Experience:
1) Qatar Aluminium Ltd. Co, Mesaieed Industrial City, Qatar
Reliability Engineer, 1-Nov 2019 – March 2023
• Anticipates and counters the causes and effects as well as the failure modes that degrade equipment performance earlier than expected, ensuring safe and cost-effective maintenance process and reliable plant equipment.
• Contributes to the efficient functioning of the Plant using reliability tools and techniques.
• Records and captures information and data about failures and problems that could undermine the correct operation of equipment and systems.
• Identifies, implements and verifies the predictive and corrective actions to prevent the re-occurrence of such failures.
• Provide information from the analysis of failures, through predictive and corrective methods and actions in order to support the analysis of reliability data
• Provide summary reports and data on Plant Equipment and Systems performance, concerning reliability and quality metrics.
• Establishes the Reliability metrics, process flows and procedures.
• Sets the maintenance directions and together with the team, drives and influences the rapid change in the implementation of the best maintenance practices.
• Performs maintenance periodic audits in the area’s maintenance process and produces clear detailed technical reports for improvement
• Generates the weekly and monthly Reliability Reports based on sub-areas Customer-Supplier Agreements.
• Applies strategic management aspects of Reliability Engineering relating to safety and quality, its relationship to customer satisfaction and their consequences to failure in performance.
• Utilizes technology analysis to achieve reliability and maintenance task improvement.
• Leads cost improvement projects, complies with the execution of the Qatalum Maintenance Improvement Program
• Ensures improvement activities take place and that the action plans are implemented.
• Audits the RCA and RCM processes and outputs. Proposes or trains the team in this regard.
• Provides technical expertise to the Plant in terms of Reliability activity requirements.
• Ensures that predictive maintenance activities take place in all selected functional locations, as planned for equipment performance monitoring and for the corrective actions.
• Ensures that equipment failure data is collected, analyzed and the identified action plans are effectively implemented.
• Ensure that the Department complies with the maintenance best practices, audits and coaches the teams / stakeholders in all relevant maintenance aspects.
• NPE (Nominated Person for Electrical), Provide guidance, coaching & assessment of New P&U Personnel for LV1 & LV2 & so with the re-authorization of all existing LV1 & LV2 P&U Authorized Personnel once the authorization expired and submit required signed documents to Technical Supervisor for SAP Update. Ensures that the Department complies with Qatalum Electrical Safety & Procedure.
• Review signed modification document & Work Permit requiring NPE Signature.
2) Qatar Aluminium Ltd. Co, Mesaieed Industrial City, Qatar
Maintenance Superintendent, Port & Utilities
1-July-2015 – 31-Oct-2019
• Implement maintenance strategies by setting maintenance and continuous improvement procedures, activities and schedules that provide integrity and align maintenance with business needs.
• Ensure major repairs and plant shutdowns are executed in a safe, timely and cost-effective manner through well-developed plans and schedules.
• Control request for plant modifications and procedural changes to ensure the provision of proper justification, completion of risk analysis and following established approval processes.
• Ensure capital and plant improvement projects gain approval through well-defined scopes of work, which clearly substantiate the benefits for production, process, cost and HSE requirements.
• Ensure the team has a focus on customer service and sustain a high level of delivery performance
• Support the development and training of National employees (Qatari).
• Develop and gain approval for department policies and procedures ensuring their alignment to overall business objectives. Monitor and control implementation and advice on the policy application to ensure that they are properly communicated and widely understood.
• Ensure the departmental reports are prepared as per management request, in a timely and accurate manner to meet company and department requirements governing reporting.
• Comply with all agreed HSE regulations in order to protect personnel and physical assets. Ensure that the work areas are kept in a clean and tidy state in order that work can be carried out safely and effectively.
• Adherence to world class best practices for safety, health and environmental standards.
• Provide input and recommend the continuous improvement of the company practices considering international best practice, changes in international standards and changes in the business environment which demand proactive action plans.
• Contribute to the identification of opportunities for continuous improvement of department system, processes and practices, cost reduction and productivity improvement.
