Rotating Equipment Engineer

PRASAD OMPRAKASH.

**/**, ******** ******, ********* road 7th Avenue, Residence: 0091- 995-***-****

Chetpet, Chennai,TamilNadu, India. Local Mobile: 00937- 38844629

Date & Place of Birth: 05.05.1972, Chennai. Nationality: Indian. Age: 46 Years old.

Education: BE Mechanical Engineering, 4years pattern (1990-1994) University: Annamalai University

Passport No: L3419949 & Validity Until 17.03.2024, Email ***********@*****.*** skype id: ompsumi

CORE COMPETENCIES

Machinery maintenance

Maintenance Reliability

Condition monitoring

Failure Analysis, RCA, FMEA

PSM, HAZOP Assessment

ISO 14000, 18000 involvements

Report Preparations

Dept Budget co-ordination

Equipment BAD ACTORS

Self-Motivated & creativity

Ability to work unsupervised.

Oral & written communication

CARRIER GROWTH

MECHANICAL ENGINEER / MACHIERY RELIABILY ENGINEER / SENIOR ENGINEER - RE

A dedicated engineer skilled in rotating equipment maintenance, reliability field for hydrocarbon industry. Capable of spearheading the efforts in Maintenance leadership roles to achieve management vision and goals.

EXPEREINCE SUMMARY

Experience in the field of all rotating machinery maintenance, trouble shooting, diagnostics studies, modifications and project supports.

Machinery condition monitoring, Vibration analysis, Lube Oil analysis, Boroscope, Field and trim balancing, Reliability improvement, RCA, RCFA, RCM on all rotating equipments and utilities including electrical motors and its related utilities in the oil & gas, Petrochemical, LNG plants & Refineries.

Worked in Steam Turbines (single & Multi stages) MHI, Shin Nippon & Dresser makes. Gas turbines: HITACH/GE, GE / Nuovo Pignone, SIEMENS Frame 5 (MS 5002) RUSTON Turbines (Gas Generators): TB 5000, TB5002.

Centrifugal Compressors: MHI, HITACHI, Reciprocating & screw types IHI & KAJI), Centrifugal Pumps: Shin Nippon BFW, Flowserve & Gould pumps, (API- single stage & multi stage & PD type), Fans, motors, Expanders, Generators, and Gearboxes.

Conversant with relevant Engineering codes & standards (API, ASME, etc).

Department SHE member in ISO 14000 & 18000 and Dept Core team member on PSM implementation.

Highlight of Employment

FROM

TO

POSITION & COMPANY

NO. OF YEARS

2008, JULY

TILL DATE

Sr. Engineer - Rotating Equipment & Reliability (Direct hire)

Maintenance Dept, Rotating Equipment & Planning section.

Bahrain National Gas Company. Bahrain.

11 Years 05 months.

2000, NOV

2008, JUNE

Machinery Reliability Engineer. (Direct hire)

Reliability & Planning Dept.

Saudi Methanol Company, Ar-razi, SABIC.Al-Jubail. KSA

07 Years 07 months.

1998, Sept

2000 Sept.

Engineer- Mechanical.

Plant Engineering Dept. MacLellan India.

(A division of Haden Jost Engineering India Ltd. a Haden MacLellan Holding company – UK)

02 Years

1994, Nov

1998 Sept.

Vibration Engineer.

Vibration Engineers & Consultants (VEC). A part of Indian Institute of Condition Monitoring Chennai. India. (Presently SKF – Reliability systems – Chennai)

04 Years

Total years of Experience: 24 Years.

CARRIER HISTORY

BANAGAS.

From 06.07.2008 to till, date Position: Senior Engineer - Rotating Equipments.

Reporting to Superintendent (Mr. Khalid Ahmed AbdulJalil)

Major Capital Equipments in Banagas. GE Gas turbine FR3(6nos) & SIEMENS Gas Turbine FR5(2nos), RUSTON TURBINE- 4nos, Elliot Propane Gas compressors- 4nos & HITACHI Gas Compressors- 12nos, ID/FD fans, IHI - Reciprocating compressor(1MW) – 3nos. I.A compressors – 9 nos (Mehrer & Kaji)

Rolls & Responsibilities:

Responsible for all rotating equipments in the Central Gas Plants (2nos), Compressor stations (7nos) & Sitra LPG loading area.

