Staff Mechanical Engineer
Maaden Phosphate company
Total years of experience :32 years, 1 Months
Responsibilities
Ma’aden Phosphate company is an ISO 9001 certified company and one of the largest producer of DAP in the world. MPC comprises of two production sites, namely mining site located at AlJalamid with Mining capacity of 11.6MTPA & Phosphate beneficiation plant capacity of 5.0MTPA, and Fertilizer complex at Raz Al Khair consisting of Sulphuric Acid Plant, Phosphoric Acid Plant, Ammonia Plant & DAP plant Which are capable to produce 3.0MTPA of granulated DAP.
Look ahead, develop reliability analysis methods for assessing plants and equipment, design-out project and commissioning issues, maintenance, and avoid failures by introducing design improvement equipment upgrades. Prepare the needed, and reports RSR . RCA, TSR, RCM Implementation and equipment reliability problems and make cost/effective recommendations to achieve a level or reliability that is commensurate with the company’s needs for current Business plan and KPI and safety, environmental, and operational performance.
Represent the company in outside meetings, discussions, committee and technical forums while working with wide latitude for outstanding actions and decisions to perform the Equipment Reliability.
Participate to design packages review and address Reliability, Availability and Maintainability.
Demonstrated ability to build business case and costing for plant and/or equipment reliability improvement.
Lead and facilitate failure investigation of plants’ critical and chronic problems and identify appropriate recommendations to eliminate the problem root cause(s).
Provide technical guidance for reliability and maintenance metrics and KPI design and data Requirement.
Responsible for ACA (Asset criticality assessment) of equipment and reviewing .
Responsible to organize preventive predictive and emergency maintenance and set priorities for maintenance work assignments supports.
Responsible for Maintains the conditions of tools, equipment and machineries. Maintains high level of safety rules and regulations set by the company and cost effectiveness on all projects and daily work
Job Profile:
Spearhead day to day activities related to maintenance/ project activities of copper concentrate plant
Prepare/ implement project expansion plans of project copper concentrator with capacity from 80 MT to 130 MT per hour.
Focus on implementation of process improvement initiatives aimed at accomplishment of KPIs
Function as maintenance in charge for grinding mill & circuit, flotation cell, filter press, high rate thickener, slurry pumps, pipe lines, utilities and related equipments of mine process plant
Ensure compliance to project delivery schedules and other SLA parameters
Involved in design, evaluation/ selection of mine process equipments, slurry and water pumps
Focus on maintenance/ selection and procurement of mining equipments like crusher, conveyor, ducting system, grinding mill, thickener, flotation cell, slurry pumps, utility plant, agitator, flocculent system, crane, hoist and other related equipments
Implement condition monitoring system and NDT techniques to plant equipment for maintenance improvement
Coordinate mechanical activities for selection/ review of equipments including evaluation of contractors and vendors
Involved in preparation/ rollout of annual budgets for maintenance of copper concentrate plant, expansion and improvement project
Set up new copper open pit mine layout/ requirements, tendering and project based on targets
Select/ finalize contracts and assign activities to ensure compliance to project delivery schedules/ other SLA parameters
Manage erection and commissioning activities of expansion projects and maintenance
Build/ maintain productive business relationship with vendors to ensure compliance to budgets and delivery schedules
Negotiate/ finalize contractors for maintenance of existing plant and copper concentrator plant
Involved in setting up maintenance system and condition monitoring for copper concentrator equipments
Vedanta Resources PLC, India ~ Aluminium Cast House & Smelter - Maintenance and Project Head ~ Jun 2000 - Nov 2007
Job Profile:
Managed aluminium smelter cast house, maintenance and improvement project through a team of 180 internal/ contractor resources
Ensured smooth functioning of casting machine, coiler winding machine, EOT crane, ingot casting machine, busbar casting machine, properzi rolling mill, utility plant, cooling tower and other related Aux equipment for wire rod, ingot and busbar production
Resolved issues using suitable tools/ methodology to ensure smooth functioning of equipment functionality
Focused on implementation of various process improvement initiatives aimed at accomplishment of KPI, business plan and targets
Optimized resource utilization to minimize maintenance cost and enhance productivity
Involved in planning, scheduling and maintenance of plant, production equipment and infrastructure
Maintained updated documentation of maintenance data/ analysis of breakdown using applicable tools
Defined/ implemented plans relate to preventive/ predictive maintenance of equipments
Generated/ updated monthly reports, prepared monthly/ annual maintenance and project plans
Prepared annual/ monthly shutdown plans for critical and major equipments
Worked on condition monitoring system, vibration analysis, oil analysis based on system development schedule
Drafted SOP as per standard and maintained records based on ISO procedures
Reduced maintenance/project cost through development of new methods and implementation of various process improvement initiatives
Maintained optimum inventory level of spares to minimize maintenance costs
Conducted training sessions for team members and convened daily/ weekly meetings based on business requirements
Ensured compliance to engineering standards and maintained EHS with applicable regulations
Focused on project planning, erection/ commissioning including preparation of comparison statement of technical details of different vendors across assigned projects
Worked on erection/ commissioning of aluminium rolling mill, casting machine and auxiliaries for aluminium cast house, aluminium cast house metal flow channel/ launder arrangement for various machine ingot casting machine, wire rod rolling mill and busbar casting machine
Set up Properzi Rolling MILL-4MT for aluminium and managed wire rod production with 1630 m2 heavy reduction cast bar for cast house
Involved in erection and commissioning of
o Automatic horizontal bus bar casting machine
o Aluminium Rolling mill and casting machine and auxiliary equipment
o Cast Iron gas hood system for aluminium pot system
o Conveying System of 250 MT / Hr. for captive power plant
o Lamella clarifier and ultrafiltration system for captive power plant
o 240 Cum/Hr Cooling Tower
o Under slung crane and hoist and required load testing method for Aluminium cast House
o Aluminium holding furnace with Monolithic Refractory brick with minimum melt loss
o Burner and blower system for furnace to reduce the oil consumption from 65 Litre to 45 Litre/MT
o Carbon Pitch melting furnace in carbon plant and required circuit flow pipe arrangement for Bush Mixer
Responsibilities:
Planning, scheduling and executing the maintenance of the plant & production equipment and infrastructure. Ensuring optimum performance levels and minimal breakdowns.
Accountable of maintenance in charge for mechanical equipment like rotary kiln & coolers, conveyors, aux plant and water pumps. Utility plant.
Over all responsibility towards plant, Men and Materials to sustain and improve the performance of Business.
Provide day to day Technical advice to operations & Maintenance.
Estimating budget for spares and maintenance. Developing vendors and sourcing suppliers and spares, preparing indents and negotiating job contracts.
Co- ordinating with the material division for procurement of spares and equipments of projects.
Overseeing erection and commissioning of equipment projects and managing work allocation and man power handling.
FIRST CLASS PASSED WITH 70% SCORE