major control system comprises of MAX1000 DCS, four Speedtronic Mark V Turbine Controllers with Allen Bradley PLC’s for some stand-alone applications such as Water Treatment Plant.
While working at Uch Power Plant I progressed from Graduate Trainee Engineer to C&I Engineer. During this process got the opportunities to work in different departments, including Operations Shifts, and involve in commissioning activities. I also attended a series of extensive on-site & off-site trainings. Some of my activities and responsibilities at Uch were as follows:
• During Plant Commissioning phase worked with Raytheon start-up team to commission the station’s Control and Instrumentation systems. My main contribution was in configuring, commissioning and testing of DCS (MAX 1000), Speedtronic Mark V and PLC’s (Allen Bradley).
• Optimizing of DCS configurations, operator screen and alarms for more efficient and safer operation of the plant. This included preparation of live help screens on DCS for quickly identifying faults and missing permissive for major plant items as well as modifying different alarms settings etc.
• Investigate and prepare write up of operation philosophy of the automatic control schemes as they exist in DCS.
• Using Computerized Maintenance Management Systems (CMMS) to plan and implement maintenance programs.
• Writing Standard Procedures & Work Instructions for PM’s and Standard Jobs.
• Planning, supervising and controlling the activities of the C&I maintenance team.
• Preparation of a comprehensive fire register covering brief description of Fire Detection and Fire Fighting Systems, periodic routines, all relevant PM’s and logs etc.
Pakarab Fertilizers Pvt. Ltd. is a public sector complex consisting of Urea, CAN and NP fertilizer plants in addition to Ammonia plant, Nitric Acid plant and 3 small conventional steam turbines for power generation. I was responsible for C&I maintenance section of Urea Plant and reporting to Unit Manager Instrument my responsibilities included:
• Planning, supervising and controlling the activities of C&I maintenance team.
• Providing technical and engineering support to the section.
• Identifying and trouble-shooting day to day C&I problems as well as engineering long-term solutions to recurrent problems.
• Controlling the stock of C&I related spares and equipment.
• Identifying and specifying the tools, equipment, test instruments and consumables needed to carry out maintenance duties.
• Annual Shutdown planning and implementation.
• Keeping loop and shutdown logic diagrams updated.
INET (Innovative Engineering & Technology) Lahore is sole Distributors & System Integrators of Rockwell Automation, Allen Bradley.
Responsibilities
• To manage, completely, projects of PLC (Allen-Bradley) based industrial control systems. This included PLC programming, CRT based operator screens developing, simulation, installation, commissioning, troubleshooting, documentation and on-site training of the relevant staff.
• Assistance of senior engineers in conducting various training courses on PLC’s at Rockwell Automation Center INET Lahore.
Accomplishment
• Complete Automation of Waste-Water Treatment Plant PAK-ARAB Fertilizers Pvt. Ltd Multan.
This was my major assignment. It was intended to install a PLC (SLC 5/02) based control system on the Waste-Water Treatment Plant consisted of almost 175 Digital and Analog I/O’s. I individually and independently completed this project, including programming using Ladder Logic, configuring touch screen display as well as hardware installation and commissioning.
Also completed the following small projects:
• Programming of PLC (SLC 5/02) for Roaster Plant PTC-AK.
• Programming and installation of PLC (SLC 500 fixed type) for “Wapda to Two Generators Switch Gear” for Johnson and Phillips Industries \[Pakistan\] Ltd-NDC.
• Programming & commissioning of PLC (SLC 5/02) for Qaiser Lucky Petrochemicals Sheikhupura.
• Successful troubleshooting of PLC (SLC 500 fixed type) installed on Nitrogen Plant PAEC KCP-1
GPA 4.0
BSc Electrical Engineering (with Honours) Marks 89%, won 2 merit certificates