Executing, co-coordinating and supporting the maintenance activities during Major and Annual maintenance inspections and in turnaround inspections.

Supporting maintenance activities for all assigned rotating equipments for day-to-day activities, during overhauling Preventive maintenance, corrective maintenance, and breakdown of the machines, condition-based maintenance & trouble shooting of the machines.

Direct and follow-up the rotating machinery repair and maintenance activities for all Categories of rotating machinery (site, local workshops and vendor overhaul facilities as applicable).

Troubleshooting plant machinery problems, Preparing and addressing the root cause analysis (RCA).

Preparing RCFA reports for the failure machines and to recommend corrective measures.

Developing maintenance strategies for critical equipments (on repair and replacements) procedures and schedules in compliance with OEM guidelines. (GE / HITACHI)

Performing qualitative Lube Oil analysis for the Plant most critical equipments on Bi-yearly basis and review the quantitative reports submitted by CHEVRON.

Preparing and identifying Equipment BAD – ACTOR from the completed work orders on yearly basis further to reduce MTBF on the flagged equipments and to increase MTTR, to enhance Condition Based maintenance (CBM)

Updating the maintenance and inspection strategy for the Dry Gas seals (12nos) and performing condition-monitoring reports for the DGS systems.

Preparation of long-term maintenance history records for the removed and installed parts.

Recording all opportunity-based Jobs, preparing shutdown reports and the lessons learnt and to expedite accordingly.

Generating day-today activities work orders and material management using ERP Genero system. (similar to SAP MM/PM)

Supports and participates on mechanical section budgetary preparation for refurbishment and capital spares.

Preparing justifications reports to the management approval for the capital parts refurbishments to the OEMS & non-OEM’s. (GE, SIEMEN, MJB, TURBOCARE & IHI)

Reviewing vendor documents, preparing proposals for new parts and hiring specialists as well

Preparing PR’s, review, and evaluate the technical offers submitted by OEM’s and vendors.

Start-up support in commissioning phase of new compressor stations in (CS 9, CGP-3) and reviewing equipment drawings & P&ID’s.

Reviews asset criticality as a part of PSM implementation based on the PHA.

Updating & reviewing the department procedures, PM work instructions.

Reviewing capital equipment spares & raising the PRs for refurbishments & final inspection & acceptance of spares from warehouse.

Liaise with Vendors/Specialists as required to improve machinery reliability.

Ensuring the availability of capital insurance spares as per the five-year maintenance plan.

Participate in implementation/follow-up of equipment condition monitoring systems

Maintains/ update/ analysis of rotating equipment-running hours/ KPI.

Headed the section as an Acting Head Engineer (RE&P) in the absence of Head Engineer (RE&P)

Developing Bahrain national engineers and technicians

As a Vibration Analyst: Plant Machinery Condition monitoring group comprising a team of Mechanical Engineer, Sr. technicians & Technicians.

Review vibration data sheet and do detailed vibration analysis on day-to-day monitored machines and to recommend for corrective actions.

Daily analyzing the detailed spectral, time wave, cascade and waterfall analysis on the equipment monitored and submitting CM report and closing work-orders.

Conduct Lube oil analysis for the most critical equipment’s (Lube oil, seal oil)

Performing In-situ dynamic balancing using SCHENCK Hand held balancer for the HP rotors, ID & FD fans. & performing trim balancing on the rotors after overhauling with Schenk Balancing machine (CAB 920) in our workshop.

Prepares and submit monthly condition-based maintenance (CBM) report with machine health conditions.

Ensures condition monitoring instrument spares and update calibration records.

Preparing yearly condition monitoring schedule plan for the critical and non-critical equipments for condition monitoring. Equipment includes, Gas turbines, gas compressors, reciprocating compressors, ID, FD fans, centrifugal pumps, Fin fan coolers & Diesel engines.

KEY ROLLS:

SHE Representative: Involved from initial to final implementation of OHSAS ISO 14000 & 18000 Certification & Risk Assessment.

Process Safety Management: PSM Core Team Member

(Consultant: Process Information Institute – USA)

Supervision Experience: During Maintenance shutdowns.