• Supervise day-to-day operations of the assigned organizational unit and comply with established standards and procedures to ensure that work processes are implemented as designed and that employees are motivated, understand what is expected of them, and perform according to the designated standards.
• Acting Department Manager when the Manager was on vacation, training & out of site.
• NPE (Nominated Person for Electrical), Provide guidance, coaching & assessment of New P&U Personnel for LV1 & LV2 & so with the re-authorization of all existing LV1 & LV2 P&U Authorized Personnel once the authorization expired and submit required signed documents to Technical Supervisor for SAP Update. Ensures that the Department complies with Qatalum Electrical Safety & Procedure.
• Review signed modification document & Work Permit requiring NPE Signature.
3) Qatar Aluminium Ltd. Co, Mesaieed Industrial City, Qatar
Reliability Engineer/Planner, Port & Utilities
27-May-2010 – 30-June-2015
• Planning and monitoring of daily activities within Port and Utilities, and ensure that it complies with established standards, procedures and work processes and are conducted according to established plans.
• Perform and coordinate planning work within the Port and Utilities and participate in planning coordination forum at plant level.
• Follow all relevant departmental policies, processes, standard operating procedures and instructions so that work is carried out in a controlled and consistent manner.
• Generate or assist in generation of any departmental reports as per management request, in a timely and accurate manner in order to meet company and department requirements governing reporting.
• Comply with all agreed occupational health, safety and environmental regulations in order to protect personnel and physical assets. Ensures that the work areas are kept in a clean and tidy state in order that work can be carried out safely and effectively.
• Provide input and recommend the continuous improvement of the company practices considering international best practice, changes in international standards and changes in the business environment.
• Review requirements for fixed condition monitoring of the plant and preparation of justifications for any additional systems for monitoring of plant condition.
• Monitor and witness Factory Acceptance Test for major components of plant (Pumps, compressors, etc.) in order to ensure compliance with Qatalum Standards
• Assist in plant commissioning as part of setting up the Plant’s initial benchmark and gather data and information for review of Condition Monitoring Strategies.
• Perform statistical analysis on executed maintenance and prepare changes to defined preventive maintenance routines.
• Coordinate with the other Smelter’s Group in order to contribute in determining engineering standards across the plant (Power, Reduction, Carbon, Cathouse)
• Cooperate with the heads of the 3 sub-units of the Port and Utilities on technical and planning issues, establish communication with planning coordinators with other units and relevant contractors.
• Acting Department Manager when the Manager was on vacation, training & out of site.
• Guide P&U on Operational, Maintenance, Manpower, Budget & Resources Issues.
• Represent P&U on Multi Department Meetings related to Interfaces Decision, Operation, Maintenance, and Improvement Programs & Critical Production Activities.
• Establishment of SAP Functional Structure, PM Program & Bill of Materials.
• Establishment of Work Management System
• Identification of Critical Equipment, critical Spares & maintenance
• KPI Reporting, Analysis, Action Plan & Recommendation.
• Establishment of Condition Monitoring & SKF Equipment Database.
• Maintenance & Operation Improvement Program & Initiatives.
• Contracts, Procurement Processing, Payments & Assessment.
• Production Data, Performance Analysis & Reporting.
• Dept. Budget Preparation & Cost Monitoring.
• Port & Utilities APICS Key User (Aluminum Production Information & Control System)
• Train P&U Personnel on Work Management Process from Work Identification, Planning, Scheduling, Work Execution, Feedback & Closure, Reporting & KPI.
4) MARAFIQ (Power and Water Utility Company for Jubail & Yanbu), Yanbu Industrial City, KSA
Planning Engineer, Water Distribution and Wastewater Dept
Planner, GTG I&C, Power Plant
April 23, 2005 –May 19, 2010
GTG / Support Services Planner
• Preparation of Weekly & Daily WO Plan & corresponding resources for all Maintenance Disciplines of 9-GTG, 5-HRSG, 2-Black Start Diesel Generators, H2 Systems & Buildings in SAP System.
