MANSOOR ALI

For processing 5 billion m3/year of natural gas with high CO2 and H2S content, produced from the gas field "Mustakillikning 25 yilligi"

Worked with GTL (GAS to LIQUID) project – Qarshi, Uzbekistan - The natural gas-to-syngas industrial complex is an integral part of state-owned energy company UNG's multi-billion gas-to-liquid (GTL) facility―one of the most technologically advanced energy production plants in the world―producing 1.5 million tons per year of high value-add synthetic fuels for domestic use and international export.

-

-

ROTATING EQUIPMENT’s INSTALLATION ON SITE: Foundation: A solid and stable foundation is essential to support the weight and vibrations of rotating equipment. The foundation should be designed and constructed according to the manufacturer's recommendations and local engineering standards. It should be able to withstand the loads and forces generated during operation. Alignment: Proper alignment ensures that the rotating equipment components are positioned correctly relative to each other. Misalignment can lead to increased wear, reduced efficiency, and premature failure of the equipment. There are different methods for aligning equipment, such as dial indicators, laser alignment systems, or reverse indicator methods. Follow the manufacturer's specifications and use appropriate alignment tools and techniques. Levelling: Rotating equipment should be levelled to ensure even weight distribution and to prevent excessive vibration. Leveling is typically achieved by adjusting the height of the equipment's support pads or using shims. Refer to the manufacturer's guidelines for specific leveling requirements. Mounting and Fastening: Securely mount the rotating equipment to its foundation using appropriate bolts, nuts, and fasteners. Follow the manufacturer's recommendations regarding the number, size, and torque specifications for the fasteners. Use proper tools and techniques to tighten the fasteners adequately. Lubrication and Cooling: Rotating equipment often requires lubrication and cooling systems to maintain optimal operating conditions. Ensure that the equipment is connected to the appropriate lubrication and cooling systems according to the manufacturer's instructions. Regularly check and maintain these systems to ensure proper functionality. Electrical Connections: For electrical rotating equipment, such as motors, ensure that the electrical connections are made correctly and comply with electrical codes and safety standards. Follow the manufacturer's guidelines for proper wiring, grounding, and protection measures. LEAD MECHANICAL ENGINEER Piping and Tubing Connections: Connect the rotating equipment to the relevant piping or tubing systems, such as the inlet and outlet lines. Use appropriate gaskets, seals, and fittings to ensure leak-free connections. Adhere to relevant codes and standards for pressure, temperature, and material compatibility. Safety Considerations: During the installation process, prioritize safety measures. Follow safety protocols, such as lockout/tagout procedures when working with electrical equipment. Use appropriate personal protective equipment (PPE) and ensure that all personnel involved in the installation are trained and aware of potential hazards. Manufacturer's Instructions: Always refer to the equipment manufacturer's installation manuals, technical specifications, and guidelines. These documents provide valuable information specific to the equipment being installed and should be followed closely. Quality Assurance: It is essential to perform quality assurance checks throughout the installation process. Inspect the equipment, connections, and systems to ensure that they meet the required standards and specifications. Conduct performance tests and verifications as per the manufacturer's instructions. STATIC EQUIPMENT’s INSTALLATION ON SITE: Lifting and Placement: Carefully lift and place the equipment on the foundation using appropriate lifting equipment and techniques. Alignment and Levelling: Ensure the equipment is properly aligned and leveled according to the project requirements and manufacturer specifications. Securing: Secure the equipment to the foundation using anchor bolts, welds, or other appropriate methods. Connections: Connect the equipment to other systems, such as piping or electrical connections, according to the project drawings and specifications. Protection: Protect the equipment from damage during the installation process by using suitable materials, such as wooden blocks or rubber pads. TESTING AND INSPECTION Functional Testing: Conduct functional tests to ensure the equipment is operating correctly. Visual Inspection: Perform a visual inspection to check for any damage or defects. Documentation: Document all installation activities, including inspections, tests, and any deviations from the project