Abdul Rafay

Experience

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  ICI Pakistan Limited

  Oct 2012 - Nov 2015

  Project Engineer

  • Responsible for Construction of 18MW CFB Power project Auxiliaries and sub stations.• Execution of coal conveying and crushing system, limestone conveying and crushing system, waste removal system, compressed air system and cooling water system.• Manage and monitor Construction Contracts, Comparatives, ITB’s &Verification of Contractor Invoices.• Develop engineering solutions to Design Conflicts in PID’s, / Isometrics, and structure drawings• Installation and Testing of Stationary, Rotary and Reciprocating equipment which involves Screw Air Compressors, Centrifugal, PD Pumps, Cooling Towers, Air Compressors, LimeStone Crushing Units.• Ensure timely Fabrication and Installation of Bins, Storage Tanks, Storage Bunkers.• Manage and ensure quality for Installation and commissioning of 12KM Underground SRHDPE within the timeline.•Timely Fabrication and Erection of Steel Structure for Outside Battery Limits steel structure• Monitor Progress for Pressure Piping Steam Lines, Fabrication, Erection and Hydro testing, completion in all aspects.• Installation and Commissioning of Conveying Rubber Belts, Screw Conveyors, Bucket Conveyor and Elevators• Verification of installation with designs and suggesting solutions w.r.t modifications where necessary and ensure implementation.• Coach and counsel employees on job performance and teamwork. Show less

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  Sendan International Company

  Nov 2015 - Aug 2016

  Mechanical Project Engineer

  SATORP is a semi-offshore site, a joint venture of 9.6 Billion USD between Saudi Aramco and Total Refinery at Jubail for the production and export of 400,000 barrels of Heavy crude oil every day. My responsibility at EPCC Project by Sedan included the Installation of Fire Water Equipment, Steel Structure, and Piping.Core Responsibilities:• Review and develop Scope of work, ITB, Costing & Services Comparatives to Sub Contractors.• Resolving design conflicts in PID’s / Isometrics / Layouts and structure drawings.• Develop execution plan and ensure timely completion for Piping / Structure / and Equipment installation.• Technical and costing evaluation for as-built drawings and killing Punch list items.• Verification of Contractor Invoices.Major Achievements:• 1.5 Million USD Financial Impact by completion of Mechanical installation via smart methodologies. • Reduction of Project Commissioning by 60 days with financial impact of 50,000 USD. Show less

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  ICI Pakistan Limited

  Aug 2016 - May 2021

  Assistant Manager Mechanical Maintenance (W&V)

  Maintenance team lead for multiple sections comprised of 88 personnel (Engineers, Officer and non-management staff) to ensure achievement of Business KPIs, Revenue & Capital expense, employee engagement and team development.Core Responsibilities:  Compliance of plant equipment maintenance plans through SAP. Managing teams for Rotary Equipment overhauling, Machining and Rigging/Scaffolding Jobs. Develop optimized spares inventory for Critical machines (Pumps, Gears, Air Compressors, Road header, Diesel generators, Wheel Loaders and Fork Lift trucks) to meet targeted equipment availability. Implementation of ICI Engineering standards and Critical plant lifting Equipment Procedure as Responsible Engineer.  Effective utilization of Capex and CRE (Revenue expenditure, Inventory & Manpower Overtime). Institute and execute improvement projects for business sustainability. Perform gap analysis to bring improvement of HSE&S in area of ownership .  Development of Skill improvement plan and ensuring its effectiveness by periodic certified training. Major Achievements: Developed and implemented maintenance regimes of plant equipment through SAP CMMS.  Restoration of controlled equipment including OH cranes, Diesel Engines, Compressors & Road Header as per design intent. Developed and implemented equipment reliability plan to reduce unplanned breakdowns. Upgraded obsolete workshop machinery with state of the art equipment after due diligence.  Executed and commissioned 12 KM Cross Country High Density Poly Ethylene Pipeline project Show less