Managing turbo-machinery shutdowns directly supervising 2 supervisors and 25 technicians either Day or in Night shifts 12 hrs.

30 Major overhauls inspections GE Frame 3 Gas Turbines.

28 Hot gas Path inspections GE Frame 3 Gas Turbines.

24 Combustion & Boroscope inspection GE Frame 3 Gas Turbines.

17 Major overhauls inspections Ruston TB-5000 Gas Turbines

09 Hot gas Path inspections Ruston TB-5000 Gas Turbines

16 Combustion & Boroscope inspection Ruston TB-5000 Gas Turbines

06 Major overhauls Elliot 38M7 compressor

08 Major overhauls Nuopignone MCL 807 / 608 compressors

04 Major & 03 Extended Major overhauls 1MW IHI reciprocating compressors.

Yearly inspections Annual / Major KAJI & W&J reciprocating compressors

Key achievements at Banagas.

Successfully reduced the vibration level from 0.85IPS to 0.15 IPS thru in-situ dynamic balancing for HP rotor @ 7500 rpm in the GE Frame 3 Gas turbine during plant start-up’s and in running conditions.

RCFA for the Load Turbine oil leak problem in the LP compressor in the Frame 3 Gas turbine.

RCFA for DGS failure in Hitachi compressor (Compressor station)

Diagnosed & solved the High exhaust temperature problem during the start-up Frame 3 Gas turbine.

Journal Bearing High temperature problem in the refrigeration compressor(Elliot)

Solved frequent failures of Electric motor on high temperatures.

Present Condition Monitoring instruments using in BANAGAS.

CSI 2140 (2nos) Machinery Dual Analyzer, IRD data pac1500 upgraded 2008 and IRD 308 Noise meter / SPM T30.

Olympus Make Boroscope instrument.

SCHENCK SMART BALANCER – Field Balancing.

3. Experience at Saudi Methanol Company (Ar-razi)

From 06.11.2000 to 06.06.2008. Position: Machinery Reliability Engineer.

Major Equipments in Ar-razi.

Steam Turbines up to 37mw-100mw, Natural Gas(NG) & Synthesis Gas Compressors(13& 17 MW), 1.72MW ID/FD fans, Vertical sea water pumps with capacity 5640m3/hr, Boiler feed water High pressure centrifugal pumps up to 300m3/hr, All types gears, Fin Fan coolers, Pumps and Electrical Motors.(complete inspections and recommendations) and have ability and capability to handle all type rotating equipments.

Area responsibility, PSSR committee Member, Inspector during Annual, Emergency plant shutdowns and Preventive and breakdowns.

Responsibilities:

Day to- day inspections, condition monitoring of assets based on criticality and priority basis from operation notifications and to write condition monitoring, Inspection reports based on work orders and closing with the actual spent time. In parallel Reports to be attached in the APM meridium software for Maintenance history records.

Repair maintenance inspection, checking and confirming all the inspection activities during Preventive and reactive maintenance and overhauling including motors and providing necessary recommendations maintenance the methods, procedures and standards required for repair to complete maintenance activities and hand over to operations in specific time.

Prepared complete Investigation report for the plant critical equipments and to Co-ordinate / follow – up with the other dept viz. mechanical, electrical, operation superintendents, and with supervisors to implement the RCA recommendations within the appropriate time to enhance the equipment reliability

Carried Predictive maintenance through condition monitoring from established schedule (CBM / PM) on all plant rotating equipments through SAP-PM work orders using CSI 2130 Machinery health analyzer for analysis, collecting data’s for more than 150 equipments as most critical and others 1800 as Semi and less critical equipments.

Interpretation of vibration data to diagnose machinery health condition and to prepare condition-monitoring, inspection reports with recommendations for maintenance corrective actions.

Using Bentley Nevada’s data manager 3300 / 3500 & System 1 and ADRE for windows software and DAIU 208 system for detailed analysis for Steam turbines, Gas compressors and all most critical equipments during normal operations, Before shutdown and during plant start-up’s as well.