• Lead & Conduct Daily Plan-Do-Review (PDR) Meeting with Operation & Maint Supervisors.
• Lead Area Walkdown every SUNDAY of the Week with Operation & Maint Supervisors.
• Lead & Conduct GTG Weekly Planning & Scheduling Meeting, together with Discipline Supervisors, Superintendent and Managers.
• Calculation & Presentation of Weekly KPI.
• Preparation of Daily & Weekly Reports.
• Reporting of GTG Plan & Updates during O&M Meeting with the Managers.
• Plan & Prepare Daily/Weekly Schedule for 8-SS Work Centers for all Business Units (Welding, Scaffolding & Insulation, Building, Grounds, Painting, Concrete, Workshop & HVAC)
• Calculate Weekly SS KPI, Lead SS Weekly Planning & Scheduling Meeting/KPI Meetings. Analyze Weekly performance & recommends steps for further improvement
• Prepares Maintenance Monthly Report for GM Office.
• Cover in vacation fellow PLANNER in the area of SWPH, DESAL, GTG or STG as instructed by Supervisor.
Asset Management - GTG Coach (Yanbu)
• Write, edit, deliberate and participate on the formulation of Marafiq Work Management System (Palm Book) as one of the 10 Authors on the assigned topic and chapters.
• Certified Coach by Marafiq Company President and SAMI Project Manager.
• Conduct Process trainings & related SAP Transactions to Assistant Coaches & Business Unit Personnel about Asset Management in the Areas of Work Identification, Work Prioritization, Planning & Scheduling, Work Closure & Documentation, Material Staging and Key Performance Indicator Computation and SAP Data Extraction.
• Prepare GTG 13-Wk Cycle Plan, Initiate Walkdown Inspection as per Schedule, Organize & Conduct Weekly Planning & Scheduling Meeting, Daily PDR Meeting (Plan-Do-Review) and Asset Health Check Progress Review Meeting.
• Report GTG Asset Mgt. Implementation status & measurements such as Detailed Project Plan Status, System Installation Status, Sustainability Audit and Weekly Flash Report.
• Compute weekly KPI, provide analysis to the stakeholders and published in different places for information. Analyze the trends and identify opportunities for improvement from its result. Formulate action plans to resolve the shortfalls and promote the improvement.
• Conduct Asset Health Check Progress Review Meeting Weekly with the Business Unit Managers, Asset Mgt Manager, Consultants and Superintendents to discuss the current Implementation Status, Successes, Performance Gaps and Action Plans.
• Provide Weekly GTG Work Order Backlog Status in terms of Numbers, Hours and Crew Weeks. Discuss its improvement, gaps and action plans for continuous improvement.
• Perform regular visits & coaching to Process Key Stakeholders such as Operation & Maint. Superintendent, Supervisors, Foreman, Planners, Matl Coordinator & Matl Representative. Provide inputs to Business Unit Champions (Operation & Maint Mgrs.), Asset Mgt. Consultants (SAMI – Strategic Asset Management Inc.) & Asset Management Manager for issues need to be resolved and acted upon affecting the Implementation Process.
Planning - I&C/Scada Engr.
• Check Contractor’s I&C & Water Meter Section for Manpower Utilization, Cost, Materials, Tools and Quality of Work.
• Create Manual PR exclusive for MARAFIQ Employee and do the technical evaluation in the field of I&C and WM Section as need arises.
• Monitor Notifications, Work Orders, & Backlogs of I&C and Water Meter Section thru SAP System. Perform WO Marafiq Confirmation in I&C and Water Meter Section.
• Coordinates and Monitors services, improvement programs, renovations projects in the field of I&C, SCADA and Water Meter Maintenance.
• Conduct studies prepare scope of work and investigations pertaining to facilities operation, safety, fire protection and maintenance in the area of I&C, SCADA and Water Meter Maintenance.
• Inspect and evaluate maintenance activities of I&C and Water Meter section to ensure that materials, manpower and methods follow established Marafiq Standards and Specifications.
