Maintenance Management
Resume:
Imed KHARBECH
*************@*****.**
MAINTENANCE & PROJECT PLANNER
Petroleum industry
Mechanical Engineering Master Degree, 17 years’ experience in Maintenance & Project planning, coordination and management for major industrial & petroleum companies
Core Qualifications
Planning and Scheduling Expertise.
Experience on Maintenance coordination and management (level 1 to 3 and level 4 to 5)
Expertise on CMMS system: Design, configuration, integration & monitoring.
Development and implementation of maintenance strategy.
Expertise on field/ plant Shut-down scheduling and coordination with holistic understanding and implementation of estimating principles and techniques. Field/ Asset start-up and SIMOPS (Simultaneous Operations) plans’ management.
Sound Experience on RCM (Reliability Centered Maintenance), Roote causes analysis, Risk analysis.
Experience in development and implementation of strategic and major maintenance, renovation & extension projects within SIMOPS plans’ management.
Experience on facilities topside and subsea inspection management. Asset integrity plan and RBI (Risk Based Inspection) process integration and monitoring.
Experience on knowledge transfer. Leading team of junior engineers. Training package development and administration.
Member of several committees such as safety, maintenance & project management.
Analytical and strategic thinker, organizational skills, problem solving oriented and multi-cultural environment leaning.
Proficient computer skills, including Primavera P6-8, MS-Project, SAP-PM/MM, Maximo, Fame+, Outlook, MS applications(MS Excel, MS Access, MS P.P …).
KEY ACHIEVEMENTS
Successfully designed, implemented and managed all asset planning processes and duties at SNL/Total Block 3 (fourteen offshore platforms) & SNL/Chevron Block 2 (twenty five offshore platforms).
Effectively centralized, developed and implemented asset Level 1 to 5 maintenance contract. Structured maintenance department budget and integrated maintenance policy into CMMS system. Completed tender document preparation and bid’s appraisal for asset maintenance contract.
Successfully designed, configured, Implemented and monitored global SAP CMMS system on Block 3 & Block 2 assets. Integrated Maintenance, Inspection, HSE, FED and Well Intervention Departments’ work flow processing and management.
Successfully Scheduled and coordinated major and strategic maintenance, refurbishment & extension projects:
Top-side structure and piping refurbishment (or replacement) of all block 3 platforms (05 years duration campaign). Directed throughout SIMOPS plans’ management.
FSO Terminal PALANCA revamping project (03 years duration project_ 01 Million bbl storage capacity) including: Hull steel repairs (Underwater and topside parts), Turret and chains anchoring system renewing, piping, superstructure, vessels, tanks and main equipments refurbishment, Export and import flexible hoses replacement. 2x 5,5kV subsea electrical cables replacement.
Block3 main equipment turnarounds/ overhauls (6x 7.2MW Turbo-alternators, 2x 2900 kW Gas-Lift trains, 3x 4260 kW + 2x 1800 kW Water-Injection Electro-pumps, 6x 700 kW Water-Injection Turbo-pumps …).
H.V Electrical system retrofit/ replacement (6x 20kV & 2x 5,5 kV H.V Sub-sea cables, 3x 20kV Busbar, 4x 20/5 kV H.V transformers replacement …)
Since 2005, successfully completed all Block3 & 2 field Shutdowns (300.000 M-H per S/D_ 750 POB). SOW (Scope Of Work) and Cost appraisal & optimization, Integrated S/D Scheduling and coordination. Risk assessment and permit to work development. Field/ Plant partial start-up and SIMOPS plans’ management.
Soundly supported the development and implementation of block3 plant integrity project throughout design, integration and monitoring phases. Integrated R.B.I plan ( Fame+ B.V system) for criticality assessment and corrosion monitoring of overall block3 pressure Vessels, PSVs, piping and facility structure (03 years duration project).
Directed the deep foundation & civil construction of power station plant for General Electric, successfully completed mechanical assembly and inspection activities.
PROFESSIONAL ACHIEVEMENTS
Since August 2005: SONANGOL/ TOTAL – Angola : Planning and CMMS Manager at SNL/Total Block 3 & SNL/Chevron Block 2
Planning and maintenance duties
Design, implement and manage asset planning process.
Implement global asset integrated Planning encompassing maintenance, inspection, well interventions and construction department’s activities (offshore plants).
