Yamama Cement plant relocation project

Mechanical consultant replacement

Engineering and Material Planning for Projects and Maintenance Activities

Revising drawings of new installations.Checking supplied equipment parts, Inspection of locally fabricated parts.Following up the progress of erection activities.Conducting erection checks after every step.Supervision on the performance guarantee tests & commissioning.Documenting the equipment drawings, reports & initial parameters.Preparing the list of required first time spare parts.Supervision on the operation & maintenance contractor.Evaluation of plant performance & calculating KPIs.Troubleshooting & root cause analysis for the plant major problems.Revising annual spare parts budget and all spare parts studies & orders.

Establishment and follow up the implementation of preventive maintenance system.Preparing Master Plan & yearly budget for mechanical spare parts. Leading the inspection team for doing the inspection activities for all plant equipments to detect any failure and plan to repair it before it stops the equipment.Leading the preparation team for keeping the suitable stock of spare parts, consumables and material required for maintenance activities (Material Requirement Planning).Analyze the failures and inform the executive department by the recommended solution and repair needed.Analyze the equipment condition through doing several measurements on it, and apply the condition based monitoring system.Follow up the maintenance activities to ensure the best quality of doing the job.Monitor the plant operation parameters to ensure that the equipments are running with the best conditions.Prepare preventive maintenance plan and assure the availability of the required material and the optimum use of resources.Manage PM teams, define the missions and objectives for them, carry out their performance reviews and evaluation, motivate the team personnel, and facilitate communication and relationships.

Analyze the failures and inform the executive department by therecommended corrective actions and repairs needed Major Problems Solved: Repeated cut of the chain of apron feeder for the limestonecrusher. Repeated damage of Limestone crusher hammer bolts. Repeated cut of rubber belts of raw material. Repeated cut of the scraper chain of the reclaimer. Skewing of reclaimer at the fast speed. Broken wear segments of raw material vertical mill (Atox). Malfunction of spray lubrication of kiln gearing. Repeated damage of (cross bar) cooler grate parts. Bending of the shaft of clinker crusher.

Preparing Master Plan & yearly budget for mechanical spare parts. Making spare parts studies to Specify and keep a strategic stock from critical spare parts, and a stock from consumables and raw materials.Preparing consumables & materials needed for maintenance works, by coordination with Inspection section to determine the works needed.Preparing preventive maintenance check lists for the plant equipments.Preparing lubrication lists.Monitoring the stock level of spares, consumables and raw material.Initial arrangement and implementation of coding system for the items in the warehouse.Description of items for new spare parts & consumables in the warehouse.Participation in the annual physical count of the warehouse.Using MAXIMO system to follow up maintenance work orders, purchase orders, inventory transactions & stock levels, and creating the job plans of preventive maintenance and lubrication work.Placing purchase requests for raw materials & spare parts needed, and evaluating the suppliers offers technically.Preparing Overhaul Plans & Crusher/Mill PM Shutdown Plans (MS-Project).Preparing the parts to be manufactured locally in local market workshops or Plant workshop, by preparing raw materials and drawings (Auto-CAD).Sharing with maintenance & inspection teams in troubleshooting for maintenance problems, by selecting alternative materials or studying a suitable modification. etc.

Mechanical maintenance shift engineer (Day or Night shift).Troubleshooting for the problems appear during the shift in all mechanical equipments from “Raw mill” area to “Clinker storage” area.Determining if any spare parts are needed to solve the problem in the equipment and get the specifications of the part from the maintenance manual to issue it from the store during the night shift.Monitoring the critical points in the line where there’s a repeated failure detected to take the necessary action if needed and to determine the causes of this failure.Preparing daily shift reports.

Preparing cement plants flow sheet, and mass flow.Designing the Pyro-section (pre-heater, kiln) based on the technical know-how of (Taiheiyo) engineering company (Japan)Revising and evaluating technical offers received from our suppliers [FL-Smidth, KHD, Others …].Checking the specifications of the mechanical equipments and spare parts included in the suppliers’ offers.Follow up the progress of the company projects.