Turnaround planning engineer
SAFCO SABIC
Total years of experience :18 years, 8 Months
Highlights:
• IBB TA 2014 Turnaround (Jan 2013 to April 2014 ) (Ammonia, Utility, Urea & Product Handling Plants)
• SAFCO 2 TA 2016 Turnaround (June 2014 to April 2016 ) (Ammonia, Utility, Urea & Product Handling Plants)
• IBB SSD 2016 Turnaround (May 2016 to Nov 2016 ) (Ammonia, Utility, Urea & Product Handling Plants)
• SAFCO-5 2017 Turnaround (Jan 2017 to Nov 2017) (Urea, Utility & Product Handling Plants)
• IBB SSD 2018 Turnaround (Jan 2018 to Nov 2018 ) (Ammonia, Utility, Urea & Product Handling Plants)
• IBB SSD 2020 Reliability Improvement Project (Mar 2019 to Mar 2020 ) (Ammonia, Utility, Urea & Product Handling Plants)
• Already received 5 Year service award from Saudi Arabian feritilizer company.
Job Scope & Responsibilities:
•Maintenance instrument planning engineer in PM module of management tool ORACLE EAM client -server system.
•Leading meeting with operation & maintenance on daily basis to get the feedback operation for any issue and plan to resolve the on priority basis.
•Handling the multi-craft planning & schedule in Phosphoric acid plant for Mechanical, Instrument & electrical.
•Planning, monitoring & controlling all shutdown & turn around maintenance activity for the production requirement.
•Preparing shutdown schedule & execution package and planning the resource as well as arranging resources for the shutdown requirement to complete the shutdown / TA within schedule.
•Leading & Conducting the shutdown schedule meeting and regulate the maintenance department towards scheduled target without deviation.
•Developing the MS project schedule for the any shutdown in the PAP plant and tracking the same by S-Curve by leading the team and drive the maintenance to achieve the startup target as per plan.
•Conducting kick off meeting before the shutdown with all the arranged vendor to achieve better shutdown progress as per target.
•Co-coordinating with vendor for procurement of Spare, service contract coordination and bid evaluation, proper planning for spares and consumables spare item and ensure meeting proper engineering standards in all aspects
•Develop various performance indicators to measure performance / progress of various maintenance parameter like Maintenance spent cost, man hour, planning accuracy, Like controlled through various KPI.
•All the sort the planning activity to satisfy the PAP plant requirement.
•Monitor the performance of the various instrument and report the performance.
•Periodically monitor the stock level of all the spare parts, estimate the requirement the future upcoming shutdown or unplanned shutdown, and alert the warehouse to procure the necessary spare parts.
•Conduct RCA meeting to study the root cause of the failure to control future repeated occurrence and develop procedure. Support maintenance team to trouble shoot the problem.
•Based on historical data, Standard maintenance activity will be planned in both maintenance of Shutdown & Normal, As well as update & record the proper history for future RCM study.
•Additionally assigned as a safety coordinator for whole maintenance department to monitor & also involved in safety regulation to control the contractor under the MPC safety rules & regulator and promote the best safety practice in maintenance department
Job Scope & Responsibilities:
•Maintenance Instrument planning engineer in PM module of management tool SAP R/3 client -server system.
•Planning, monitoring & controlling maintenance activity for the production requirement.
•Preparing routine plan based on available the resource for day-to-day operation demand & prepare Turn around execution package for the TA execution within schedule.
•Be a team member & organizing meeting for problem analysis & trouble shooting, participate in studies, investigation and improvement projects .etc.
•Conducting kick-off meeting with service contractor to complete of TA within the schedule.
•Conducting improvement meeting with various vendors to get the Knowledge improved technological current trends to update the working plant with modern updated instrument.
•Co-coordinating with vendor for procurement of Spare, contract coordination and bid evaluation, proper planning for spares and consumables spare item and meeting proper engineering standards in all aspects.
•Maintain the Spare parts for Critical equipment ahead for unexpected emergency shutdown, in order to reduce the equipment down time & production loss.
•Advantage: Capable to drive on planning & control the maintenance activity for any other craft like, Electrical, Static & Rotating.
•Develop various performance indicators to measure performance / progress of various maintenance parameter like Maintenance spent cost, man hour, spare procurement, resource handling and proper documentation of maintenance activity report.
•Understanding with all International standard such as IP, NEMA, ASME, ISA, ANSI, API, ASTM and IEC & SABIC standards to meet the maintenance requirement.
•Following safe work method Statement: Conducting JSA, near miss Incident reporting system, Work permit system, Confined Space Entry, Hazard Analysis & Risk Assessment, Working at height, Thermal Stress Prevention, Lock-Out Tag-Out, Electrical Safety, Gas Testing.