Establish asset planning procedures and associated documents
Define and develop Planning’s Work Breakdown Structure (WBS).
Develop activities timelines and define Work priority.
Control and monitor 1W & 4W planning (Asset daily and weekly activity program)
Develop, implement and monitor 1Q and 6Q planning (Asset Major Activities) in collaboration with offshore/ onshore teamwork and cost control department support.
Estimate and submit offshore POBs assessment (Personnel On Board per platform).
Achieve optimal utilization and deploy all asset input resources ( material, manpower, and equipment) with minimum delay and idleness through scheduling estimating techniques and resources leveling histograms
Apprehend, assess and schedule risk, safety hazards and activities conflict
Track and report Planning Progress (progress reports, S curve
Perform RCM analysis. Enhance performance of equipments (reliability, maintainability and availability) in accordance with asset maintenance strategy. Analyze plant and equipment’s performance and downtime data to identify current and potential defects. Issue RCM analysis report including accurate KPIs (MTBF, MTTR, MTTF, Prev%Cur rate).
Supported the development and the implementation of Asset Level 1 to 5 maintenance strategy. Organized general maintenance contract and completed tender document preparation and bid’s appraisal.
Develop maintenance and inspection dashboards & KPIs and establish realistic expectancy targets (based on international standards).
Establish periodic analyzes reports for maintenance department, asset managers and company technical committee (notably 1Q TCM _ Technical Committee Meeting with concessioners).
Make recommendations concerning both short and long-range planning needs
Create an extensive library for planned job packages with integrated up to date maintenance operational procedures and technical data base
Define and perform material and spare parts criticality ranking in accordance with asset maintenance strategy, manufacturer recommendations, and method engineers’ approval _ (ABC analysis method).
Schedule and follow-up all jobs requiring common equipment access as appropriate ( to avoid duplicate equipment shutdown).
Oversee predictive maintenance analyses. Establish comprehensive preventive maintenance program. Using CMMS system, generate, plan and control the schedule of preventive maintenance work in accordance with the maintenance strategy and site supervisors’ recommendations.
Maintain accurate backlog status and perform a backlog analysis, categorizing, prioritizing, cleaning & execution within resources and equipment availability. Issue a backlog detailed monthly report and provide execution settlement program.
Accurately planned, scheduled, coordinated and fulfilled all Block3 and block2 field Shutdowns since 2005 (day and night shifts/ 1hour base schedule unit). Defined and reviewed SOW and Cost. Developed integrated Risk assessment and permit to work process with concerned trade and HSE teams.
Implemented estimating techniques (mainly CPM method_ Critical Path Method) and established optimal resources deployment for plant Shut-down. Define required intervention team’s constitution (quality & quantity) for all trades.
Developed and issued every shift tracking and progress reports, including progress curves Emphasize on reported delays, anticipate potential troubles and recommend, when necessary, remedial actions. Establish lessons learned report after Shut-down accomplishment.
Skillfully and perfectly scheduled, coordinated and fulfilled plant partial start-up and SIMOPS plans’ management during overall field shut-down.
Planned, scheduled and coordinated major and strategic projects on behalf of maintenance, inspection and construction departments ( refer to “Key Achievements” part). Project SOW review and integration into asset planning. Accomplishment of SIMOPS’ plans coordination and technical document and drawings updating.
CMMS main duties
Designed, configured, Implemented and monitored overall SAP CMMS system on Block 3 & Block 2 assets, including the integrated four sections: Organizational Structure, Master Data, Maintenance & Inspection Processing and Preventive Maintenance. Review, and create if any, all required procedures and documentation support to perform the new CMMS development.
Organizational Structure development
Defined and configured (manually) the General Organizational Units (onshore plants, storage locations, authorization profiles groups …) in liaison with finance, accounting, cost control, logistics, contract, purchasing and material management departments.
Defined and configured (manually) the Location-based Organizational Units (onshore and offshore Maintenance plants, offshore locations and plants’ sections…).
Defined and configured (manually) the Planning-based Organizational Units (PM Planning plant, PM planner groups, PM Work Centers…).
Master Data development
Review and check the entire asset P&IDs. Undertake required document updating, if any, with concerned department and document controller.
