Oversee Engineering Projects in planned Shutdown :
Compile CAPEX / OPEX using Technical Studies, HAZOP & Feasibility Studies.
Resolve Operational and Process Flow issues (debottlenecking).
Project Plan, Schedule Project Tasks, Assign Resources
Ensure Project complies with Safety Acts & Regulations, Engineering & Quality Standards.
Contractor Site Supervision - Access to Site, Permit to Work, Scaffolding, Safety.
Logistical issues /Transport of Equipment on Site.
Punch List - Follow-up on corrective action to deviations prior to commissioning.
Revise and Track Project Deliverables - Timelines/Milestones, Costs, Quality, Man-hours,
Size and selection of component/equipment as per OEM specifications/simulated software stress analysis.
Resolve Plant interfaces issues, ensure Plant changes match Engineering Final Drawings.
Monthly & Weekly Project Status Review Meetings - Technical Support, Client Feedback.
Comply with ISO policies and Safety Procedures.

Projects Undertaken:
• Replace 300m3 Feed Tank, Repair plinth (Mechanical, Piping, Rigging, Structural, Civil).
• Modification of Caustic Tank & Platforms (Vessel, Structural & Piping, Electr).
• Cooling Tower Replacement (Mechanical, Electrical, Piping, Civil) & modify plinth.
• Install 3x Vacuum Breakers on Feed Tanks, level indicators, transmitters, rotameters.
• Replacing Industrial Compressor, Dryer & Filtration Unit 2 & modify intake ducting
• Purchase Industrial Pump & spare brass impeller.
• Purchase & install SO2 Heat Exchangers.
• Feasibility Study - replace pump discharge pipework causing high frictional head loss.

GCC Responsible Person: OSHACT GMR 2.1. for the whole tyre plant:
Ensure that all Statutory Equipment are Safe and Technically compliant - Pressure Vessels, Hazardous Locations, Lifting Equipment, Powered fixed/portable Equipment, Goods & Passengers Lifts, conduct surveys.
Investigate IOD's with permanent solutions to prevent reoccurrence.
Conduct Hazop Study / Hazardous Identification Classification (Flame-Proof Zoning Risk Identification) for each Work Station & upgrading to comply with minimum OSHACT requirements.
Revise Shutdown and routine Maintenance Inspection Checklist for Tyre-Building Machinery.
Safeguarding of Hydraulic Presses, Extruders, Mixers, Rotating Tyre-Building Machines.
ISO 9001 Quality Audit Compliance

Reporting to the Engineering Dept I managed the following Sections:

MOULD SHOP:
Mould Shop Service delivery to Production and Central (Germany) - Improve Turnaround time, Repair Cycle, & QC service. Increasing PM Cleaning Activities thereby reducing Call-Outs.
Implement corrective action to prevent mould damage, scrap tyres, mould-press breakdowns.
Pareto Analysis - Identify Daily Bad Performances (Hyd. Presses/Mould Spec through analysing SFI faults logged (CMMS), SAP CM maintenance data & Quality Department.
Budget Control and Forecasting.
Monthly KPI Reports - Workflow, Manpower, Production Demands and Scheduling.
5-S Housekeeping
Upgrade SAP data Bin Location and renumbering Mould Storage Bays

MACHINE SHOP:
Create Proactive Maintenance Strategy on leaf skids - repaired and maintained daily to reduce call-outs.
Modifying frame on cradles (trolleys) and interlocking devices or proximity sensors. Drawing revision when modified (Industrial Engineering Department). Revise Operating Procedure (POMs) to prevent them being by-passed.

PLANNING DEPARTMENT:
Manage the Planning Department (Eng Planner and Assistant).
Track PM & CM Downtime KPIs and recommend improvements.
Maintenance Strategies: Improve the current PM work procedures for different tyre industry plant machinery (routine/minor/major/shutdown).

Projects Undertaken:
• Audit Flame-proof Requirements for the whole factory & upgrade each explosive solvent spray booth.
• Upgrade HCS Flame-proof Main Storeroom.
• After a near miss where the storage shelving collapsed, I motivated & executed a more robust and resilient shelving design for the tread ply Production Store. (The existing modular shelving system was repurposed in the tyre bladder store).

