Senior Electrical Engineer, Control & Instrumentation Engineer

Position

Senior Electrical (Control & Instrumentation) Engineer

Education & Qualifications

BSc (Hons) in Electrical Engineering, University of Zimbabwe, 2002

Professional Affiliations

SAIEE (South African Institute of Electrical Engineers): 12285

ECSA (Engineering Council of South Africa): 20085748

Summary

Key Strengths

Key Skills & Experience

I have more than 19 years extensive experience and firm E,C&I engineering experience that will be used to the company’s full benefit. I have successfully worked in various plants, modules or machines in the mineral processing industry (wet mills, jaw crushers, HPGR crushers, gyratory crushers, ship loaders, stackers, reclaimers etc. including minerals pyro metallurgy – submerged arc furnaces and induction furnaces), cement industry (rotary kilns, dry mills, bucket elevators, bag filters etc.) and lime industry (vertical shaft kilns) from plant conceptual design, detailed design of the engineered components, modules and plants, procurement, construction thereof, commissioning and maintenance (equipment services and any upgrades including rebuilds) thereafter. I can work under pressure in required and I work to deadlines though very much safety conscious, very resilient with good communication skills and excellent hands-on skills. I work well in team set-up and am a good team leader. This experience stems from having worked extensively in Sub-Saharan Africa and with European companies across the different races, languages, and cultures.

I have successfully managed E,C&I teams across several mineral processing (mining & pyro-processing) and cement and lime manufacturing plants for various projects and maintenance teams.

I have managed budgets (both CAPEX and OPEX) worthy millions for projects/contracts as well as for maintenance teams without overrunning.

I have safely managed engineering design and maintenance teams at the planned work force and utilisation levels for maximum company benefit.

I have very strong leadership and man management skills which I have used across different countries and cultures successfully.

I have extreme site experience, which was done in the successful plants construction, commissioning and maintenance support.

I have very good verbal, written, interpersonal and organisational skills.

I am well-experienced in various computer packages, which include EPLAN electrical CAD, AutoCAD, Excel spreadsheets, MSWord, Ellipse ERP expert user and SAP ERP.

I have great time management skills and eye for detail.

I have done various conceptual and detail designs of the plants E,C&I systems (P&IDs, FEED, HAZOPs, FATs, SATs, etc.)

I have prepared and adjudicated tender documents, project specifications, technical specifications, and enquiry documentation to vendors/clients.

Vendor’s documentation review to ensure design integrity and compliance to projects’ specifications.

Reviews of electrical, instrumentation & control documentation from vendors/clients as well as other disciplines documentation.

Management of E,C&I projects and sub-contractors/vendors

Plant control (PLCs, SCADA and network topology) systems design.

Motor control centres (MCC), cable block diagrams & SLD and multi-line diagrams design using EPLAN CAD and AutoCAD software.

FAT and SAT for the outsourced (VSDs, MCCs, motors, instruments) and in-house equipment.

Very experienced in Root Cause Analysis across industrial problems.

Experience: Jan 2010 to Present Senior Electrical (C&I) Engineer - thyssenkrupp Industrial Solutions, SA

Contract/Project Experience

BHP Iron Ore,

Finucane Island

Western Australia

Kamoa Copper, Ivanohoe/Zijin JC,

DRCongo

Handyman Lime Plant, Ndola, Zambia

I have worked on plenty of mineral processing plants, lime plants and cement making plants in Sub-Saharan Africa. I have worked in diverse multi-national and multi-cultural teams; some of the plants worked on include the following: –

Presently working on the BHP Finucane ship loader 3 design with the thyssenkrupp Industrial Solutions Australia team, as one the key Senior E,C&I engineers.

Lead E,C&I engineer in the design, procurement construction and commissioning of 2 off HPGR crushers driven by Weg MV VSD with 1200 kW motors with Siemens control system (S7-1500 PLC and local Siemens TP1200 HMI)

Lead E,C&I engineer in the greenfield (turnkey) design, procurement construction and commissioning of 600 tpd Lime Production Plant. The work I did included: -

oMV electrical network basic design

o3-phase transformer specifications, procurement, FAT and SAT

oFull plant MCC design and instrumentation using EPlan CAD

oFull plant P&ID design using AutoCAD (LT)

oPlant control system specification, FAT (Switzerland) and SAT

oOversaw MV, LV and instrumentation installation

oVarious plant E,C&I components technical specifications

oPlant commissioning and post commissioning support.

Petra Diamonds Cullinan South Africa

Lead E,C&I engineer in the design, procurement construction and commissioning two milling plants with 7000 kW motors and MV VSD as well as two HPGR crushers driven by 600 kW motors with MV VSDs and Siemens control system (S7-1500 and local Siemens TP1200)

PPC Cimerwa, Bugarama Rwanda

Lead E,C&I engineer in the brownfield design, procurement, construction and commissioning of double roll crusher with 600 kW motors electrical, instrumentation, control philosophy write-up and integration into main plant controls.

Zimplats Selous MC, Zimbabwe

Barrick (Randgold) Loulo

Mali

Barrick (Randgold) Kibali DRC

Kumba Iron Ore (Anglo)

Thabazimbi, South Africa

Catoca Diamond Mine Angola

Anglogold Ashanti Siguiri Guinea

Saldanha Bay Crude Oil Storage – OTMS

Lead E,C&I engineer in the design, procurement, construction and commissioning of HPGR crusher with 160kW motors, Siemens LV VSDs, MCCs and Schneider control system (M580 PLC and Magelis HMI) integrated in a containerised E-house.

