Mechanical Engineer Manager

KAMAL MALAK P. Eng.

***-***** ******** ***.

Fort McMurray, AB T9H 2H6

Cell. Number: 647-***-****

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

Highly motivated and resourceful Mechanical Engineer with comprehensive experience in basic and conceptual engineering. Extensive experience with designing mechanical rotating equipment.

Solid leadership ability demonstrated by leading Rotating Equipment department, holding roles of Engineering Manager and Senior Design Engineer.

Developed preventative / predictive maintenance program and set up the reliability centered maintenance for Oil refinery.

Experience includes: Start to completion EPC downstream project design (Feed and Detailing).

Supervised hydraulic design, troubleshooting, vibration analysis and mechanical design to API standard per ANSI, NFPA, TEMA and NACE.

Technical courses in maintenance and operation of Gabbioneta pumps (Italy) and Sundyne centrifugal pumps and compressors (USA)

Knowledge of Infrared thermograph testing

WORK ACCOMPLISHMENT / CAREER HISTORY

Syncrude, Fort McMurray AB (contractor)

Machinery Engineer Apr. 2019 – Present

Leading the Hydrotreater pumps improvement program to eliminate the unexpected equipment failure, reduce loss of production and cost of maintenance. Using the best reliability methodology such as five whys and loss investigation tree to identify the root cause.

Generating MOCs to aim for safe design and process conditions and or required modification required.

Participating in PMT reports to collect the raw data of the equipment failures prior to finding root cause of failure modes based on facts.

Providing procedures, check sheets, scope of work and technical support to maintenance team based on my design experience to improve the maintenance work quality.

Work with equipment, mechanical seals manufacturers and repair shops to ensure scope of work was done based on the Syncrude reliability standard using the international and industrial codes.

Leading the bad actors improvement program to solve chronic machinery operation outages and frequently to eliminate loss of production, unplanned repair and risk increase by monitoring equipment behavior, visit failure and repair history to eliminate poor problem solving.

Providing safe work instruction for personal as well as machinery by inspecting mechanical and testing the mechanical seals before and after installation (example environment plant DEA charge pump)

Georgia Pacific, Easton PA USA

Asset Availability Leader June, 2016 – Sept, 2017

Manage small projects for rotating, fixed equipment and managing reliability of CNRL’s Kirby project and all Thermal Production Sites (Co-Gen projects).

As Senior Mechanical Engineer and Team Lead of Rotating Equipment group, Performed calculation for material selection, performed quality assurance checks on mechanical documents (RFQ/RFP and datasheets); wrote equipment specifications; prepared CMMS requirements of the rotating equipment; prepared material requisitions; reviewed and analyzed Sellers technical bids; obtained hands on project experience for all rotating equipment i.e. all pump types, steam turbines, fans & blowers, process centrifugal and reciprocating compressor; and participated in feed study man-hours estimation. Considered Specialist in front to end project design.

Weir Pump of Canada, Mississauga, ON

Senior Mechanical Engineer Apr. 2005 – May. 2006

Evaluated and estimated pump repair costs.

Liaised effectively with all stakeholders; Vendor, Sub-Vendor and third parties.

Inspected and evaluated the equipment, reported the methods and advised appropriate stakeholders prior to repair.

CPC Pumps International, Mississauga, ON

Engineering Manager Apr. 2000 – Apr. 2005

Provided leadership in all engineering issues from conception including design and calculations for all existing products, new products and development.

Ensured bills of material were accurate and inclusive, and in accordance with client requirements.

Calculated maximum allowable working pressure for case wall thickness, case gasket and case bolting; calculated rated horsepower to select pump coupling; calculated axial thrust to select bearing and calculate bearing life.

Calculated vertical and horizontal pump shaft deflections.

Made certain all detailing drawings were to ISO and API standard.

Checked that correct mechanical seal selection and flush piping were used to suit customer application and conditions.

Ensured that case nozzles forces, moments calculation and attachment fittings met API and ASTM standards and ASME and codes.

Developed and tested new hydraulics and designed new cases and impellers.

Worked closely with pattern shops to ensure pattern equipment matched hydraulic drawings; demonstrated skill at negotiating best price for best equipment.

Worked alongside Foundries department to ensure casting quality and procedure met company standard.

Developed QA procedures with the quality assurance team.

Evaluated pump performance problems and designs related to manufacturing inquiries and provided support to production department.

Application Engineer Feb.1991- Apr.2000

Requisitioned all materials per API, ASTM standards.

Provided assistance in preparation of calculations of pump designs, thrust calculations to determine bearing life, and shaft deflection calculations

Assisted in identification and resolution of site problems reported during manufacturing process

Coordinated Engineering activities that assisted in improving product performance.

Promoted to Engineering Manager

Head of Design, Rotating Equipment Section Experience Prior to 1991

Ameria Petroleum Refinery, Alexandria, Egypt

Troubleshot plant equipment to identify root causes of problems and provided workable solutions which improved equipment lifetime and reduced maintenance costs and downtime.

Prepared equipment specifications, datasheets and equipment selection according to required conditions such as NPSHR, head and capacity.

Analyzed and evaluated equipment vibration and trouble-shooting reports. Approved required repair method.

Verified vendor’s best quote and pricing lists for preparation of purchase orders.

Prepared equipment technical specifications to suit standards, requirements and processing type.

Calculated and selected suitable driver to suit and improve pumping condition by adjusting impeller trim diameter.

Retrofitted, designed and converted centrifugal pumps to latest API standard design

Designed replacement pump baseplate to suit existing foundation.

Prepared yearly budget requirements for equipment replacements and spare parts. Prepared yearly report for accounting department according to reliability reports for yearly maintenance.

Approved reliability schedule, analyzed daily maintenance and reliability reports to improve plant equipment performance. Implemented preventative maintenance and reliability schedule.

Involved with health and safety department to set up maintenance procedures.

Prepared work health and safety reports and documented accident causes and provided recommendations to avoid future accidents.

Installed centrifugal and reciprocating pumps and compressors, ventilators, fans and blowers, piping systems.

Scheduled and oversaw plant maintenance improvement by following preventative maintenance procedures and steps.

Managing barrel factory, controlling inventory and equipment spare parts, reducing production cost.

PROFESSIONAL MEMBERSHIPS AND AFFILIATIONS

P. Eng. Licensed Ontario PEO # 90326885

P. Eng. Licensed Alberta APEGA # 122473

EDUCATION

B.Sc., Mechanical Engineering, Menoufia University, Egypt

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