Maintenance Engineer

ESSAM HASSAN

El Awkaf Towers, Bani Suwayf, Egypt, Mobile: +2-010*-**-**-***

Date of birth: 19/05/1971

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

https://www.linkedin.com/in/essam-hassan-59860229/

Started career as Rotating Equipment Engineer, my experience is in machinery trouble shooting and diagnostics, revamp, maintenance and overhaul. Had been involved in machinery performance acceptance test, installation and commissioning. Today managing the Mechanical Department in Methanex Corporation so I'm responsible on multi discipline performance and reliability such as Rotating Equipment, Static Equipment, Workshop, QA/QC and General Maintenance, involved in root cause analysis to resolve technical problems, human factor analysis, opportunity losses and process safety KPI's.

EXPERIENCE

DEC 2012 TO PRESENT

MAINTENANCE MECHANICAL SUPERINTENDENT, Methanex Corporation

Ensure mechanical team follow safe work practices and procedures and follow all health & safety regulations to prevent any danger or accidents.

Issues and regularly update the Mechanical Safety Procedures

Leaving the workplace behind correct and orderly upon job / shift completion.

Reporting any anomaly, abnormal conditions and near miss to his supervisor.

Participating actively in HSE meetings, safety talks, tool boxes, training sessions and drills.

Lead mechanical activities (rotating, static, general maintenance and QAQC) in the new projects during construction, commissioning, startup and turnarounds.

Responsible for all QA / QC and related quality activities to ensure conformance to project specifications and international codes and standards.

Accountable for the supervision, development, and performance management of the Maintenance Mechanical teams, including recruiting and succession planning.

Works with QA/ QC Supervisor and other Maintenance Supervisors to improve plant equipment Integrity.

Manage Static activities maintenance include, pressure vessels, heat exchangers, reactors, boilers, valves.. in DAM-1 plant.

Manage Maintenance resources includes Manpower, Tools, Spare parts, Workshop material, and Workshop equipment, scaffolding and lifting equipment.

Manage major projects and repair activities by leading the team assigned to the task and provide a Mechanical Engineering advisory to the other sections.

Responsible for inventory and spares parts management; Optimized inventory aligned to support delivery of planned and corrective maintenance.

Monitor the Work performed by EPC Contractor and monitor quality and compliance with contract and Project Schedule and ensure project millstones achieved as per plan.

Ensure EPC contractor compliance with drawings and specifications on all areas of the Project.

Prepare service contract in conjunction with procurement team for critical activates with Vendors, Service Provider and Suppliers.

Assist in HAZOPs, MOC’s, Incident Investigations, and Job Safety Analysis in Methanex DAM-1 site.

Ensure plant Bad Actors are identified, tracked and solutions developed to prevent recurrence to enhance plant reliability.

Work with Reliability team to manage top Vulnerabilities items in the plant Vulnerabilities Watch List to develop a control plan for the top 10 items.

Lead RCFA of the equipment failures to ensure Causal Factors defines, Root Causes and Corrective Actions developed with appropriate time frame to prevent recurrence.

Oversee and control cost of opened project to ensure it is not exceeding approved budget.

Set Maintenance procedures in compliance with OEM recommendations, codes and standards to ensure effective Maintenance activities and optimum asset life cycle cost.

Allocate required resources to implement Maintenance activities (preventive, corrective, predictive, Inspection, and Performance Monitoring) to meet company KPI’s.

Ensure all Maintenance activities are managed through company CMMS (MAXIMO) to keep continuous and valid records for all assets.

Leads the development of annual and future years Maintenance budgets and assures annual budget is analyzed, managed and Maintained for areas of responsibility

Manage approved department budget efficiently to meet targets while optimizing cost.

MAY 2009 – DEC 2012

ROTATING EQUIPMENT SUPERVISOR, methanex

Ensure Rotating Equipment activities risks are identified, assessed and controlled as part of effective Maintenance delivery.

Lead DAM-1 rotating construction activities as apart from the site PMT to meet the project millstones and ensure the rotating equipment correctly installed according to the project codes with a high quality.

Establish clear guidelines for the development of the best working practices for Rotating Machinery Inspection function during Construction, Commissioning and Start-Up.

Order two-year spare parts for plant rotating equipment also review plant capital spares and order missing items, develop storage procedure to keep them in good condition.

Provide required analysis, development and documentation for the replacement, refurbishment and overhauls of the major Rotating Equipment.