Defining asset topo-functional structure including Master Data hierarchy (systems, sub-systems, functional locations, units, equipment, BOMs & assemblies, material Item).
Review of asset Integrity plan and related inspection requirements procedures.
Establishment of functional locations’, equipments’ and piping’s numbering & tagging procedures in accordance with asset P&IDs tagging, engineering department requirements and international standard.
Development of naming procedure (codification convention) for every one of CMMS object (Functional Location, Equipments, BOM, Material, Measuring point/ counter, Maint Plan, Task List, Measuring Route, CMMS Object Class & Sub-class & Characteristics…)
Defining and configuration of Classification system in accordance with maintenance engineering, and asset integrity plan requirements (for F-Locations, Equipments and M-points). Development of mass uploading program with related templates and performing data uploading.
Defining, and configuration of Technical Characteristics (qualitative & quantitative types) related to each object Class and sub-class, and including associated list of values catalogues. Development of mass uploading program with related templates and performing data uploading.
Creation of Asset Functional Locations’ & Equipments’ lists, according to reviewed asset PIDs and manufacturers’ documents ( Tag nbr, Serial nbr, Location, Planner Group, Main W-Center, Class & Sub-Class, Cost center, Criticality and Failure classes …). Development of mass uploading program with related templates and performing data uploading.
Creation of BOMs’ lists, according to manufacturers’ documents and maintenance strategy requirements (Components Refs, Quantities, Plant, superior F-Location or Equipment…). Development of mass uploading program with related templates and performing data uploading.
Creation of Inspection Measuring points’ lists and Routes, according to RBI system’s requirements, for asset pressure Vessels, PSVs, piping and facility structures. (M-P Position, Class Type, Class, Code Group…). Development of mass uploading program with related templates and performing data uploading.
Through pre-configured Technical characteristics data bases, and by means of PIDs, Manufacturers’ documents and inspection registers data, establishment of values lists for equipments’ and F-locations’ characteristics. Development of uploading program and templates, and performing data uploading.
Assignment of technical documents (P&ID, Data-Sheet …) to F-Locations, Equipments and Task lists, via PRT (Production Resource Tool) function. Preparation of mass uploading program with related template and performing objects’ links uploading accordingly.
Maintenance Processing development
Review and enhancement of the work management processes related to, mainly maintenance and inspection departments, as well as FED (Facilities Engineering and Construction), HSE, and Well intervention departments.
Defining and configuration of integrated CMMS work flow process including creation, preparation, approval, execution, validation, closing and settlement phases.
Defining and configuration of maintenance, inspection and FED activity types (BK- Breakdown, PS-Preventive Scheduled, PC- Preventive on Condition, BL-Baseline, RO-Routine, ST-Statutory, SP-Special, MD-Modifications, MS-General Maint. Support…).
Defining and configuration of Notifications’ and Work orders’ types (NC-Malfunction Report, NI-Integrity, NG-Work Request, NP-Activity Report & WDF-Breakdown Order, WGN- General Work on Request, WRO- Special Orders, WPM-Planned Work Order)
Defining and configuration of overall Notifications’ and Work orders’ elements, such as: system status, user status, work priority codes, Shut-down codes, Objects-Damage-Cause & Activity Catalogues, settlement rules…)
Defining and configuration of CMMS standard and flexible reports. Development of synthesized dashboards and accurate KPIs (MTBF, MTTR, MTTF, Prev%Corr Mait…) through customized database Queries and ABAP programs with combined data sources and personalized layouts.
Establishment and performing complete statistics extraction for maintenance reliability analysis, as well as required appraisal data for inspection, FED and HSE departments.
Preventive Maintenance development
Development and configuration pre-defined maintenance and inspection strategies’ packages, according to manufacturer recommendations, maintenance engineering and asset integrity plan requirements as well as international applicable standards.
Determination of strategies’ scheduling parameters such as cycle type and hierarchy (cycle type: time, activity or calendar), Call horizon, Shift Factor and execution tolerance rate.
Development and configuration of maintenance and inspection preventive Task lists in accordance with manufacturer’ recommended SOW, maintenance operational procedures and RBI predefined inspection schemes (Non-intrusive or intrusive Major inspection NI-MA, IN-MAJ).
