Project Engineer/Manager

Essam M Kamalbrahem

Senior Project Process Chemical Engineer

Rochester, NY, 14618, USA

Phones: Cell- +01-832-***-****, Skype-+01-585-***-****, Work-+966(0544)-089-704

Email: ************@*****.***

Summary of Qualifications

A US Citizen experienced Senior Project Process Chemical Engineer professional for years in Chemical Process Engineering, Project Management, Manufacturing Chemicals, Equipment & Steel Structure Fabrication, Safety, and Construction. Experience and high knowledge in:

• Chemical, Petrochemical, Refineries Fertilizer, Onshore Oil & Gas Production, and Powder industries.

• Reviewing Basic Engineering Design provided by Know-How Licensor, working with the engineering team on the submission of the Detail Design Engineering Packages.

• Team member for several study workshop meetings; Hazard and Operability “HAZOP”, Process Hazards Analysis “PHA”, and Safety Integrity Level Assignment and Verification “SIL”.

• Familiar with HYSYS simulation software for process design and solving process problems that created during details design preparation or plant operations.

• Computer skills: MS Office Professional, MS Project, Primavera-P6, Outlook, AutoCAD LT, Caesar II,SAP, Minitab, PARADIGM II,NWA(Northwest Analytical).

• Familiar with Siemens and Allen-Bradley’s PLC, HMI, SCADA system, SQL Database and reporting software.

• Using Projects management techniques controlling the project’s cost and schedule throughout the project’s life cycle from concept initiation to completion & closing out.

• Applying C&E Matrix (Cause and Effect) and FEMA Matrix (Failure Modes and Effects Analysis), Green Belt Six Sigma Methodology improving the process, operation and productivity to meet risk reduction and cost saving goals.

• Working knowledge with standards such as Saudi Aramco’s Engineering e-Standards (SAES, SAMSS, SAEP, SASD, SABP),and international standards/Codes such as Process Industry Practices “PIP”, ASME, API STD, etc.

• Site construction execution skills including piping system design & installation, Mechanical installation, Pipe rack &Steel Structural fabrication- installation, Electrical, Control and Civil works.

• High skills with chemical manufacturing and operation management, manufacturing &operation process improvement, Optimization to increase manufacturing productivity.

• Actively supporting skills with plant during commissioning, start-up, optimizing operations, troubleshooting, shut-down &maintenance.

• EHS & OSHA skills, supports compliance with Process Safety Management “PSM”, prepare Management of Change “MOC” documents, Familiar with U.S. Army's Corps of Engineers Safety and Health (Manual-EM 385-1-1).

• Expert in general Arabic linguistic, Middle East’s cultural support, translator &interpreter.

Professional experience

Jan. 2014 to Present/Contract (SMP) Engineer II Saudi Aramco, Dhahran, Saudi Arabia

Saudi Aramco headquartered in state of Dhahran in the Eastern Province of the Kingdom of Saudi Arabia is the -owned oil company of the Kingdom of Saudi Arabia. It ranks first among oil companies worldwide in terms of crude oil production and exports, and natural gas liquids (NGL) exports, and is among the leading producers of natural gas, Engineer II of new Onshore Gas project, Report to Project Manager.

Responsibilities Include:

• Member of Saudi Aramco Project Management Team” SAPMT” managing new Onshore Gas project consisted of three sections (Well heads & Flowlines, Process Plant, and Pipelines).

• Acting as the deputy to the Project Manager supporting the Project Manager as required.

• Completing all assigned tasks as delegated by the Project Manager.

• Tracking project activities and ensure meeting Saudi Aramco Engineering Standards & Specifications, working with other Saudi Aramco departments clarifying any Saudi Aramco standards’ deviations when occurred during engineering, procurement, fabrication, and construction activities.

• Ensure technical requirements defined in the contract are properly incorporated in the Detail Designs Engineering deliverables (30%, 60%, 90%, and 100%) and the same for the 3D Models Design, participated with related technical review meetings with other Saudi Aramco’s departments.

• Review the overall process HYSYS simulation report and apply improvement to the related sections of the process area during scope design changes that needed to meet the optimum design.

• Team member of project ‘study workshops of “HAZOP”,”PHA”, and “SIL“, ensure safe evaluating of the project’s process designs and follow up implementing decisions that recommended during these workshops.

• Manage, follow up, and response to the EPC Contractor’s communications.

• Reviewing Technical Quires that submitted by the EPC contractor and corresponding with related Saudi Aramco Departments manage and evaluate the related changes orders that occurs due to these TQ’s.

• Track project progress for the Engineering deliveries, Procurement, equipment and modules fabrication activities, Construction activities and participated with related follow up meetings.

Accomplishments Include:

• The project is running in progress with the planned schedule and cost.

