Lead Maintenance and Reliability Consultant
Wood
Total years of experience :16 years, 6 Months
• Led a team of maintenance and reliability professionals within a Perth-based business unit. Guided diverse teams in optimizing maintenance practices, leveraged data analytics to pinpoint performance gaps, and implemented coaching programs to upskill personnel, achieving operational excellence.
• Promoted a culture of continuous learning and improvement within the team, leading to enhanced skill sets and adaptability in changing business environments.
• Key projects:
‒ Santos Moomba Carbon capture Facility: Architected a comprehensive Reliability Management Plan for Santos Moomba CCS Facility, driving optimal system performance, cost-efective maintenance, and maximized carbon capture eficiency.
‒ Woodside: Championed LORA (Level of Repair Analysis) framework implementation across critical assets, maximizing operational eficiency to derive spares requirements and BOM development guides. Pioneered LORA integration within Woodside maintenance teams and streamlined workflows.
‒ Abu Dhabi National Oil Company (ADNOC): Streamlined RCM strategy development and implementation within ADNOCs Crude Flexibility Project, fostering data-driven decision-making and enhancing asset reliability. Updated RCM integration tool for maintenance plans load sheet generation.
‒ Transurban Queensland: Led the development of a tailored spares management process flow, crafted a compelling business case, and identified key value drivers. Developed detailed spares management requirements and KPIs to work with service providers.
‒ ExxonMobil Energy storage system RAM modelling: Develop investment case Reliability, Availability and Maintainability model to validate the investment proposal with required RAM targets. Find opportunities of improvement for existing power system infrastructure to achieve network reliability.
‒ Wesfarmers Chemical Energy & Fertilizers: Develop enterprise-wide asset criticality procedure, develop failure codes for CMMS and generate PM library for maintenance plan generation automation.
• Implementation of Maintenance and Reliability frameworks, Asset base of B$ 38 in water, wastewater, advance water recycling and desalination plants. It consists of more than 350 treatment plants across the state.
• Key Responsibilities:
‒ Lead a team of Reliability Engineers to drive an approach to Reliability Centred Maintenance (RCM), enabling databased decision-making for increasing reliability across all asset classes and systems. Implemented design improvements to enhance equipment/system reliability.
‒ Well-versed in applying various RCM, HAZOP, Reliability, and Safety standards such as ISO 14224, OREDA Standards, IEC 61882, IEC 61508. Consultant
‒ Performed asset criticality analysis (ACA) using corporate risk matrix, failure likelihood and consequence of failure (Severity ratings), and recommended equipment reliability improvements by analysing trends, historical and field data.
‒ Facilitate Failure Modes and Efects Analysis (FMEA) as per SAE JA1011 standards on process facilities with cross function team. Consolidate FMEA outputs and primary actions into tactical plan for maintenance budgeting.
‒ Develop and support PM change management program to establish changes in CMMS in time and with accuracy. Developed MS Access quality check before auto upload into CMMS.
‒ Perform availability and remaining useful life (RUL) using reliability, availability, and maintenance (RAM) modelling techniques in Isograph availability workbench (AvSim, RCMCost and Weibull Modules).
‒ Develop Reliability block models (RBD) and Fault tree analysis to support and perform defect elimination process.
‒ Lead and facilitate root cause failure analysis using Reality Charting (APOLLO Methodology). Prioritise investigation using priority matrix to choose right level of efort and method selection. Consolidate action items and track it completion and monitor its efectiveness.
‒ Utilise SAP workorders, PI Vision and AF, AIMS, Business warehouse data, Asset deficiency register and performance monitoring systems to collect failure data, cleansing and apply for analysis.
‒ Analyse and compile reports on Asset reliability focused on criticality, providing details on asset availability, uptime, downtime, MTBF, MTTR and identify opportunities to improve asset health and reduce risks of failure.
• Major Achievements:
‒ Lead transition project - old reliability software (RCM TURBO) to new tool (Isograph Availability workbench)- developed business rules and architect for RCM, failure management, data capturing and maintenance feedback reporting.