Complete Inspections during overhauling, ESTA/ ATA / STA and to provide complete recommendations and "Scope of work to repair" to the maintenance departments, Inspection and witnessing for the repair works in the outside shops on Turbine, compressor rotors, Electrical motors, and providing required recommendations and scope of work for completion of jobs as per as per API and NEMA standards and to ensure mechanical integrity of the plant assets.

Protective system testing on all Critical equipments (Turbines over speed trip test/ solo-run test) during plant start-up’s as per the SABIC safety protection standards.

Critical spares review and advice for the additional spares requirement and Initiating warranty claims as required for the newly commissioned facilities, coordinating improvements and tracking its progress.

Participated in "Criticality Assessment Study" and deciding "Equipment Strategy" for maintenance of rotating equipment.

Auditing storage condition for spare rotors and raising corrective actions.

Monitoring Dry Gas Seals Condition and performance and assuring its reliability.

Review of equipment drawings and providing material specification during maintenance and reviewing of Critical and non-critical spares and carrying out Inspection after receiving the spares parts in the ware house for most, semi and less critical equipment and to optimize the availability and inventory.

Reviewing any mechanical engineering project plans and drawings and participating in preparation of Capital and operating budgets for Reliability Engineering Unit. In addition, recommending the purchase of new mechanical equipments, condition-monitoring tools.

Involvement in Key achievements at Saudi Methanol Company (Ar-razi)

On modification the cross head with sleeve of the brass material from frequent oil leak from the cylinder and damage of cross heads for the Reciprocating compressor. Make Mikuni, Capacity 750Nm3/hr.

Design modification change in the AFC-Unit (Air Fan cooler units) to change the Aluminum blades (8nos) to the PVC blades (7nos) to reduce the load for the Gear reducer to avoid frequent failures.

Boiler feed water pump frequent oil discoloration problem was solved after replacing the oil ring (metal) to Plastic material to the pump bearing assembly.

Replacement of gland packing seal to Mechanical split seals for the vertical seawater pumps capacity 5640m3/hr.

Condition Monitoring Instruments used in ARRAZI SABIC.

CSI Make and Model 2130 (3nos) Machinery analyzer with RBM ware software version V4.50 and CSI- 5200 Tri - vector analizar / mini LAB.

APM (Asset performance management) meridium software Inspection Management Ver. 3.1.1,

Bentley Nevada's 3300 /3500 Data manager ADRE for windows software DAIU 208 and

Bentley Nevada’s System I.

Project wise explorer / PIMS –Process information and management system.

SAP system R/3.

Bruel & Kjaer Model BZ7201 Sound analysis software / Model BZ 7201 enhanced sound, VIDEO PROBE XL Welch Allyn.

2. Experience at Maclellan - India from 16.09.1998 to 16.10.2000.

Position: Mechanical Engineer.

Responsibilities.

Preventive, Predictive Maintenance and condition monitoring of all plant critical and non-critical equipment failure analysis and recommending corrective measures for improvement

Supports during alignment and bearing replacement for corrective actions.

Monitoring and trending for centrifugal compressors and In-situ dynamic balancing for all air blowers, Cooler fans.

Supporting major overhaul of centrifugal compressors and Review & recommend for preventive and condition monitoring schedules.

Advise on insurance spares and preservation for critical issues.

Preparation of PM CBM activities for the rotating equipments, review of standard maintenance procedure (SOP’s) and work instruction for all rotating equipments for condition monitoring.

Spares review for all rotating equipment and Commissioning of new turbines, pumps and fans

Rotor replacement and in situ balancing of FD fans for boilers

Key achievements at Maclellan:

Establishment of Vibration Monitoring program including machine configuration, deciding routes and establishing monitoring frequency.

Implementing the baseline data for all the plant equipments

Frequent failure of Blower pulleys was prevented and rectified after installing vibrodampers by design study of proper blower loading locations.

Condition Monitoring Instruments used in Maclellan

SPM Cond master pro- 46 software. Sweden make. / Entek IRD 889 instruments.

Thoroughly used Entek IRD 305, 838, 880, datapak1500

1.Experience at VEC-Chennai, from 07.11.1994 to 07.09.1998

Position: Vibration Engineer.