Ensure that Rotating Engineers, Foreman and Technicians are adequately trained, equipped and motivated to achieve Maintenance targets.

Manage Maintenance activities for DAM-1 plant rotating equipment such as MAN DIESEL AND TURBO, SIEMENS, GE, KSB, DRESSER RAND, ELLIOTT, WEIR GABBIONETA, CRYO STAR, GOULDS, STERLING, SUNDYNE, SULZER…

Promoted the effective use of the Maximo Computer Maintenance Management System used for the planning, reporting feedback and documentation for maintenance activities.

Witness the mechanical test of the rotating equipment during the project phase of DAM-1.

Select and develop Rotating Equipment team members according to developed solid selection criteria.

Work to develop a motivated and empowered rotating workforce in DAM-1

Develop Maintenance Strategy for plant rotating equipment and review it periodically.

Develop Maintenance Work Instruction (MWI) for plant Rotating Equipment and Workshop Equipment.

Overhaul for Main Air Compressor (centrifugal compressor) to resolve the problem of the high vibration during startup.

Replace DGSs of the SYN gas compressor due to secondary seal failure.

Replace Rotor of the BWFT due to rotor unbalance lead to high vibration during turbine startup.

Develop Centrifugal pumps and compressors rebuild procedure.

Manage cranes and heavy equipment preventive and corrective maintenance.

Develop Switch over plan and auto cut in test plan for site rotating equipment and ensure it is applied by operation team according to the Master Plan.

JUN 2006 TO MAY 2009

ROTATING EQUIPMENT ENGINEER, Segas

Identify and assess safety hazards for rotating equipment activities.

Identifies turnaround (TAR) scope and review TAR job plans for rotating equipment.

Understands and apply rotating equipment engineering standards such as API 610 Centrifugal Pumps, API 611/612 Steam Turbines, API 617 Centrifugal Compressors/ Expanders etc.

Monitors critical rotating equipment conditions and performance.

Order Rotating Equipment spare parts using SPIR forms for NUOVO PIGNONE gas compressors, GE turbine, Hitachi compressors and turbines…

Complete overhaul and repair for propane and mixed refrigerant compressors (NUOVO PIGNONE).

Repair and overhaul for reciprocating gas compressors (IHI).

Gas turbine 8,000 and 24,000 Hrs services include combustion inspection and hot gas bass inspection.

APR 2001 TO MAY 2006

MECHANICAL SECTION HEAD, khalda PETROLEUM company

Develops, mentors, and supervises the Mechanical Engineers through coaching, training, and other developmental tools.

Set Maintenance Strategy for site equipment (static and rotating).

Manage spare parts min /max level in warehouse.

Lead new projects in Tarek gas plant such as Nodal gas compressor project.

Oversee workshop activities include fabrication, welding, machining and repair workshops.

Develop effective management system for Corrective Maintenance and repair orders to safeguard asset performance.

Apply combustion inspection, Hot Gas Path Inspection and bearing inspection for Solar MARS 100 Gas Turbine.

Review plant equipment condition through lube oil analysis, equipment vibrations monitoring thermal image survey and videoscope inspection.

Execute planned and unplanned Maintenance for site gas and air compressors such as MAN-TURBO, ATLAS COPCO and MITSUI.

Execute schedule inspection programs for site static equipment include vessels, heat exchangers, towers, heaters and separators.

JUN 1999 TO APR 2001

MECHANICAL ENGINEER, SANTA FE

Operation and Maintenance for all drilling rigs equipment include diesel engines, centrifugal pumps, air compressors, top drives and Draw work,

JAN 1997 TO JUN 1999

OPERATION AND MAINTENANCE ENGINEER, EGYPTIAN AIR FORCES

Operation and maintenance for airport power station equipment.

JUN 1996 TO JAN 1997

CONSTRUCTION ENGINEER, EL KORIMAT POWER STATION

Responsible for construction activities of the 650MW power plant air and exhaust ducts of unit 1 and unit 2 include workshop ducts fabrication, welding, site installation, testing and handover to the client.

EDUCATION

MAY 1996

B. Sc. Mechanical Engineering, Power Dept., May 1996

Zagazig University Shubra Faculty of Engineering

JAN 2017

Study MBA in Arab Academy for Science and Technology “Second year”

SKILLS

Excellent communication- verbal and written.

Develop direct reports.

Managing by Walk around (MBWA).

Vision and initiative.

Ability to manage a variety of cross-functional team members.

MS Office.

Technical Report writing.

Rigor.