‒ Various asset class-based failure modes library developed which includes more than 350 asset class (Mainly consist of Pumps, Compressors, Piping, valves, heat exchanger, fire heaters, Boilers, pressure vessels, High voltage switch gears, transformer, switchboards, HV motors, starters, Heavy duty engines, Generators, control system, Diferent analysers, instruments, and renewable energy equipment mainly solar and wind power generation), 3500 uniquely workshopped failure modes and its maintenance strategies. This library is standard template to create new RCM projects within Water Corporation. It produces prepopulated RCM data (Appx 85 %) for new project and saved significant time and eforts.
‒ Developed digital Presentative Maintenance Instruction template to allow technicians to read through iPad and provide feedback with photos. This feedback consists of asset class-based tables of 48 Problems, 86 causes and 35 Remedies. By doing this, CMMS get consistent corrective and/or failure data for Root cause failure analysis and defect elimination process. Consultant
‒ Performed various PM optimisation on Desalination plants and water/wastewater plants using RCMCost Availability simulator and Weibull Analysis which reduces significant operational cost. Also, It enhanced availability of the plants.
• Gorgon and Wheatstone LNG RCM facilitation and maintenance optimisation projects at Chevron, Perth WA.
• Key Responsibilities:
‒ Lead a team of Reliability Engineers to drive an approach to Reliability Centred Maintenance (RCM), enabling databased decision-making for increasing reliability across all asset classes and systems. Implemented design improvements to enhance equipment/system reliability.
‒ Provide guidance to the asset reliability team to identify the assets which need to be reviewed to improve reliability, performance, and maintenance tactics through balancing of cost, risk, and performance.
‒ Implement principles of reliability centred maintenance and uses data to influence changes to maintenance tactics including refurbishments and capital replacement planning.
‒ Facilitate Process FMECA to improve asset availability, eficiency, and risk mitigation. Define Likelihood, consequence, and predictability of failure to calculate Risk priority number (RPN). Mitigate high risk actions, record into action register, and follow up. Update and align failure modes library in database as required.
‒ Lead maintenance issues investigations using cross functional teams to ensure appropriate changes to the PM/ PdM program made which improves plant availability and reduce avoidable maintenance costs.
‒ Prepare bad actor register at plant level. Identify the gaps present in current reliability strategies by analysing unplanned failures based on the impact of each failure on maintenance cost and plant downtime. Examine the outcome of the bad actor analysis, which consist of PM amendments, additional PM tasks or redesign tasks.
‒ Participate in, take relevant agreed actions for operation team meetings to ensure high equipment availability and help to develop a culture focused on solutions.
‒ Perform Business Efectiveness Index (BEI) analysis to analyse cost impact of doing maintenance verses not doing maintenance and recommend changes in maintenance plans. Optimise maintenance tasks and drive eforts to reduce maintenance cost.
‒ Coordinate PdM eforts on site to measure and secure an upward trend of the Asset Health. Identify and implement opportunities for improvement of asset health to detect early failures and potential failures.
• Major Achievements:
‒ Lead RCM developer for AGRU (Acid Gas Recovery Unit) on Wheatstone project. Delivered the RCM Outputs with auto upload sheets, Risk assessed with criticality analysis, FMEA database. I utilised GE APM Meridium suites to analyse FMECA, and MS access to develop templates to validate the Quality of the maintenance planning data. Project handed over to client before 1 month with agreed workshop.
‒ Critical spares and Insurance spares holding philosophy developed for client for Wheatstone project. I utilised completed FMECA and RAM modelling data to calculate the required spares, economic order quantity, and vendor stocks. Also frame Consultant
agreements to provide routine maintenance spares within time and cost at Burrow Island.
• Responsible for asset maintenance engineering of Al Khaleej oil field consist of eight platforms, forty-eight oil producing and ten water injection wells.
• Key Responsibilities:
‒ Support lead engineer in formulating maintenance strategies based on Reliability Centred Maintenance (RCM) principles and maintain schedule for strategy reviews and optimisation.
‒ Perform Failure Modes and Efects Analysis (FMEA) on ofshore mechanical assets, derive primary tasks, consolidate into task groups, prepare job plans and activity packaging.