requirements. MECHANICAL COMMISSIONING WORK HANDLING: To verifying and validating that mechanical systems are installed correctly and operate as designed. This includes testing and performance validation of various systems like pumps & Vessels and pipelines to ensure they function efficiently, safely, and reliably. The goal is to increase the reliability of mechanical systems after installation by identifying potential problems and establishing baseline values for future performance comparisons. Verification of Installation: Confirming that all equipment and components are installed according to design specifications and that interface connections between equipment and systems are correct. Performance Testing: Performing tests to verify that systems meet design specifications and operate efficiently and safely, often involving electrical readings, timing mechanism operation, and measurable inspections. Baseline Values: Establishing baseline values for system performance during initial testing, which can be used for comparison with routine tests in the future. LEAD MECHANICAL ENGINEER Troubleshooting and Rectification: Identifying and resolving any deficiencies or issues found during the commissioning process, ensuring that systems are ready for operation. Documentation: Creating and maintaining detailed records of all commissioning activities, including test results, findings, and corrective actions. RESPONSIBILITIES IN MECHANICAL WORK EXECUTION: Mechanical Engineering Assessments: Provide and review mechanical studies, and design solutions for new and existing facilities including static and rotating equipment, such as separators and other vessels, exchangers, tanks, pumps, compressors. Production support and Troubleshooting: Assist in operational trouble shooting and prepare proposals for resolving equipment integrity bottlenecks and other operational problems. Contribute to assessment of change proposals. Maintenance Support and Troubleshooting: Assist in maintenance trouble shooting, corrosion management and prepare proposals for resolving mechanical equipment integrity and improve checks and procedures. Feasibility Studies: Conduct feasibility studies and assessment of mechanical parameters for various grass root projects under guidance from technical experts. Provide support in FEED like reviewing datasheets, project specifications, technical bid evaluations, ITB preparation. Ensures the Equipment engineering support to different projects Tenders and job start-up. Perform conceptual, FEED and detailed analyses and design as per design basis, project specifications, design codes and standards. Equipment Tests: Prepare, witness or review results of Project Equipment Tests such as Factory Acceptance Test (FAT), Site Acceptance Test (SAT) and Performance Acceptance Test (PAT), pre-commissioning & Commissioning. KEY SKILLS: ➢ Good mechanical engineering skills; hands on knowledge of key discipline tools. ➢ Good insights in metallic and non-metallic material behaviors. ➢ Ability to analyze problems and develop pragmatic concepts and solutions. ➢ Good team player, effective communicator and able to work independently. ➢ Develop communication and presentation skills (e.g., write technical papers, participate in conferences and/or seminars, present design solutions, etc.) ➢ Leading the Mechanical Engineering team, developing design scope and ensuring that all related deliverables are in compliance with the applicable codes, standards, project and company requirements and procedures. ➢ Lead the specification, design, and procurement of static and rotating equipment packages (e.g., compressors, pumps, heat exchangers, flare packages, KODs, Drain pots). Ensure compliance with project requirements, industry standards (e.g., API, ASME), and client specifications. ➢ Provision of technical services relating to the Mechanical Engineering elements of project scopes; with special attention to the design basis, FEED, and EPCC scope preparation and execution, design/safety reviews, specification and procurement of equipment and materials, vendor selection and timely resolution of technical and engineering issues. ➢ Develop and review package specifications, data sheets, and technical bid evaluations. ➢ Ensure equipment design and selection meet safety and quality standards. ➢ Select and design equipment to meet project requirements and optimize performance. ➢ Fully familiar with international design codes and standards. Experienced in ASME codes, API codes (for installations, tanks and rotating equipment) and European EN codes (for piping and vessels). ➢ Familiar with various pressure vessels software like PV Elite, CODECALC, COMPRESS, TANK, Nozzle PRO etc. ➢ Review and approve requisitions, technical quotation evaluations and queries, compiled bid tabulations and recommendations, and purchase requisitions; and coordinate with