April 2011 to Nov. 2012/Position eliminated Project Engineer Ferro Corporation Inc., Penn Yan, NY, USA

Ferro Corporation Inc. of Penn Yan, NY,designs manufactures and markets chemicals products in the fields of semiconductor, coatings, polishing, solar and more, Project Engineer responsible for execution capital projects. Report to Engineering Manager.

Responsibilities Include:

• Act As project manager in leading the projects management activities for current/new capital projects throughout the project’s life cycle from concept inanition to completion & closing out.

• Define the project’s overall scope of work and the produce estimates and initiate capital fund appropriation requests (ARs),

• Plans and executes projects to meet company’s goals of eliminate safety issues around process operation areas, increase production capacity to meet the market demands, reduce process variability, increase yields, optimize raw materials, reduce labor, reduce cycle times, reduce energy consumption, and reduce waste streams.

• Using Microsoft Project tracking the project with applying project management technique and reviews/approves change orders when required.

• Reviewing Basic Engineering Design that provided by Know-How Licensor for the new project, eliminate using outside engineering service by preparing part of the Detail Designs Engineering Package including preparation and remodeling of P&ID’s, PFD’s, energy and materials balances calculations, equipment and pipe lines sizing, fire and safety equipment layouts, Piping isometric drawings, plot plan equipment layouts, piping &cables rack support and civil foundation design, steel structure platform/stairs, PLC&HMI setting to meet the process operation sequence, and data logging system setup recording production data.

• Review the HYSIS simulation report and apply re-simulation on the existing process of the production area that needed to improve the process operation and minimize capital operation cost.

• Manage conducting and Participated with the study workshops of “HAZOP”,”PHA”, and “SIL“, for existing process operation or for the new project to ensure safe operation.

• Create notifications, purchase requisitions included estimation and preparation the bill of materials with the suitable specifications/codes, initiate, negotiation, and manage proposal/contracts w/ outside contractors/suppliers/customers, coordination and prepare work permits as required, plan and format of deliveries.

• Applying Green Belt Six Sigma Methodology to improve the process, operation procedure, productivity, and cost saving of the Tunnel Kiln Calcinar/Heat treatment System.

• Ensures the processes are running according to approved safe operation procedures and standards, plans and executes process improvements on assigned projects/processes.

• Improve and optimize manufacturing and operation procedure inside the facility to increase productivity and cost saving.

• Identify, manage and execute equipment continuous improvement. Lean manufacturing techniques to identify, reduce cost/working capital, and drive production management.

• Provide & manage training for juniors and new hires supporting operations and maintenance department for running the plant with the optimum operation.

• Provide strong support and leading team during plant commissioning, start-up, optimizing operations, troubleshooting, shut-down &maintenance.

• Comply with procedures and work instructions of both the Quality and Environmental Management Systems, and performs these responsibilities in a safe manner;

• Maintain OSHA safety policies and programs, supports compliance with Process Safety Management, produce Management of Change ”MOC” documents, tracking safety deficiencies in daily basis, issuing/approve the Job Safety Analysis for operation/construction activities, applying Lockout/Tagout procedure around the operation equipment, improve safety culture inside the facility to reduce the losing in time/recordable accident rate.

Accomplishments Include:

• Effectively managed and implemented multi internal projects at the planned schedule and cost for variable amount of budgets.

• Successfully implemented KUKA Robotic System project improving the operation procedure and materials handling around Tunnel Kiln Calcinar System.

• Effectively Improving process and operation procedure of the Formulation operation unit to meet reduction in cost, increase productivity, reduce costumer complains, and improve product quality.

• Successfully implemented Formulation products packaging area project included implemented new bottling & pails packaging machines.

• Conduct high progress implemented new Rotary Kiln Calciner System Project increasing the facility’s production capacity of Alumina Oxide products.

• Complete advance stages of the Green Belt Six Sigma project target to improve the process, operation and productivity of the Tunnel Kiln Calcinar/Heat treatment System with cost saving planned to be around +0.5M.

• Leading joined venture project with Ferro New Jersey’s facility to relocate an existing Dielectric process unit in New Jersey’s facility with all related equipment and rebuilt it again with new improvement in Penn Yan, New York’s facility.

April 2008 to June 2009/Plant closed Site Manager H2Gen Innovation Inc., Alexandria, VA, USA

H2Gen Innovation Inc., of Alexandria, VA, designs, manufactures and markets cost efficient on-site hydrogen generators and gas purification plants. Site manager for H2 Purification project built in Kingdom of Saudi Arabia for a client called TASNEE (SPC SAUDI POLYOLEFINS COMPANY) own a petrochemical complex Gas-Phase technology producing Ethylene as a mother unit producing LD & HD Polyethylene, Polypropylene, and Chlorine products, Report to Engineering Manager.

Responsibilities Include:

• Acts as the project manager's deputy in activities such as attended all site construction coordination meetings with the client’s management when needed and with the design teams & contractors, issuing and approves change orders related to the job site construction activities.