‒ Carrying out Cause Tree Analysis, responding to equipment faults, diagnosing breakdown problems and perform quality inspections on jobs.
‒ Prepare condition monitoring program for vibration analysis, thermography, motor current analysis and lube oil analysis.
‒ Co-ordinate with respective contractor for scheduled data collection. Report non conformance and create corrective work order.
‒ Diagnose vibration issues through waveforms and spectrum analysis, determine the vibration severity, identify frequencies and patterns, associate the peaks and patterns with components, form conclusions and advise on corrective actions with expected p-f curve duration.
‒ Prepare scope of work for major maintenance, shutdowns, and inspections. Coordinate and monitor the contractor activities, timesheets, and invoices. Collaborate and liaise with contractors, engineering & production teams.
‒ Frequent site visits to work with Technical Authorities on critical data for safety critical element identification and Performance Standard review.
‒ Facilitate review on critical spares, min/max inventory levels, Material Master coding, support on list of materials creation and upload into CMMS.
• Major Achievements:
‒ Developed contingency plan scenario for oil transfer pump for DP4 ofshore platform, Al Khaleej. All 4 pumps were duty/duty arrangement. It was developed with cross functional teams of operation, safety, marine and maintenance personnel. It reduced uncertainty in case of any pump fails and provided clear direction on production throughput reduction. Also, it triggers emergency work order to repair and attend the failed pump.
‒ SAP asset hierarchy for Al Khaleej field platforms which consists clear 7 levels of asset hierarchy from Plant to process to system to units and components. Also developed standards Bill of materials, removed duplicates, and add the spares required. Also, Criticality analysis for the unmanned platforms and Halul Island process facility.
‒ Diagnosed and resolved one of the critical vibration issues on DP2 platform water transfer pump. I utilised PRUFTECHNIK VIBXPERT II system to diagnose the issues and found structural resonance and pump vibration combined issues. Identified and resolved which saved significant vendor cost, unnecessary pump overhauling and spares cost and 6 days of production downtime (Appx 2.6 m$).
• Responsible for maintenance and shutdown planning at Polyethylene and Polypropylene Plants.
• Key Responsibilities:
‒ Develop preventive maintenance and predictive maintenance planning schedule. Provide feedback on incomplete maintenance tactical plans and SAP codes.
‒ Record tasks and information within the work order and review work orders for technical completeness. Filter out work orders to process activity coordinator if incomplete.
‒ Undertake the task activities necessary for job plan considering constructability, maintainability, and quality feedback from person doing work, archived plan, and input from other crafts as well as field checks to ensure all dimensions are considered.
‒ Identify materials, tools, equipment required to perform tasks efectively. Consider material costs when selecting materials from specifications to ensure costs are minimised where possible.
‒ Identify safety information and requirements necessary to safely perform tasks system update input plans into SAP indicating the required resources, materials, and services to ensure their availability when needed. When materials availability has been confirmed, store job in active backlog for future retrieval.
‒ Comply with all relevant health, safety, security and environmental management policies, procedures and controls to guarantee employee safety, legislative compliance and a responsible environmental attitude.
• Major Achievements:
‒ Developed Poly propylene and Polyethylene Shutdown and turn around plans with eficient use of SAP PS module. I utilised ERP resources to leverage the crafts and material required to save significant amount of material and spares cost. Provided ideas to create Revision codes to apply for shutdown to manage within budget as well as dedicated spares and resources for shutdown.
‒ Quick Learner and applied various maintenance planning principles.
• Responsible for Refinery (Crude Distillation Unit)- Commissioning, field maintenance and repairs, shutdown, and turnaround.
• Key Responsibilities:
‒ Have in depth knowledge of process equipment packages: centrifugal pumps, centrifugal compressors, reciprocating compressor, turbines, mechanical seals, pressure vessels and columns.
‒ Competent reading and understanding of isometrics, piping & instrumentation diagram (P&ID), piping layout, general arrangement, foundation & equipment Drawings.
Mechanical Engineer