Procurement to expedite vendor documents as required ➢ Attend project kickoff and review meetings, vendor meetings, engineering meetings and site surveys, as required LEAD MECHANICAL ENGINEER ➢ To review the engineering drawings and the relevant mechanical calculations of pressure equipment supplied by the vendors. ➢ Collaborate with vendors to resolve technical issues ➢ Expedite vendor documentation, drawings, and delivery schedules. ➢ Ensure vendor compliance with project requirements and quality standards. ➢ Review and (as Lead Engineer) approve vendor and subcontractor submittals, checking for compliance with project specifications and providing comments as necessary ➢ Coordinate with the procurement team to ensure timely and cost-effective package delivery. ➢ Ensure seamless integration of equipment packages with overall project design. ➢ Coordinate with other disciplines (e.g., piping, electrical, instrumentation) to ensure compatibility. ➢ Manage interfaces with vendors, contractors, and stakeholders. ➢ Coordinating and aligning the Mechanical Engineering interfaces between the project phases. ➢ Ensure interfaces and deliverables are clearly identified ➢ Interface with other departments to obtain input for Discipline designs and drawings ➢ Experienced in quality control requirements and quality assurance for engineering work. ➢ Contributes to define the Discipline list of activities, list of deliverables and time schedule in accordance with Contract requirements. ➢ Coordinates the evaluation of the design changes to the original scope of work and verify the implementation of those approved. ➢ Attends to internal review activities and inter-discipline check meetings. ➢ Provides technical support to Procurement, Subcontracting and Construction activities included in the scope of work ➢ Maintain close co-ordination with other engineering disciplines, Planning and Project Management Team, as required ➢ Prepare, review, and (as Lead Engineer) approve Discipline engineering design basis, philosophies, and technical specifications ➢ Participate in finalizing deliverables lists and deliverables, ensuring compliance with specifications and functional integrity ➢ Review project schedule and fabrication schedule in relation to construction sequence, milestones, and engineering scope ➢ Check/ Prepare/ Participate in Approval of detailed engineering documents/ deliverables such as: ➢ Mechanical Equipment Specifications and datasheets. ➢ Participate in Factory Acceptance Testing of various items, as assigned ➢ Update electrical load list, P&IDs, and equipment lists based on receipt of vendor information ➢ Participate in HAZOP meetings, as necessary ➢ Participate in 3D model reviews, as necessary ➢ Lead the Discipline team during project audits and Design Reviews ➢ Review Basis of design, design calculations, Mechanical datasheets, job specifications and Material Requisitions as per code and Client requirements. ➢ Perform technical bid analysis, raise technical clarifications, checking of vendor drawings / calculations, technical recommendations, and purchase requisitions. ➢ To guarantee the quality of the generated mechanical calculations of pressure equipment (vessels, columns and heat exchangers) and their compliance with the contractual and company standards, procedures and work instructions. Perform detailed static equipment design calculations using engineering software, including stress analysis, pressure drop calculations, and thermal design. ➢ Develop technical specifications for static equipment based on project requirements and design basis. ➢ Review and approve vendor drawings and technical documents to ensure compliance with design specifications. ➢ Conduct design reviews and technical evaluations for static equipment. ➢ Lead the mechanical static engineering team on assigned projects, assigning tasks and reviewing work. ➢ Manage project schedules, budgets, and quality control for the static equipment scope. ➢ Coordinate with other engineering disciplines (electrical, piping, structural) to ensure design integration. ➢ Installation of Column equipment’s with internals in site. LEAD MECHANICAL ENGINEER ➢ Ensuring that the ERP system meets industry standards like ISO 9001, ISO 14001, or API Q1. ➢ Monitoring post-deployment performance and suggesting upgrades or refinements. ➢ Communicating and liaising effectively with clients, colleagues & designers. ➢ Vendor Assessment: An audit activity on documentation & different aspects of quality control & quality assurance at vendors site, analysis of system of NC follows ups & effectiveness of implementation of QMS, product testing. Subsequent Vendor Rating based on observations. Capacity assessment of manufacturing facilities of manufacturers for various clients. ➢ Review all specifications and prepare procedures. ➢ Ensure compliance with the project quality plan and