PROJECT MANAGER (Oct 2013 - Feb 2014)

Managing EPCM Turnkey Projects:
GA Layout Drawing Approvals - Modification & Execution
Supervise Project Engineers executing projects.
Client Feedback on Project Progress
Ensure Project Milestones are achieved - Milestone Payments, Time Constraints, Ensure Quality Standards are upheld and compliant.
Compile Quotations & Contract Amendments, Scope Variation (SV) Orders..
Issuing - Early Warnings, SV Requests, QC Procedure Approval, Payment Certificates
Reporting: Kick-Off Meetings, Progress Meetings, Client Feedback Meetings, Close-out Meetings.
Investigate & Resolve Warranty Claims by Clients.

Projects Undertaken:
• EPCM TURNKEY PROJECTS
One-stop Turnkey solutions provider (Engineering Consultation & Site-work) involving all disciplines - Mechanical & Piping, Electrical & Instrumentation, Civil & Structural on various Mining Equipment as stipulated below.

PROJECT ENGINEER (May 2012 - Oct 2013)

Initiating, Planning, Executing, Monitoring & Controlling and Closing Out various EPCM Engineering Projects:
Costing and Establishing the Target Margin, compile Project Program
Assessing vendors and negotiating with suppliers, select quotations.
Create Purchase Orders (spares/components/fabrication work).
Equip/component Sizing and selection.
GA Layout Drawing Approvals - Resolve plant interface issues (Nozzle orientation, Grating, platforms, stairways etc.)
Track progress of fabrication work to meet deadlines.
Create Quotations - Scope Variations (SV) Orders / Contract Amendments, Milestones payments.
Witness Factory Acceptance Tests (FAT). Alignment/ tolerance checks and QC Reports.
Prepare Export Documentation (Logistics)
Change QC Document Packs & Operating Manuals to suit client requirements.
Arranging Field Service Technicians to conduct site work and oversee site work.
Commissioning & Hand-over to Client.
Investigate & Resolve Warranty Claims by Clients.

Projects Undertaken:
• OVERSEE DESIGN, FABRICATION & DELIVERY OF MINING MACHINERY
Gyratory Crushers, Cone Crushers, Jaw Crushers, Apron Feeders, Vibratory Feeders, Grizzly Scalpers, Flotation Vessels, Attrition Scrubbers, Samplers, Stirred Media Detritors (SMD), Ball Mills, slurry pipelines.

Supervision of Artisans and Semi-Skilled Maintenance Team on the Concentrator Plant:
- All Pumps (Centrifugal and Positive-Displacement)
- Thickener Plant
- Flotation Plant
- Milling Plant
- Tailings Plant

Conduct Interviews
Stock Taking - Establishing the required stock level for Maintenance Contract.
Compile Maintenance Procedures (new & revise).
Creating Work Packages - Determining Man-hours and Tool Requirements.

Reliability Engineering & Technical Support on all Rotating Equipment (Pumps and Fin Fans) on SASOL 3 Gas Circuit Plant:
- Gas Reforming
- Benfield
- Cold Separation

Shutdown Activities - Oversee Repairs & Modifications by Contractors & MOC.
Business Cases: Technical / Feasibility Studies, Capital Expenditure (CAPEX), Operating Expenditure (OPEX).
Initiating & Executing Projects (Upgrades/Modifications)
Reliability KPIs - Mean Time Before Failure (MTBF), Mean Time to Repair (MTTR) and Efficiency Improvements
Mechanical Seals - Troubleshoot Failures & Technical Selection, Management of Change (MOC)
CAD Pump Drawings revisions, Bill of Material (BOM) & MOC
Rotational Standby Duties

Budget Control
QC Plans
Maintenance Strategies on Pumps, Maintenance & Operation Procedures (OMOP)
Root Cause Failure Analysis (RCFA)
Investigate Injuries on Duty (IOD’s). Behavioural-Based Safety (BBS)
Centralised Coordinator for OSHACT Compliance (Load Beams in Gas Circuit)

Projects Undertaken:
• INSTALL MIXER IN VESSEL
Feasibility study, tech selection of the equipment, purchasing, installation and
commissioning
• REPLACE BUCKET ELEVATOR
Feasibility study and sizing of the equipment, purchasing, installation and commissioning
• MECHANICAL SEALS ON CRYOGENIC PUMP
When these pumps are not running they tend to freeze up on their sealing faces.Prior to Start-Up even after these Pumps have been sufficiently warmed externally (normal start-up procedure), the faces are still frozen. This has led to major damage to the mechanical seals on start-up. To Improve the thermosiphon effect of the Methanol the pipework leading to the mechanical seals was finned and the return line be lagged. This temperature difference (assisted by capillary action) would then be sufficient for adequate circulation of the methanol in the closed loop system preventing the mechanical seals from freezing up when the pumps are on standby.
• PUMP COMPONENTS
Modified Pump component drawings to get them manufactured locally resulted in a significant cost reduction. Certain Pumps were changed over from a gland-packing arrangement to mechanical seals.
*All Projects done according to API Codes of Practice as governed by the ASME.