• Evaluate & Recommend various contractors’ personnel including but not limited to, hiring, performance appraisal, promotions, transfer and time-off scheduling of O&M.
• Prepares correspondence, reports, memorandums and recommendation pertaining to facilities operation and maintenance.
• Participate in the implementation of Marafiq Safety Rules, Best Practices, & Housekeeping of work area. Implements safety rules and regulations, corporate code of discipline, policies, guidelines and other administrative orders.
• Performs other related jobs as maybe assigned.
5) National Power Corporation
Batangas Coal Fired Thermal Power, San Rafael Calaca, Batangas Philippines
QA/QC, Principal Engineer B, Performance Section
March 2003 – April 2005
Duties and Responsibilities (2 X 300MW)
Deputy Management Representative in the Certification Process on ISO 9001, 14001 and OHSAS 18001 Standards (Quality, Environment, Safety and Health Management System), and the following:
• Leads and performs periodic QC and Safety inspection/verification of NPC power installation and/or projects to assure implementation, effectiveness and optimized use of available manpower/resources.
• Documents and reports the results and findings of conducted inspection including recommendations thereto.
• Prepares and/or reviews plans and checklist necessary to ensure adequate coverage and depth of quality and safety inspections.
• Leads the development/preparation of procedures and instructions necessary in the effective implementation of inspection activities in the power installations and projects and initiates changes thereto when necessary.
• Evaluates responses by inspected power installations and projects to issued inspection findings and, as necessary, provide recommendations to ensure adequacy and to preclude recurrence.
• Leads verification, and/or verifies committed corrective actions/remedial measures to identified inspection findings in power installations and projects.
• Conducts surveillance inspection of new or modified major/vital, critical items to be used or used and installed in the power installations to ensure their application adequacy
• Conducts source surveillance of major/critical systems and equipment during manufacture at the vendor’s shop to ensure compliance with the NPC Quality and Safety Program requirements, standards and specifications.
• Leads and/or conducts receipt inspection of major/critical equipment and material deliveries to assure compliance with quality specifications
• Evaluates significant abnormal conditions identified during quality control and safety inspections and recommends, as deemed necessary, the issuance of stop work or stop operation directive to management of concerned/inspected group when work or activity in progress is found and
Determine to endanger limb, life, and property or grossly violate quality operations and safety requirements.
• Performs status tracking of identified quality control and safety inspections deficiencies related to power installations, participating organizations, and projects.
• Performs fact findings and investigation of abnormalities and accidents resulting to breakdown of major equipment or forced outage of power installations and loss of life, limb, or property to determine the root causes and corrective measures to prevent recurrence.
• Studies pertinent codes standards and other references which may apply to work settings.
• Participates in relevant training, seminars and workshops including presentation efforts to keep abreast on new and changing industry development and practices.
• Performs other related jobs as maybe assigned.
Special Jobs Undertaken:
• Boiler Internal Inspection (Superheaters, Reheaters, Economizers, Sootblowers, Windbox & Etc.)
• Air & Gas Ducting Internal Inspection, Air Heaters & Dampers
• Electrostatic Internal Inspection (Emitting Electrode, Collecting Electrode, Rappers & Hoppers)
• Boiler Drum Internal Inspection
• Condenser Internal Inspection
• Heat Exchangers & Heaters internal Inspection
• Steam turbine and Generators Internal Inspection
• Seawater Cooling Pipeline Internal Inspection
• Condenser, Heaters & Heat Exchangers Leak Test
• Boiler Hydrotest
• Burners, Induced Draft Fans, Force Draft Fans, Primary Air Fans & Pulverizers External & Internal Inspection
• Boiler, Turbine, Ash Handling, Coal Handling, Switchyards, Auxiliary Systems Equipment and Facility Premises Inspection.