quality strategy. ➢ Ensuring the system aligns with operational, safety, and compliance needs ➢ Assessment of the Subordinates’ performance. ➢ Participate in Design Reviews: Engage in design reviews, risk assessments, HAZOPs, vendor qualifications, and bid evaluations. ➢ Stakeholder Coordination: Coordinate communication between different stakeholders in Projects and Operations. ➢ Manage teleconferences and communication/reporting tools. ➢ Maintain Discipline Documentation: Support functional initiatives and maintain relevant discipline documentation. ➢ Mentorship: Provide technical mentorship to early-career professionals, focusing on identified skill gaps. ➢ Continuous Knowledge Growth: Maintain current knowledge through industry conferences and forums. Proactively enhance technical expertise in relevant technologies. ➢ Provide support for operations and maintenance, including: ➢ Equipment testing, Troubleshooting, Routine equipment surveillance, Startup activities, Developing permanent solutions to equipment/system problems. ➢ Creating test cases, SOPs, and training materials for ERP users. ➢ Preparing the Repair plan and Method of statement for the jobs. ➢ Preparing the load test procedures and handling the load test inspections. ➢ Performing periodical audits as per Audit plan and performing vendor audits. ➢ Maintaining NCR register and ensure all NCs are closed in time. ➢ Implement approved ITP for all projects and inspect record & report all inspection requirements as per ITP. ➢ Verify all equipment Calibration and material certificates. ➢ Inspection of Piping: Piping inspection for Process plant, including activities like stage-wise inspection, components inspection, Dimensional, Spool inspection at fabricators site. ➢ Inspection of Pipes & Tubes: Inspection of ERW & SS pipes as per ASTM, IS and API standards. Including Raw- material stage to Final inspection i.e., review of documents, witness of strip & pipe U.T., Eddy-current testing, MPT, Hydro-test, mechanical test & other test requirements for black as well as galvanized pipes. Handled many projects of pipes inspection as per different grades. ➢ Inspection of piping components like Flanges, Fittings, Valves, Pumps including various testing activities as per applicable piping code & product standard. ➢ Responsible for preparation of weekly and monthly Testing activities as per the project schedule ➢ Monitoring the Productivity of resources and ensuring the optimum utilization of the same. ➢ Responsible for Safety implementation on site, attending safety meetings, providing training and safety awareness to the Technician. ➢ Monitoring the work progress which coincides with the scheduled work program. ➢ Attending progress review meetings with QA/QC Manager/CM ➢ Technical support and guidance’s to the site foreman / Supervisor to perform effectively. ➢ Familiar with various ISO, NORSOK Standards, Work Instructions (WI), General Instructions (GI). ➢ Participating while testing for coating personnel like applicators, abrasive blasters, crew supervisors. ➢ Review and approve the coating procedure with reference to applicable standards. ➢ Performing the surveillance, focus assessment, violations, route site visits and updating them in the Company QMS system. ➢ Co-ordinate & Monitor Painting applications. LEAD MECHANICAL ENGINEER ➢ Raising the Request for Inspection (RFI) for the inspection of Blasting and Painting activities. ➢ Witnessing and carrying out the checks accompanied with pre-application, application e.g., surface preparation, climatic conditions, material preparation, after application checks, marking areas of defects and assurance of repair compliance, validity of equipment and materials storing conditions...etc. ➢ To ensure all painting works comply with relevant project specification & classification requirements. TEST HANDLED: ➢ Typically handles tests related to material properties, equipment performance, pressure testing, dimensional inspections, non-destructive testing (NDT) methods like ultrasonic testing, radiography, and magnetic particle inspection, as well as performance analysis of critical components like pumps, valves, and piping systems to ensure safety, reliability, and compliance with industry standards. TECHNICAL TEST HANDLED: Material Testing: ➢ Tensile strength testing ➢ Hardness testing ➢ Impact testing ➢ Chemical analysis ➢ Fatigue testing ➢ Equipment performance testing ➢ Pressure testing ➢ Flow rate measurement ➢ Efficiency analysis ➢ Vibration analysis Non-destructive Testing (NDT): ➢ Ultrasonic testing (UT) ➢ Radiographic testing (RT) ➢ Magnetic particle inspection (MPI) ➢ Liquid penetrant inspection (LPI) Dimensional Inspection: ➢ Coordinate Measuring Machine (CMM) ➢ Caliper measurements ➢ Micrometer measurements ➢ Performance analysis of specific components: ➢ Pump performance curves ➢ Valve flow characteristics