- Mechanical Maintenance Engineer Feb. 2012 - to Nov 2018
Worked in Mechanical Maintenance team at fertilizer producing plants, Took full ownership of plant assets/equipment and the associated performance of these items. Provided a full range of maintenance services to Area Maintenance Crews, such as Fabrication, Welding, Machining, Pressure Safety Valve Overhauling and Mobile Equipment maintenance. Planning and detailed design stage through fabrication, installation, performance testing and hand-over to operations. Led Root Causes Analysis (RCA) & Bad Actors Elimination team multiple times.
Job Responsibilities
Responsible for all aspects of maintenance engineering including but not limited to:
- Maintenance and continuous improvement of systems, plant and equipment to meet Health & Safety legislation, industry standards and Production requirements.
- Schedule daily work load and generate work schedule plans.
- Act as a mentor in training team members about DuPont model of PSM (Process Safety Management) and its 22 elements.
- Constant review of maintenance plans to reflect dynamic environment.
- From maintenance plans, developed details and stock of critical spares.
- Lead the teams working on Calibration and Maintenance of PSV’S during Annual Turnarounds as per API-527 and 576.
- Responsible for dynamic balancing of all rotors of compressors and pumps of Ammonia, Urea and Nitric Acid plants as per ISO-1940.
- Compile/Provide input for preparation of division/department capital and operating budget and monitor annual expenditure budget.
- Developing training plans for Maintenance personnel.
- Conduct work safety awareness programs for company and contract sub-ordinates.
- Comply with all company Health, Safety and Environment as well as Work Permit, policies and procedures.
Achievements:
Development of Reliability Incident Reporting systems in organization, related to Mechanical Maintenance Division.
- Successfully Managed Multiple Contractor/ Maintenance partners in project planning and control reporting through rigorous follow-up and excellence in Project Management.
- Manage cost saving on development of plant spares by developing, keeping focus on HSE, timelines and quality and saved a considerable cost.
- Developed Injury prevention plan after conducting a survey for identification of Hazards.
- Designed and developed additional safety guards of all machines of machine shop in order to prevent all concerned people from metal chips being produced by machines.
- Developed Integrated Management System (IMS) procedures and co-ordinated in IMS audit and certification.
- Developed Job Qualification Procedures for validation and assessment of annual performance of staff employees.
- Nominated and awarded as BEST HSE COORDINATOR for the year 2015
- Project Planning and Contracts Management: Dec. 2007 – to Jan. 2012
Worked as Engineer-planning & Contracts in Fatima Fertilizer Company Ltd, during construction stage. Looked after & coordinated plant erection activities along with out-sourced job scope developments / evaluation & execute through contractors. Also reviewed / finalized bid evaluation / technical procedures / method statements & their implementation.
Job Responsibilities
- Contracts Management Planning/ Construction Monitoring of all phases of the project from Re-location, Engineering, Maintenance, Civil, Erection, Testing and Commissioning of the whole Complex to ensure timely and safe completion of the new Plants and Modification as per the engineering packages within the framework of the project budget, material requirements, specifications and schedule.
- Develop detailed project schedules with resource and cost loading and ensure consistency with contract documents (Conditions of Contract, Specifications, Bill of Quantities, Drawings and Method Statement). Also insure that project schedules are being maintained by having regular updates
- Support project manager and site team in maintaining the baseline programs, and ensure that the project schedule is being updated on periodical bases.
- Analyze project progress versus baseline program and identify/ forecast delays and risks
- Consolidate all project reports and prepare executive progress reports for management.
- Support the Project Manager in all the most important meetings; ensuring Planning analyses are promptly kept informed which affect all decisions or events impacting the project
- Participated in all Contract negotiations and participated in signing off most of them on behalf of Fatima. Participated in Construction Contract meetings for the whole Complex with CNCEC China.
- Despite most of contract in lump sum basis, successfully convince Chinese Top management to increase resources because of well-presented trends and Earn Value Analysis.
- Enforce and motivate plant teams for construction management and get them all on tract after huge delay in Project. Develop comprehensive Database system for Master Schedule to bring Overall plants online.
- Preparation of annual Maintenance Services Contracts, evaluation/selection of contractors based on their HSE/professional performance in coordination with IR department ensuring compliance with company policies.
- Preparation of job scope, specifications & award of Contracted out services through competitive bidding & its supervision.
- Main contractors job measurements & approval of running bills & verifications for payments.
- Descon Engineering Limited
(Dec 2005 - Dec 2007)
Descon Engineering is well recognized Pakistan biggest EPC Company, with over 350 Million man hours of work executed in industrial & Infrastructure projects. The services portfolio covers project management, engineering, procurement, construction, maintenance and manufacturing of process equipments for Oil & Gas, Chemical / Petrochemical, Power, Fertilizer, Cement & Infrastructure sectors.
- Assistant Engineer
- Fabrication, Erection, Equipment Installation, Maintenance and Commissioning.
- Experience of making drawings, B.O.Q., Material Take-Off from Drawings, Making Cutting Plans etc.
- Fabrication of Heat Exchanger, Storage Tanks, Ducts, Cyclones, Heavy Steel Structure etc.
- Experience of Managing Operations of Workshop.
Projects:
Engro Urea Ammonia Project
- Worked on ENVEN 1.3 a tremendous expansion in Engro’s urea manufacturing facility. World’s largest single train Urea Fertilizer plant worth US$ 1.14 Billion with a production capacity of 1.27 M tons Urea and achieved COD (Commercial Operation Date) on Jun 24, 2011.
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- Extensive experience of construction management, planning, contracts and project management.
- D.G. Khan Cement Factory (14000 TPD)
Worked on DG Khan Cement Khairpur, Chakwal, Pakistan. DG Cement Project involves 4500 Tons of equipment fabrication and erection, having overall 3 Million man-hours.