•Additionally assigned as a safety coordinator for whole maintenance department to monitor & regulate the SHEM rule and promote the best safety practice in maintenance department
Job scope & Responsibilities:
•Maintenance instrument engineer as planning the Maintenance activities and controlling Manpower.
•Leading the maintenance craw to deliver the optimum maintenance support, utilizing predict maintenance techniques and prevent critical equipment failures while eliminating defects in a systematic manner.
•Review manpower requirements and specify resources required to sustain maintenance operations during Normal plant operation and Annual shutdown activities.
•Initiate timely procurement of Equipment Spares and consumables for equipment criticality and ensure availability of adequate level of spares to sustain maintenance operations. Ensure proper engineering standards are observed in all procurement activities related to maintenance activities and spares procurement.
•Supervise/guide a team of subordinates and Contract Skilled and Semi-Skilled Manpower for achieving maintenance targets within budgeted costs and maintain all associated technical and administrative records of work performed.
•Identified and implemented Several Continuous improvement in Maintenance, which resulted in cost saving, resource optimization like Temperature controlling of steam turbine extraction to process, suggest to implement microprocessor based load cell sugar bagging method, suggest to introduce ultrasonic level system is used to control the overload in bagges feeding, suggest to introduce diaphragm type level transmitter for evaporator to better control. Suggest introducing the microprocessor based auto changeover drier system from conventional relay system.
•Ability to manage multiple priorities in a fast-paced environment & possess strong leadership & interpersonal skills.
•Programming and configuration of electronic controller’s instruments. Trouble shooting and ensure linearity of Speed & Vibration Monitors/Transmitters (Bentley Nevada) and Vibration/Speed Probes and equipments.
•Monitoring the Servicing, assembling, seat leakage test blue matching, bench leakage test, calibration, maintenance of all types control valves, IGV (make: Masoneilan, Fisher controls, ABB, Valtek, Kitz, Biffi, Neles, KV, Samson) and accessories like smart/pneumatic positioners, regulators, solenoid valves, limit switches, volume boosters, lock up relays, transfer valves, converters, position transmitters, NRV etc.
•Experience in process control applications, carrying out on-line troubleshooting, tuning adjustments etc. to these systems with minimum or no process disturbances.
•Carried out new installations (Processes instruments & Equipments / Control systems) loop testing and debugging processes, and commissioning as per established engineering scope of work and drawings.
•Carryout emergency maintenance tasks related to Instrumentation and controls and assist in plant / process / equipment start-up after systematic logical troubleshooting and fault elimination.
•Knowledge in P& ID, ILD loops, hookups, review for the maintenance requirement.
•Worked with Various makes of Pressure, Level, Flow& Temperature Controllers and Transmitter.
Project Co-ordination with Siemens vendor:
•Co-coordinating with SIEMENS vendor, reviewing P&ID as per the process requirement, identifying the critical logic loop for ESD system.
•Technical discussion with SIEMENS vendor for right selection of the SMART Sensor’s for implementation in various equipment to enhance the process operation performance effectively.
•Co coordinating with vendor regarding the Graphical presentation modification for various bar graphs setting for system criticality.
•Co coordinating with vendor to complete the site acceptance test activities for DCS system.
•Perform the Functional Test activities of all field Instruments with co coordinating cause & effect checking.
•Troubleshoots, fault finds, repairs process and supporting as needed, Identifies Instrumentation problems and raises site queries & TMR (Technical Modification Requests).:
Assigned scope of work & Responsibilities:
•Monitoring the progress of project commissioning jobs including checking of design documents, drawings, the BOM, review of the Project Quality plans of OEM / Project Consultants to expedite smooth commissioning.
•Directly involved and monitor and coordinate all phases of instrument works to ensure all materials and tools needed are available and accomplished at target scheduled. Establish close communication and teamwork with other discipline to ensure over all successful completion.
•Ensure compliance to Standards and regulatory guidelines in respect of newly installed Equipments. Maintain and update instrument Control systems engineering drawings, standards, specifications, manuals and data books for final incorporation to Plant documents/ records.
•Conducting performance test of newly installed equipments including certification/verification of performance parameters as per design/drawings/operational requirement.
•Co-ordinate with Executive Instrument Engineer to identify the area for improvement and implement the same based on cost benefit analysis.
•Handled maintenance of all Automated Process equipment in Hazardous environments (including clean room facility) related to Process Industry.
•Anchored execution of several small modification projects and commissioned in the plant successfully and handled problem during commissioning effectively.
•Coordinates with Civil, Mechanical and Process Executives for timely Completion of projects.
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First class