PROCESS TEAM LEADER (Jan 2007 - Apr 2007)

Supervise Contractors (Mechanical Fitters, Electricians, Instrumentation Mechanicians) in the Ash & Dust Plant
Preventative and Corrective Maintenance: Ash Hoppers, Sluice-ways, Precipitators, Rotary Feeders, K-Pumps, Dust Silos, Venturis, Industrial Blowers, Various pumps , Valves and Pipework, Pumps & Motors for: Ash Crusher, Hopper-filling, Sump-Lowering and Sluice Pumps.

LV Regs/Permit to Work (PTW) - Responsible Person for electrical equipment up to 1000V.
Conduct Investigate Incidents and Injuries, Report unsafe conditions and enforce remedial corrective action to prevent recurrence.

SENIOR TECHNICIAN / WORKSHOP SUPERVISOR (Aug 2001 - Jan 2007)

Supervise & Oversee all Maintenance activities in the Workshops & Services Dept::
- Mechanical Maintenance Workshop
- Auxiliary Services
- Central Tool Store
- Civil Maintenance Workshop (Safety)
- Aircon & Electrical Workshop (Safety & Stock Ordering)

Budget Control - Mechanical Workshop & Contracts
Conduct Performance Appraisals & Compile Personal Development Plans
Hold Work Team Sessions and Safety Meetings
Resolve Grievances, Conduct Disciplinary Hearings
Ethics & PFMA Coordinator
Update Staff Time-Sheets
Pressure Vessels (Portable/Fixed Air Receivers - up to 27.5MPa). Installation, Maintenance, Rigging Out Receivers, Pressure Testing, Re-Commissioning and Visual Inspections, Calibration of Safety Valves.
Repair & Maintenance: Ash Plant & Slurry Plant Pumps, Ash Crushers, HP Compressors, Ball Mill Industrial Gearboxes.

Projects Undertaken:
• TURBINE HOUSE CRANES (50T)
These Gantry cranes which work in tandem had normal contactors which created a problem for precision control during planned shutdowns (turbine and generator overhauls). Oversee the conversion from contactor banks to thyristor (frequency drives) for better accuracy of movement between the two cranes.
• BOILER HOISTS (5T)
These hoists located about 70m above ground level did not have a load cell - a load limiting device (which trips power to the crane if the maximum permissible load is exceeded) (OSHACT req). Because it did not have a hook block and just a single fall wire rope it was a project of mine to install a load cell that could detect fluctuations on the dynamic loading on the wire rope.
• BOILER HOISTS (5T)
As mentioned earlier, these hoists were located very high (70m), but the pendant control needed to be at point of use ie. ground level, where material needed to be safely slung. Crane signaling from that distance proved unsafe. The pendant control was then made wireless and which over-rode the fixed pendant control on the crane. The fixed pendant control was still needed as the maintenance staff at the top would wait for the material/scaffolding/machinery to be hoisted up.
• SEMI-PORTAL CRANE ON TURBINE FLOOR GALLERY (2x 20T)
After a near-miss incident, the safety on both cranes were upgraded. Now every long travel of the crane is equipped with infra-red proximity sensors, loud siren & flashing light (electronic, visual & audible warning system). This proved to be very effective during Turbine/Gen set Outages.
• RE-ENGINEERING WORK
Due to the long lead time in obtaining spares, I embarked on a process to refurbish Slurry Pump/Ash Crusher drive shafts & other ash crusher components. This reduced the lead time for new spares and a significant cost saving for my department.

TECHNICIAN (Nov 1996 - Jul 2001)

Contract Supervision of Millwrights and Assistants:
- Overhead Cranes, Hoists, Lifting Beams, Portable Lifting Equipment
- Scaffolding & Lagging Maintenance Contracts
- Passenger & Goods Lifts, Smoke Stack Passenger Lifts
- Budget Control

CAPEX - Feasibility Studies (Cost-Benefit Analysis), Engineering Modifications
Re-Engineering and Refurbishment Processes (Ash Crushers, Slurry Pumps)
Compile and manage NEC Short Engineering Contracts
Root Cause Failure Analysis (RCFA), SWOT Analysis
Incident Investigations & Safety Inspections
OMOPs - Compile/Revise PM & CM Maintenance Strategies, Overhauling Procedures
QC Inspections
Supervisory & Planner functions: Mechanical Workshop, Aircon Department, Auxiliary Services, Mill Maintenance Squad.
Ordering of Plant Maintenance Equipment, Stock & Non-Stock Spares and Tools.