• Working with the engineering team in setting up and produce the Detail Engineering Designs including preparation and remodeling of P&ID’s, PFD’s, piping isometric drawings, energy and materials balances, plot plan equipment layouts, equipment and pipe lines sizing, fire and safety equipment layouts, piping &cables rack support, steel structure platform/stairs, civil foundation, PLC, HMI and data logging setting.

• Working with engineering team in preparing the HYSIS simulation report for the process design.

• Manage conducting and Participated with the study workshops of “HAZOP”,”PHA”, and “SIL“, to ensure safe process design.

• Create notifications/Hiring a local contractors, estimation and preparation the bill of materials with the suitable specifications/codes, initiate, negotiation, and manage proposals/contracts with inside/outside contractors/suppliers/customers, coordination and prepare permits required, plan and format of deliveries.

• Define the job site’ overall scope of work, using Microsoft Project for tracking the project, and reviews/approves change orders when required.

• Actively supporting plant during commissioning, start-up and taken the plant to steady state operation.

• Comply with procedures and work instructions of both the Quality and Environmental Management Systems, and performs these responsibilities in a safe manner;

• Maintain OSHA safety policies and programs, supports compliance with Process Safety Management, tracking safety deficiencies in daily basis, issue/approve the Job Safety Analysis of each construction activities, applying Lockout/Tagout procedure around the construction equipment; improve safety culture at the construction job site to reduce the losing in time/recordable accident rate.

Accomplishments Include:

• Effectively managed and implemented all project activities at the job site with efficiently and profitable finishing under budget and turn over the plant to the client and grew client satisfaction of quality of work being produced.

June 2005 to July 2007/Relocation to USA Deputy Program Manager BERGER/URS, Baghdad, Iraq

Berger/URS joint venture both specialized in managing EPC projects, Deputy Program manager helps managing the Iraq Reconstruction program with overall budget around $700M of US funds, consisted of seven project codes support the mission of rebuilding the country's infrastructure in different industries by renovation or expansion of the existing plants and implementing a new projects in the chemical, petrochemical, refineries, fertilizer, power stations, waste water treatment and other fields covering improve the civilian infrastructure. Report to Program Manager.

Responsibilities Include:

• Provide support to the Program Manager in leading the activities throughout all project’s life cycle listed under the program, work with the program team to apply successful project management techniques from concept initiation to completion & closing out.

• Prepares technical reports and documentation of project activities that required Issuing the ITB (Invitation to Bid), meetings arrangement with all parties involves with the project.

• Effectively define the scope of work, planning, produce estimates the capital budgets, using Microsoft Project for tracking the project with applying project management technique, and reviews/approves change orders when required.

• Estimation and preparation purchasing details using the suitable specifications/codes create notifications; purchase requisitions which included initiate, negotiation, and manage contracts w/ outside contractors/suppliers/customers, coordination and prepare accordingly permits required, plan and format of deliveries.

• Provide & mange training for client’s staff and new hires.

• Maintain OSHA safety policies and programs, Comply with U.S. Army's Corps of Engineers Safety and Health (Manual-EM 385-1-1).

Accomplishments Include:

• Effectively managed and implemented the program with its approved available budget and meet scheduled timelines.

• Savvy communication skills and networking efforts throughout all 18 Iraqi governorates led to the delivery of all open distribution equipment and projects into the hands of Iraqi experts with overall budget around $700M of US Government funds and grew client satisfaction of quality of work being produced.

June 2004 to June 2005/Contract Deputy Safety Manager Parsons Corporation, Baghdad, Iraq

Parsons Corporation specialized in EPC projects, Deputy Safety manager support managing the safety programs and the US’s mission efforts of rebuilding the country's civilian infrastructure, consisted of different industries’ fields covering over 160 construction sites around Iraq .Report to Safety Manager.

Responsibilities Include:

• Maintain OSHA safety policies and programs comply with procedures and work instructions of both the Quality and Environmental Management Systems, and performs these responsibilities in a safe manner.

• Apply U.S. Army's Corps of Engineers Safety and Health (Manual-EM 385-1-1) at the construction sites

• Provide & manage training in daily, weekly and monthly basis for topics related to the work activities for junior’s employees, contractor’s staff, and new hires.

• Determines appropriate Personal Protective Equipment (PPE) during each job site activities or in any hazardous environments.

• Monitor the effectiveness of the job accident investigation process, and periodically prepares an audit report.

• Tracking safety deficiencies in daily basis issue/approve the Job Safety Analysis for each construction activities, applying Lockout/Tagout procedure around the construction equipment; improve safety culture at the construction job site to reduce the losing in time/recordable accident rate.

Accomplishments Include:

• Effectively managed around 160 job sites and maintain safe and health environmental at the construction sites.

