Maintenance Head DR Process Gas Plant
Emirates steel Industries
Total years of experience :7 years, 5 Months
Total Years of Experience: 10 years
Name Emirates steel Industries
Current Job Title: Maintenance Head DR Process Gas Plant
Duration From: 2007 Till Now
- Excellent Internet research skills, Mat lab Programming.
7 yrs experience in U.A.E
I. Presently working as Plant Maintenance Head for Emirates steel Industries.
• Safely maintaining 5000 TPD of hot DRI for the past 4 year with over 98 % availability & reliability.
• World record production of 155000 ton/month safely.
• Documentation of SMP, HAZOP and Commissioning procedure for the new installations.
• Prepare the CAPEX &OPEX budget yearly.
• Prepare the external service contracts required from the OEM.
• Set up the NDT plans for the plant static equipment
II. Experience as Plant Maintenance Supervisor for Emirates steel Industries.
• Supervise the maintenance activities based on CM and PM programs.
• Eliminate all the deviations which had existed since erection and commissioning of the plant.
• Establish the overhauling procedure for the Rotary equipment.
• Organize the external services required for the Plant maintenance activities.
• Prepare the list of spare required for the annual shutdown activities.
III. Experience as Rig Mechanic at Global-Santa-Fe off-shore drilling co.
• Execute maintenance &repair activities on the Rig as per the maintenance program.
• ZERO breaks down and Zero accidents with 100% availability of the Rig for 3 years.
ROUTINE JOB DESCRIPTION:
For last 7 years I am working for Emirates Steel (ES) as mechanical section head and Maintenance supervisor for Direct Reduction
Plants (DRP) . My experience is in the field of construction, commissioning, and maintenance of Process plants.
During this period the management assigned the task to establish the maintenance team for the plant and build up the maintenance
organization and plan for this type of plant. The DRP at ES is the biggest in the world. Implementing state of the art maintenance systems was both a long and enjoyable journey.
Below are the major tasks I am responsible for:
• Establish the facility maintenance planning to meet the production budget requirements.
• Develop and implement production tracking, analyzing production and maintenance reports to detect and correct problems.
• Identify and provide industrial training needs for the team.
• Organize the coordination with Production team.
• Ensure that facility, equipment & systems job plans (maintenance plans) are defined according to corporate typical job plans.
• Plan for a major shutdowns and finalizing the scope of work for the NDT services for Pressure Vessel and Reformer inspection.
• Develop and implement facility maintenance policies and procedures.
• Ability to trouble shoots and solves technical problems aiming at reducing down time.
• Participate in sub-contractors selection, qualification, and follow up.
• Perform security and safety reporting; participate in root cause analysis of events and in development of the corrective and preventive measures.
• Monitor and adjust process parameters to ensure safe operation and product quality/reliability of the equipment.
• Patrol work area and listen for warning signals to determine potential malfunctions.
• Report and address abnormal operation situations.
• Ensure proper coordination with operating teams, network coordination or other neighboring production facilities (either personally or via shift leaders/supervisors)
• Ensure first-line plant security and safety. Identify potential hazardous situations and educate shift leaders.
• Supervise maintenance personnel and ensure compliance with safety standards and work procedures.
Memberships, Certification
- Mechanical Maintenance Diploma in HYL TECHNOLOGY Direct Reduction Gas Process plant from Tenova, MEXICO.
- Project management professional Certificate
- Certified to implement Professional lean six sigma.
- Certified Boiler Operation, Maintenance, Failure Analysis, Performance, Optimization & Steam System Management.
- Turbo-Compressors training in KKK-SIEMENS, Germany.
- IELT Certificate from the British council with overall score of 6.0 Academic
- Membership with Steel Institute VDEh, Germany.
- Various off-shore safety trainings, Red sea off-shore Rigs.
- AUTODESK INVENTOR training in mechanical modeling and piping assembly,
- CNC lathe m/c programming training at ATOMAT on AT-830 CONTROL SIEMENS.
- Tensile test for steel on zwick/roell test machine, for quality control system development.
- FOCUS III Safety program at Global Santa-Fe.
- Permit to work training at Global Santa-Fe.
- Hydraulic maintenance at Alexandria National Steel Dekhela."ANSDK", Alexandria
- Hydraulic maintenance at Hydraulic Machines Lab., Faculty of Engineering, Alexandria Egypt.
- University Diesel engines maintenance at Combustion Lab, Faculty of Engineering, Alexandria University
- American Language Courses, American Center, Egypt
KEY SKILLS & EXPERIENCE: - Leading With Emotional Intelligence.
- Managing Conflict & Handling Difficult People
- Negotiating & Convincing Others Successfully
-Building up Performance through Employee Motivation & Empowerment
7. EMERSON control valves and actuators.
8. Maintenance of HYL Reactor the Biggest DR Reactor (Furnace) in the world.
9. ARZNER Screw compressors.
10. Hydraulic systems design, construction, Startup and maintenance.
11. Piping systems installation, pickling and pressure test.
12. Steam Boiler maintenance, inspection and Repair.
Operation & Preventive Maintenance of following Machines & Equipments.
1. SIEMENS Gas Turbo- compressor.
2. CO2 Plant Maintenance Wittemann.
3. SIAD reciprocating nitrogen compressors.
4. LINDE Reformer and Process Gas heater.
5. Flowserve, Sulzer & KSB water & Chemical pumps.
6. Dresser Rand Steam Turbines.
BSC. Degree Mechanical Engineering Alexandria university/Egypt Member of the Institution of Mechanical Engineers as Incorporated engineer, London, UK. Presently working as Direct Reduction Plant Maintenance Head for Emirates steel Industries UAE. Major current Responsibility: - According to the technical demand of the plant, I compile the requirements of maintenance and improvement projects and identifying the resources of manpower and materials, drafting the scope of work for each service including the technical specifications. - I carry out the cost estimation for the resources according to the market value and the approved budget, I send this data to the procurement department to issue the tenders to invite suppliers, upon the supplier offers submissions; I carry out the technical and commercial evaluation. - For each year we prepare the Assets budget and the operational budget for the plant maintenance and the continuous improvement projects. - Review the drawing of Process Engineering, Pressure Vessels, Reactors, Tanks, Compressors, Pumps and Piping System. - Creating and managing the Preventive maintenance programs for Pressure Vessels, Reactors, Compressors, and Process Pipelines, Pumps and Piping system. - Responsible for preparing Inspection and Testing procedures Provide inspection Services & Non-destructive testing, periodic Corrosion, Erosion Protection Maintenance program, preparation of reports of the fit of service data. - Responsible for external services contracts during normal plant operation and Annual shutdown. - Reporting to the plant Manager with the monthly progress and budget balance. Computer Skills and Software Used - Using Inventor pro 2012 for design, assembly mechanical parts and failure analysis. - Proficiency in 3D Studio MAX 10 including mechanical systems simulations. - 2D and 3D Solid Modeling using AutoCAD & Mechanical desktop. - Excellent Programming skills using MS Visual BASIC 6, Currently studying and preparing for the MCSD "Microsoft Certified Solution Developer" using MS Visual BASIC.net, - Familiarity with Microsoft Office Programs especially MS Word, Excel and MS Power point.