• Raw Water Intake, Sea Water Intake and Ash pond Area Inspection
• Safety Valves & Relief Valves Testing
• Plant Related Items Warehouse Inspection and Quality Control
• Annual Overhauling Activities and Plant related activities acceptance and quality control
• Inspection result reporting and deficiency monitoring
6) National Power Corporation
Batangas Coal Fired Thermal Power, San Rafael Calaca, Batangas Philippines
Principal Engineer C, Instrumentation and Control
March 1996 – Feb 2003
Boiler & Ash Handling Areas
The Principal Engineer C (Instrumentation & Control) is responsible for attending and coordinating the maintenance of all plant's major and auxiliary equipment's pneumatic, hydraulic, mechanical, electro-pneumatic, electronic and computer-based instrumentation and control system to ensure condition at highest level of accuracy. His duties and responsibilities include but not limited to the following:
• Prepares preventive and corrective maintenance, troubleshooting, repair, overhauling, rehabilitation and servicing of all instruments and control devices to ensure maximum operating accuracy and reliability.
• Conducts precision repairs, calibrations, fine-tunings, adjustments and testing on control system set up and configuration for accurate and reliable operation.
• Conducts and coordinates performance tests on control loop systems, simulation and interlock test and performs necessary adjustments for improved reliability.
• Undertake studies for plant instrumentation and control improvements. Works with supervisors in troubleshooting and test of complicated instruments and control systems.
• Compiles and maintains complete records of calibration data, procedures, maintenance schedules, instruction manuals, diagrams and other engineering documents for safekeeping and reference.
• Prepares purchase requisitions and evaluate Bid Quotation. Inspects materials and spare parts deliveries. Checks availability and stock levels of various instruments and control devices, tools and measuring and test equipment.
• Orients and trains newly hired and lower rank Instrumentation and Control personnel on various types of instruments and controls including their calibration procedures and other applications for consistent skills and technology transfer.
• Observes and practices housekeeping of work area. Implements safety rules and regulations, corporate code of discipline, policies, guidelines and other administrative orders.
Special Jobs Undertaken
• Commissioning and troubleshooting of DCS (Distributed Control System ) of Unit-2
• Troubleshooting of Functional Group Control, Boiler Sequence Control, Unit Coordinate System, Automatic Boiler Control, Furnace Safeguard Supervisory System,
• Data Acquisition System, Event Recorder, Instrument Transducer Panel, Annunciator System, Ash Handling Control System and Electrostatic Precipitator System.
• Calibration of Coal feeders, control drives, valves, vanes, dampers, transmitters, switches, modules and associated instruments to the system above.
• Troubleshooting of Operational Training Simulator of Unit-2
• Troubleshooting and Maintenance of Unit Control Desk CRTs, Data Communication, Networking, and Unit Control Panel Instruments.
• Modification, Simulation, Reprogramming and Testing.
• Brand of PLC: Mitsubishi, Allen Bradley, Modicon, Foxboro, Forney, Yaskawa etc.
7) Mitsubishi Heavy Industries Technical Services Corp., Makati City, Philippines
Instrumentation & Control Engineer, I&C Section
Oct. 1994 – Feb. 1996
Duties and Responsibilities: (Batangas Coal-Fired Thermal Power Plant Unit-2 Project)
Data Acquisition System (DAS), Event Recorder & Sootblower System:
• Control Module Calibration of Data Acquisition Systems & Instrument Transducers Panel
• Loop Checking (Transmitters, Thermocouples and Instruments Switches)
• Data Highway Installation and Commissioning
• Database VAX Tagmaster Creation /Modification for Alarm & Event display of CRT
• PFU Tagmaster Modification for CRT Plant Flow Diagram and
• Master Control Data Display
• Graphics Design for Initial Firing CRT Display of UCD
• I/O Checking of DAS Instruments
• CRT/ Printer Operation Functional Test
• I/O Checking of Boiler, Turbine and Generator Signals
• Event Recorder Functional Test
• Sootblowers (Long Retractable, Wall Deslagger & Air Heater) Wiring & Functional Testing
• Different Control Mode CRT Operation Functional Test (Auto and Individual)
• Trip Signal, Alarm Signal & Event Signal Troubleshooting and Commissioning