Lead E,C&I engineer for design, procurement construction and commissioning of HPGR crusher with 160 kW motors, Nidec LV VSDs, MCCs and Rockwell control system (Controllogix PLC and PanelView HMI)

Lead E,C&I engineer in the greenfield (turnkey) design, procurement construction and commissioning of two ball mills with 7 000 kW slip ring motors, E,C&I, auxiliaries equipment design, procurement and commissioning.

Lead E,C&I engineer for the refurbishment of the in-house industrial test HPGR crusher and integration into balance of plant for a full pilot industrial operating plant.

Lead E,C&I engineer for the design, procurement, construction and commissioning of two SAG mills with 1 700 kW squirrel cage motor MV VSD driven, auxiliary equipment design, procurement and commissioning.

I performed an E,C&I engineering audit for the gyratory crushers, and mills and thereafter provided them gap closing initiatives after detailed RCA and provision of latest upgrade solutions for two ball mills.

Executed detailed design of the bulk crude oil storage fire suppression system pump station.

Experience: Jan 2008 to Dec 2010 Electrical (C&I) Engineer - thyssenkrupp Industrial Solutions, SA

Contract/Project Experience

FQML Guelb el Morgraine, Mauritania

Randgold Loulo Mine

Mali

Lubambe Copper Mine,

Zambia

In this job, I was responsible for low to medium complexity projects design, procurement set-up and commissioning of the electrical, control and instrumentation for the cement and mineral processing plants. I would be the lead electrical, instrumentation and control engineer; actively guiding and assisting E,C&I engineers and managing installation contractors. If needed I would oversee technical issues clarifications, design changes, execution and commissioning of the equipment, machines, modules, or full plants. Additionally, I ensured the projects were to client specifications and executed within required time and within budget. I have overseen total engineering lifecycle support for the executed projects/contracts. Projects and contracts executed include the following: -

HPGR crusher with a Weg VSD and a Siemens control system comprising a S7-300 and local control HMI.

HPGR crusher with a Weg VSD and a Siemens control system comprising a S7-300 and local control HMI.

E,C&I design, procurement, construction and commissioning of two ball mills with 7 000 kW slip ring motors, auxiliary equipment design, procurement and commissioning.

Randgold Tongon Gold Mine, Ivory Coast

E,C&I design, procurement, construction and commissioning of a ball and SAG mill with a fixed speed and MV VSD drive respectively.

Commissioning of the split lubrication unit of a 7 000kW powered mill. Wrote up the updated control and performed SAT for the PLC control program.

Athicem Cement Plant, Athi River, Kenya

Martin’s Drift Diamond Mine, Botswana

De-Beers Voorwal Mine

South Africa

Reason for leaving

Design, procurement, installation and commissioning of electrical equipment (MCCs, VSDs, LCS, PLC panels, field IOs, motors, control stations, field panels etc.) of an 80tph cement grinding facility.

Layouts design, procurement, installation and commissioning of 80tph cement grinding facility lighting and small power.

Cable sizing calculations, cable racking and routing design and termination schedules design and production.

Instrumentation engineering (P&ID production, instruments selection, hook-up drawings production, loop drawings production, installation drawings production) and integration into PLC system.

Cement plant construction management, commissioning and post commissioning support.

HPGR crusher design, instrument and electrical lists, PFDs, P&IDs design.

E,C&I equipment procurement, FAT, installation supervision and SAT

E&I installation contractor supervision and equipment commissioning.

HPGR crusher and scrubber commissioning after E,C&I design, selection, procurement, installation supervision and commissioning.

Appointed to a higher position after two years.

Professional Experience: Dec 2002 to Dec 2007 Section Engineer - Zimasco Smelter, Kwekwe, Zimbabwe

Zimasco (Pvt) Ltd

Zimbabwe

Reason for leaving

Electrical Engineer: - Plant Maintenance & Projects

Oversaw a number for the E,C&I upgrades to the 6 off 18 MVA submerged arc furnaces.

Budgeting, control of maintenance costs and section project management

Process control systems continuous improvement, re-alignment and gap closing initiatives setting-up and checking effectiveness.

Setting up of best Maintenance (RCM/TPM) philosophies and evaluation of effectiveness.

MIMs/Ellipse ERP (Super User) maintenance modules software set-up and maintenance.

Plant design, set-up and maintenance of PLC/SCADA and VSDs systems.

MV thermography analysis, MD and PF correction units’ maintenance.

OSH Act (NOSA systems) adherence, implementation and experience in ISO (90001 system and 1400 environment) systems.

Autotransformers (24 MVA), single-phase transformers (6MVA) and MV switchgear maintenance.

Maintaining transparency with colleagues in order to develop a team capable of delivering successful solutions.

Developing maintenance personnel skills through on job training and mentoring graduate trainee engineers.

Ensure EPC(M) companies designs were to specifications and projects were executed to specifications, within budget and in time.

Migrated to South due to a depressed Zimbabwean economy.

Graduate Trainee: - Electrical Engineer

Performed power optimisation for the plant MV distribution

ZESA (Electricity Supply Company) 33kV switching certified.

Relay Systems (SA) Certificate in Electrical Power Control systems.

Performed submerged arc furnaces power circuits and ancillaries optimisation and maintenance.

Oversaw induction furnace power control AC to DC to AC electronic control reliability centred maintenance.

PLCs (AB PLC 5, SLC500) programming, program debugging and maintenance.

Managing maintenance staff and ensuring safety and procedures adherence in relation to NOSA (SA) audits.

PTs, CTs and protection relays (Siemens, Strike etc.) set-up and maintenance.

Education & Qualifications

BSc Honour in Electrical Engineering – 2002, University of Zimbabwe

University of Cambridge GCE Advanced level – 1997, Sanyati Baptist High School,

University of Cambridge GCE Ordinary level – 1995 St Francis Xavier’s College

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