• Meet the company goal of reducing the recordable incidents to below 1 per year.

Oct. 1989 to June 2004/Start new position Project/Process Chief Engineer SIDCCO, Baghdad, Iraq

SIDCCO (State Industrial Design and Consultation Company) under the organization of the Ministry of Industry, specialized in chemical, Petrochemical and refineries projects as an EPC contractor for execution projects such as Refineries,Chemical, and Petrochemical Plants, a Project/Process Chief Engineer for Polyethylene (LLDPE & HDPE) plant, Butene-1 plant, 3 Refineries, Methanol plant(Built inside Fertilizer Complex producing several types of Ammonia & Urea Products),team member for improving manufacturing, renovations, maintenance, commissioning, and start-up for the existing Polyethylene plant and with rebuilt several existing damaged plants and refineries and others, Report to Engineering Manager.

Responsibilities Include:

• Worked closely with the Know-How Licensors delivering approved revisions of Basic Engineering Designs; as

• BP Global, Gas-Phase technology to produce 80,000 M Ton of LLDPE and 80,000 M Ton of HDPE (the design was included third future train of 80,000 M Ton of LLDPE/HDPE).

• French Institute of Petroleum – IFP, Gas-Phase technology to produce 15,000 M Ton of Butene-1 as a Co-monomer for Polyethylene plant.

• Familiar with Basic Engineering Designs of Union Carbide Corporation for LDPE & HDPE plant built in Basra City (South of Iraq).

• Kim-Technology, Ukrainian company, Gas-Phase technology to produce 40,000 M Ton of pure Methanol.

• Member of the SIDCCO Project Management Team, familiar with different Know-How technologies for several petrochemical units producing Ethylene as a mother unit feeding the downstream unites of the PE, PP, TEG, EOG, Polypropylene Oxide, MTBE, Styrene, and more other and several side products.

• Leading and working with the engineering team to produce effective Detail Engineering Designs including preparation and remodeling of (P&ID’s), (BFD’s), (PFD’s), (UFD’s), energy and materials balances, equipment data sheet calculations for typical unit operations and for different plant’s Equipment, PSV calculation, pipe lines seizing, piping isometric drawings, equipment layouts, fire and safety equipment layouts, piping & cables rack support and its civil foundation.

• Manage conducting and Participated with the study workshops of “HAZOP”,”PHA”, and “SIL“, and follow up implementing the changes and decisions that recommended.

• Acts as a Project Manager in leading the projects management activities throughout the project’s life cycle from concept initiation to completion & closing out.

• Meetings arrangement with all parties involves with the project, presentation, effectively define the scope of work, planning, produce estimates the capital budgets, using Microsoft Project for tracking the project with applying project management techniques and reviews/approves change orders when required.

• Create notifications, purchase requisitions which included estimation and preparation of the bill of materials with the suitable specifications/codes, initiate, negotiation, and manage contracts w/ outside contractors/suppliers/customers, coordination and prepare accordingly permits required, plan and format of deliveries.

• Effective skills with project implementation stage, tracking the equipment fabrication and material deliveries, managing and monitor execution of the site construction activities related to the scope of work such as civil work for foundation and buildings, steel structure holding the equipment and pipe rack, piping system, mechanical installation, electrical and control system and perfect approval experience with the required inspection at the job site for civil materials, piping system and electrical equipment.

• Provide strong support and leading team plant during commissioning, start-up until deliver the plant to the steady state operation.

• Provide & mange training for juniors and new hires supporting operations and maintenance client’s staff for running the plant with the optimum operation.

• Provide support during plant improvement and optimize manufacturing and operation procedure to increase productivity, troubleshooting, shut-down &regular maintenance.

• Maintain OSHA safety policies and programs, supports compliance with Process Safety Management, comply with procedures and work instructions of both the Quality and Environmental Management Systems, and performs these responsibilities in a safe manner.

Accomplishments Include:

• Active team member managing and implementing multi projects with planned schedule and budget.

• Successfully implemented 3 refineries with capacity of 10,000 Barrel/Day.

• Successfully implemented Methanol plant with capacity of 40,000 Ton/Year.

Education& Certification

• Bachelor Degree”B.Sc.”, in Chemical Engineering, University of Technology.

• Green Belt of Six Sigma Methodology Certification, Certificate #002******** issued on June 07, 2012.

Others

• Language: Arabic. Iraqi (Native), English (Fluent).

• Holding active American Passport and Driving License issued from New York State with clean driving records.

• Holding active Residency (Engineer IQAMA) and Driving License of the Kingdom of Saudi Arabia,

• Member of the American Institute of Chemical Engineers- AIChE-ID#:009*********

• Consultant Engineer member of Saudi Council of Engineers, Membership number 175140.

• Consultant Engineer member of Iraqi Engineers' Union.

Contact this candidate