Dealing with ambiguities.

High energy level.

Organization and planning.

Committed to coaching and training.

Managerial courage.

Maximo.

Document Management System

Time Management and set priorities.

High commitment.

TRAINING

Equifactor Equipment Troubleshooting

Tap Root incident investigation and root cause analysis

Turbo-Expander (GE Rotoflow)

Centrifugal Gas Compressor Maintenance

Customized PI client tools workshop

System 1 (Ver. 6.5)

Technical report writing

PMP Exam preparation

Lifting practices for supervisors

Bearing Identification Fitting and Servicing

Advanced Machinery Vibration Analysis

Engineering Lubrication

Valves.

Pressure vessels.

Rotating equipment operation and maintenance.

Situation leadership II

Role of the manager

Safety leadership workshop

Human Factor

Safety Performance

Human Factors Analysis Tools

Managing Risk, Recognizing What Can Hurt US”

Communication skills

Supervisor skills

Switch On Workshop

Project Management Professional

OHSAS-18001:2007

Dale Carnegie Seminar in effective communication and human relation

Train the trainer

Lean production and Six Sigma

ACHIVMENT

Lead Rotating Project Management Team (PMT) during construction phase of DAM-1 methanol plant (1.2 billion US$ project) responsible for equipment installation, pre-alignment, grouting, final alignment, auxiliary’s installation and equipment testing achieve zero LTI and without major incident.

Lead competence assurance program for the mechanical team in Khartoum refinery by identifying core and technical competencies for each job title, prepare competency dictionary, job profile, assessment tools, define gaps, create development plan with time line for implementation and reassessment.

Change Auto Thermal Reactor Arch due to key bricks cracked and some of them failed down due to repeated start stop for the plant, this Arch carry 50 Ton of catalyst which is very critical for the plant operation. The job includes investigate the root cause of the bricks failure which indicate ovality in the inner diameter of the brick ring. Problem solved by adjusting the bricks dimension during new Arch installation.

Replace catalyst of the Auto Thermal Reactor, Reformer, LP and HP converters includes catalyst deactivation, dumping, Reformer tubes/ vessels inspection and catalyst loading during plant shutdown and turnaround.

Reformer tubes internal inspection during catalyst replacement to ensure the integrity of the Reformer tubes till next Shutdown.

Investigate the failure of the boiler roof tubes repeated failure by covering the roof tubes by refractors.

Repair different types of Heat exchangers by plugging ruptured tubes, strength weld repair, tube and shell cleaning using different methods of cleaning such as dry blasting cleaning, brush cleaning, jet cleaning and chemical cleaning.

Support Risk Based Inspection (RBI) study/ implementation for DAM-1 static equipment through Quest Integrity by defining the potential damage mechanisms to assess and rank failure probability and consequences and develop equipment ITPs.

Participate in the Safety Critical Element (SCEs) identification project of the DAM-1 methanol plant.

Review and approve PSVs testing, inspection and overhauls procedure and apply it during shutdown and TAR.

Lead capital spare parts criticality study for the turbo-machinery spares to rank the recommended spares based on the study output and allocate budget for recommended spares.

On line leak repair for critical leaks that needs plant shutdown to enhance plant availability and ensure clamp list are developed and frequently reviewed and develop permanent repair plan.

Investigate and solve the high temperature problem of the Booster Air Compressor thrust bearing due to oil varnish accumulation in the thrust pads, upgrade the thrust bearing base metal from stainless steel to chrome cooper metal to enhance heat dissipation which decrease the temperature from 120 C to 82 C.

Replace Dry Gas seal of the SYN gas compressor due to secondary seal failure which lead to primary seal leak to flare decreased and activated LL alarm that trip the compressor, this job saved more than three weeks of production due to vendor unavailability and job done by local team.

Attend Dry Gas Seal test (Static and dynamic tests) in Eagle Burgmann after seal repair to ensure seal repair is completed as per Siemens recommendation.

Lead several plant shutdowns and achieve target from shutdown according to defined scope and within shutdown schedule, achieve zero LTI, zero leaks and no reworks.

Complete overhaul for different types of centrifugal compressors and reciprocating compressors in DAM-1 Methanex, SEGAS and Khalda Petroleum Companies.

Complete overhaul of different types of API and non-API pumps includes overhung, vertical and horizontal single stage and multi stages pumps.

Overhaul for reciprocating Mitsui compressors after four years of operation include bearing replacement, piston rings, ridder rings and load control system.

Contact this candidate