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  ICI Pakistan

  May 2021 - Aug 2021

  Maintenance Manager Workshop

  Responsible to lead 4 sections comprised of 120 personnel (2-Engineers, 5-Management Officers, 6-Foreman & 110 Contractual Employees) including CRE management of PKR 50 million and CAPEX spending up to PKR 260 Million annually.Core Responsibilities:• Overhauling of Rotary Equipment including Pumps, gearbox, and compressor. • Develop and maintain spare inventory for Rotary Equipment, Diesel Generators, and wheel loaders. • Innovate and embrace new technology and high-quality Engineering Standards while executing capital jobs and managing CRE (Revenue expenditure, Inventory & Manpower Overtime).• Institute and execute improvement projects for business sustainability.• Creation and closure of preventive maintenance plan.Major Achievements:• Winner of Three Consecutive CE Best HSE Initiative Awards for the Fiscal Year 2017-2020.• Restoration of redundant Diesel generators and Wheel Loaders. • Selection and Commissioning of 1250KVA Diesel Generator. • Developed and implemented maintenance regimes at Matan Salt Mines to ensure 98% availability of Road Header and Diesel Generator.• Slashed downtime, increased productivity, hired and encouraged new staff and workers to develop proprietorship through teamwork and persuasion.• Restoration of controlled equipment as per ICI.SA.09B. • Enhancing equipment reliability by various initiatives. • Selection and Installation of new machinery in Engineering Workshop. Show less

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  ICI Pakistan Limited

  Aug 2021 - Jan 2023

  Mechanical Maintenance Manager CFB

  Management of Coal Fired Boilers Mechanical Maintenance teams at ICI Soda Ash complex to meet production volume and HSE&S targets of the Business, maximizing operating efficiencies at optimal cost and supporting the Business in planning for future growth.Maintenance of 2x80 TPH and 2x40 TPH Coal Fired Boilers with 18MW and 3MW Extraction Steam turbines including their plant auxiliaries.Core Responsibilities:• Execution of Business Sustainability Projects within their budget and timeframe. • Development and Compliance of Plant Equipment Maintenance Plan through SAP CMMS as per OEM and Business guidelines. • Management of Equipment Outages, Plant Reliability Analysis, Development of Methodologies to minimize contractual cost, Reduction of Outsources jobs, and Formation of Failure Analysis Reports. • Innovate and embrace new technology and high-quality Engineering Standards while executing capital jobs and managing CRE/ Business KPI’s (Revenue expenditure, Inventory & Manpower Overtime).• Ensure closure of jobs by Zero Loss Time Injury/Medical Treatment Injury for ICI and contactor staff as per ICI HSE&S policy.• Management of Spares Inventory and ensuring the availability of critical spares. • Ensure 100% compliance with HSE&S Safety Improvement Plans and Initiatives. • Bringing improvements in Environment, Health, and Safety through gap analysis. • Author and conduct comprehensive training for the company’s Management and Non-management staff.• Formation of SOPs and Risk assessment Show less

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  ENI PAKISTAN LIMITED

  Jan 2023 - now

  Team Lead Mechanical

  • Managing 100+ contracts with OEMs to cater spares inventory and services for Plant Reliability.• Ownership of 20+ Maintenance Local Operating Procedures (LOI) and 200+ Risk Assessments.• Planning & Execution of Maintenance for 12+ Wellhead Compression Sites and Gas Purification Plant Facility. • Implementing Asset Integrity Reports & Inspection regimes to minimize MTBF via SAP CMMS and RCFA’s. • Maintenance of Nitrogen Rejection Unit, Amine Contactor and Regenerator Columns, Turbine, Centrifugal and Reciprocating Compressors, Gas and Diesel Engines, Centrifugal pumps, LP Methane Pumps, Propane Compressors etc. • Compliance to API-579 (FFS-1 Qualified), API-1163 Pipe Line Pigging, API-686, API-570, ASME Sec. VIII / API-510, using various NDT inspection methodologies including RT/UT, LRUT, PAUT, etc. • Providing 10 years+ CAPEX framework for Business Sustainability. Show less