Mostafa Kato

Experience

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  TCI SANMAR CHEMICALS SAE

  Aug 2017 - Mar 2018

  Condition Monitoring Engineer

  • Diagnosed and troubleshot 100 rotating equipment issues at the PVC chemical plant using vibration analysis and thermography techniques, ensuring equipment operated at peak efficiency.

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  Egyptian Petrochemical Company

  Mar 2018 - Aug 2018

  Rotating Equipment Engineer

  • Provided ongoing technical support for a total of 20 (various API 610 OH2, OH6, BB1, BB3, BB4, BB5, VS4, and VS6) pumps, 5 (API 611) steam turbines, 1 (API 617) centrifugal compressor, and various (API 682) mechanical seals/plans focusing on proactive, preventive, and corrective maintenance strategies.• Leading and supporting 8 maintenance technicians for best practices during maintenance activities.• Participate in complete overhaul of 1 (FS-ELLIOTT) integrally geared compressor.• Managed spare parts inventory through interchangeability that led to minimize the downtime by 3% after 4 months.• Preceded laser alignment and lubrication proactive best practices during maintenance, resulting in avoiding infant mortality failure modes, which increased safety, reliability, and uptime across critical assets. Show less

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  Petromaint

  Aug 2018 - Oct 2021

  Machinery Diagnostics Engineer

  • Supported Sidi Kerir Petrochemicals (SIDPEC), overseeing the reliability of rotating equipment within a facility with a production capacity of 225,000 tons/year of LDPE and HDPE.• Conducted diagnostics and vibration analysis on key 220 equipment (e.g., API pumps, extruders, conventional/planetary gearboxes, centrifugal/axial fans, centrifugal compressors, dry and oil flooded screw compressors) using advanced tools like CSI 2130/2140 and Bently Nevada System One, identifying and troubleshooting issues before failure.• Detected an early outer race defect using the PeakVue technique in one REB of the 33 REB Extruder’s gearbox (the most critical asset), the company has saved millions of dollars by preventing secondary damage and providing stakeholders ample time to schedule a safe shutdown and maintenance plan.• Utilized IBM Maximo CMMS to schedule daily maintenance tasks and monitor equipment history, improving asset productivity, reliability, and reducing reactive maintenance events.• Played a critical role in Root Cause Failure Analysis (RCFA) and perform modal tests for 11 equipment to resolve resonance issues, ensuring optimal equipment operation and performance. Show less

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  Egyptian Projects Operation and Maintenance (EPROM)

  Oct 2021 - Apr 2024

  Machinery Reliability and Diagnostics Engineer

  • Served as an essential member of the diagnostics and reliability team at the Middle East Oil Refinery (MIDOR), which has a production capacity of 100,000 barrels per day and produces LPG, premium gasoline, gas oil, kerosene, aviation fuel, coke, and sulfur.• Developed and implemented Factory/Site Acceptance Test (FAT) criteria for new machinery during the commissioning phases of the new MIDOR project (increase to 160,000 barrels/day), resulting in the detection of 21% (42 equipment) of new rotating equipment defected, which significantly reduced unit startup disturbances.• Conducted comprehensive routine evaluation of total 600 existing various types of rotating equipment (centrifugal and positive displacement pumps, centrifugal and positive displacement compressors) health using proactive and predictive tasks utilizing detailed vibration, lubrication, and thermal signatures, succeeding a 17% reduction in total maintenance costs and a 20% increase in equipment uptime.• Accountable for quality control inspection and test plans (ITP) for more than 200 new rotating assets during installation, commissioning, and final site testing, acting as a member of the technical authority team in negotiations for non-conformance reports to the main contractor to take corrective actions with vendors based on contract.• Directed rotor dynamics final test evaluations and protection/diagnostics system (Bently Nevada System 1) for 43 critical machinery equipment, ensuring alignment with API 670 and each equipment type API standards.• Designed and delivered training programs for over 30 operators to develop safety and operator driven reliability tasks (ODR), managing maintenance technicians ISO 18436 certification processes for lubrication and vibration analysis.• Managed more than 50 Root Cause Failure Analysis (RCFA) for rotating equipment using techniques such as Five Whys, Ishikawa, and FRACAS, enabling the identification and elimination of defect causes which improve safety. Show less