LV Regs/Permit to Work (PTW) - Responsible Person for electrical equipment up to 1000V.
Safety Rep, Incident Investigations & implementing corrective action.
NOSA Safety Audits & Compliance / Achieving & Maintaining NOSCAR Status
Hazardous Locations Coordinator (Zone 0-2)
Evacuation Officer

Projects Undertaken:
• FUME EXTRACTION SYSTEM IN WELDERS & BOILERMAKERS WORKSHOP
As a proactive Health & Safety Rep, I was concerned about the long-term effects of inhaling toxic welding fumes in the Welders & Boilermakers Workshop. I Motivated, Installed & oversaw Commissioning of a fume-extraction system. This entailed a common manifold with extend-able & retractable ducting arms to reach every workbench, covering the whole affected area.
• SPRAY-PAINT BOOTH IN WELDERS & BOILERMAKERS WORKSHOP
Hazardous Location Zone 2 Spray Painting Booth (complete flame-proofing ancillary equip) for paint overspray of completed fabricated welded/boilermaking jobs complete with time extension for proper fume extraction between jobs.
• SHUTDOWN FIXED LOAD BEAMS
Reduced the annual cost of load testing by identifying infrequently used load beams and exempting them from load testing on an annual basis. From over 950 load beams approximately 600 were identified as infrequently used. They are now only load tested prior to use and only during outages.The exemption was enforced when my safety sign was approved by the Department of Labour and applicable nationwide. This resulted in a significant annual cost saving as Load Testing was now only done prior to shutdowns.
• PURCHASE NEW 20T MOBILE CRANE
Feasibility Study, CAPEX Motivation,Approval, raise Purchase Order.
• PURCHASE 2x INDUSTRIAL SWEEPERS & INDUSTRIAL SCRUBBER
Feasibility Study, CAPEX Motivation,Approval, raise Purchase Order.
• CAPEX Motivation
Feasibility Study: Vendor fabrication costs vs Welding Shop Project expenses

PUPIL TECHNICIAN (Nov 1995 - Oct 1996)

STRUCTURED TRAINING PROGRAMME:
Power Station Induction: Module-Based Theoretical Tests
Workshop Machinery: Milling Machine, Centre Lathe, Shaping Machine, Pedestal Drill.
Overhauls to OEM Specs: Multi-Stage Pump, HP 2-Stage Compressor, Double-Reduction Gearbox.
Hydraulics Circuit Design & Fault-Finding
Pneumatics Circuit Design & Fault-Finding
Laser Alignment: Opt-Align Machine operation & Shimming
Manual Alignment: Clock Gauge, Magnetic Base & Shimming.
Welding Practical: Electric Arc, Oxy-acetylene Gas-Cutting, Brazing, Silver-Soldering.
Bearings & Valves: Overhauling, Re-assembly, Lapping v/v seats, Gland-Packing
Power Tools & Hand Tools: Operation & Safe Use
Bench Work: Engineering Practicals, Plumbing/Pipe-Fitting, create Gaskets, Seals
Overhead Crane: Operation & Basic Rigging

ON-JOB TRAINING:
Turbine Plant (BFPT, Steam Turbines, Solenoid Valves, Hazardous Locations, Taprog Pump).
Coal Plant (Conveyors, Idlers, PF Burners).
Ash Plants & Pneumatic Fly-Ash Conveying System (Precipitators/SO3 Plant, Fly Ash Hoppers, Dust Silos, Bellows, Venturis, Air Blowers, V-Belt tensioning).
Boiler Plant (Sec Air-Heater, Soot-blowers, Lapping Safety Valve seats, MSSV Stop Valves).
Condition Monitoring (Segrit Samples on Economisers, Vibration Analysis, Log Temperatures)
Mechanical & Welding Workshop (Centre Lathe, Milling Machine, Shaping Machine Pedestal Drill, Pedestal Grinder, Bandsaw).
Engineering Department (Technical Modification Proposal: Boiler Penthouse Doors, Isometric CAD Drawing - Platforms).
Milling Plant Maintenance, PF pipes,
Water Treatment Plant (Cooling Water Pumps, Cooling Towers, Splash Packs)
Manual Alignment, Spider-couplings
Basic Rigging & Overhead Crane Operation