Defining overall Task lists’ elements and calling for integrated predefined databases (T-L Group, W-Center, Maint Strategy, Operations SOW, material, operating procedure, standard Texts …). Development of mass uploading program with related templates and performing data uploading.
Development and configuration of multi-trades & multi-cycles Maintenance posts. Defining overall posts’ elements and calling for integrated predefined databases (F-locations’ or equipments’, W-Order type, Activity type, Priority code, T-List Group, S/D code, Route …). Development of mass uploading program with related templates and performing data uploading.
Development and configuration of multi-trades, multi-strategies and multi-cycles maintenance plans. Defining overall maintenance plans’ elements, calling for integrated predefined databases and assignment of scheduling parameters (F-location or equipment, Maint Strategy, Maint Post, Call Horizon, Completion Requirement index Development of mass uploading program with related templates and performing data uploading.
Scheduling, monitoring and executing maintenance and inspection plans. Generating half-yearly preventive maintenance and inspection work orders for overall asset facilities.
2001 – 2005 PIRECO - Tunisia
International company providing construction products and services for the petroleum and manufacturing industries, €450M revenues, 200 employees
Project Engineer and Proposal Manager
Main Duties:
Site manager for gas turbine power plant construction project (125 MW) at La Goulette in Tunisia for General Electric: (€18M ). Planned and organized work activities. Directed the deep foundation & civil construction, mechanical assemblies and inspections works.
Managed power plant shutdown at Rades (2x125 MW). Planned site activities and oversaw the inspection and maintenance work execution.
Managed projects for the Iraq Petroleum Minister as part of the Oil for Food Program (for Kirkuk_ NOC): coordinated with UN inspectors, clients, and suppliers. Provided technical engineering support, planned and oversaw engineering and procurement SOW for gas and steam turbines refurbishment project_ 09 stations_ €10M.
Responded to requests for proposals (RFP’s): prepared technical and commercial proposals, structured and planned the project, consulted with suppliers and sub-contractors, and negotiated offers with clients:
Projects for SONATRACH:
Bejaia petroleum port renovation, Algeria_ € 12M.
Renovation of instrumentation, electricity, and control command systems of 99 turbines for compressor stations_ serving 4 gas pipelines in Algeria_ € 105M.
42” EPC pipeline project_ 404km in Algeria_ € 60M.
Projects for Thyna Petroleum Services:
Turnkey engineering, procurement, and construction (EPC) for a 100km sub-sea gas pipeline in Tunisia_€ 09M.
2000 – 2001 CETIME (Technical Center of the Mechanical and Electrical Industry), Tunisia
Organization affiliated with the Minister of Industry, €1M revenues, 145 employees
Industrial Control Engineer
Main Duties:
Managed industrial inspections with the Mechanical Inspection and Testing Department. Defined, planned, and conducted mechanical tests and inspection procedures, supervised site personnel, performed technical inspections on imported and shipped equipment, and led seminars (NDT, corrosion)
Oversaw the certification of NDT inspectors with the Tunisia Commission of Non-Destructive Testing (COTEND). Trained inspectors, administered and graded certification exams according to International and European standards (ISO 9712 and EN 473), and implemented the COTEND quality system.
EDUCATION, LANGUAGES & COMPUTER SKILLS
Initial
Mechanical Engineering Master Degree – National School of Engineering, Tunis (2000)
Mathematics and Technical High-School Diploma (with honors) - Tunis (1994)
Vocational
Security Trainings: First Aid / Helicopter Underwater Escape Techniques & Offshore Survival
Basic Fire Fighting / Personal Survival Techniques / H2S Awareness
ISO 900& Quality Assurance / MS Project 2010 (Master level)
NDT inspection by Eddy current (level 2) and ultrasound (level 2)_ Tecnatom, Madrid, 2001
NDT inspection by ultrasound (level 2), National Welding Institute_ France.
NDT inspection by industrial X-ray (level 2), COFREND _ France
NDT inspection by Eddy current (level 2), IFAT_ France
Radioprotection (level 1), CNRP_ Tunisia
Languages Arabic mother tongue English bilingual French bilingual
Software
Microsoft Project 2010, Primavera Professional Project Management P6
CMMS: SAP P.M/ MM / Maximo / DataStream D7i.
MS applications (Word, Excel, PowerPoint, Access, Outlook), Lotus Notes
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