Responsibilities:

Served more than 500 Industries all over India (Cement, Heavy, Power, Paper, Steel, Automobile, Chemical, Petrochemical, Oil & Gas plants) and conducted vibration analysis, in-situ dynamic balancing, alignment correction and solving critical plant problems in most of the cement plant ID/FD/ESP/cement mill/ coal mill / Pre-heater fans using portable vibration analyzers like IRD 350,838,880,Datapak, FAST TRACK,IRD 890 CSI 2115 etc.

Diagnosed several number of rotating machinery problems such as unbalance, misalignment, bowed rotor, eccentricity, rolling element bearing faults, journal-bearing faults etc, and using tools like vibration spectrum/signature analysis/orbit analysis/waveform etc and preparing Inspection and Diagnostics / balancing reports to the customers.

Inspection of all plants equipments such as turbine, compressor (Centrifugal & reciprocating), ID/ FD/ESP Fans, all types pumps, motors, Elevators, Conveyors, Mills, Kilns, DG sets, scrubber fans, cooling tower fans, and lobe type blowers reducers make Flender-Graffenstaden, Lufkin.etc.

Carrying In-situ dynamic balancing (Single / double plane) static balancing, alignment to all the rotating equipments and developing and implement preventive maintenance procedures and conditioning monitoring programs.

Pumps supplied by KSB, Ebara, Sulzer, Gurdlestone, Ingersoll rand dresser, Sundstrand etc and More than 500 pumps having various types of mechanical seals and API flushing plans

Elliott make integral geared compressor 12 MW integral gear type Process air compressor manufactured by M/S MAN-GHH, Germany with 36 kg/cm2 pressure and capacity 70,000 Nm3/hr.

Commissioning and start up assistance and performing mechanical checks and following up testing,

Provided turnaround support to various Plants like PAP, Aromatics, CDU, Polypropylene etc for major overhauling of rotating machines like Wet Gas Compressor (MHI make), FCC Expander (Dresser) and Recycle Compressor (GHH).

Served in Major companies as 3rd part engineer in GAIL, ONGC, SAIL, TATA & Birla group Industries.

Condition monitoring instruments used

Entek IRD 305, 350, 838, 880 & IRD data PAC 1500, ONOSOKKI balancer & SKF condition monitoring portable T30 instrument. B&K Noise meter.

Training courses, Conferences / Certification programs attended:

Program Details Organization / Venue

Machinery Lube Analyst MLA II Certified Int’l Council Machinery Lubrication -USA.

Vibration Analyst CAT II Certified Vibration Institute - USA.

CMRP - Maintenance & Reliability course PetroLabs India

PSM - Process safety management Banagas, PII – USA.

Certified Reliability Professional Training. Centre for Reliability, Govt, of India.

Governing, Protection of Steam Turbines. Engineering staff college of India.

Bentley Nevada system 1. Bentley Nevada Saudi Arabia.

Asset Performance Management SBM-Meriduim Saudi Arabia

Industrial Hygiene. SABIC / In-house.

Mechanical Integrity. SABIC / In-house.

Root cause analysis (RCA) SABIC / In-house.

SAP system R/3. SAP-Arabia.

Centrifugal pumps (1998 Maclellan) KSB Pumps & Valves / In-house

Seminar on Advance Predictive maintenance & Condition Monitoring

oVEC & IIT - Madras Jointly in 1997- Aug

Industrial Training - 1993 Madras Refineries Limited Chennai.

Technical Paper Presentation (SABIC TECHINICAL MEETING-8 in 2007)

"Systematic Condition Based Maintenance (CBM) using advance diagnostic techniques”. In Ar-razi a Perspective challenge". Ref# STM8/579/ASM/156 has been approved & selected.

Professional Membership:

SMRP & Bahrain society of Engineers.

Vibration Institute,

The AIM-UK

Software proficiency

Day to day working with CMMS / SAP-R3 PM, Modules, APM (Asset performance management) meridium software Inspection Management Ver. 3.1.1, Ramis software.

CSI 2140 RBM ware V 6.2 and Bentley Nevada's software tools like, DM3500 Bentley

Nevada's ADRE for Windows software DAIU 208 & Bentley Nevada's System 1.

Computer Skills : Good knowledge and well versed in office automation software.

Date: 20.10.2019 Signature.

Place: Riffa - Bahrain. (Prasad.Omprakash)

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