Engineer - DR-1.Mechanical

Role Overview

Engineer - DR-1.Mechanical at Qatar Steel, responsible for mechanical maintenance engineering in the Direct Reduction plant.

Role Purpose

To ensure continuous plant availability and equipment reliability through comprehensive mechanical maintenance planning, execution, technical improvement, and compliance with safety and quality standards.

Key Responsibilities

Technical Maintenance Activities

• Analyze daily maintenance activities from logbooks and record sheets against the plan and modify subsequent daily plans to support maintenance plan achievement.
• Analyze vibration and maintenance result sheets, identify technical issues, design and propose maintenance improvements and equipment developments to support continual technical improvement.
• Identify and address technical problems and implement rectification solutions.
• Conduct technical research and apply new knowledge.
• Study and review engineering designs for new projects and identify variations.
• Prepare Tender documents for CAPEX projects, evaluate technical offers, schedule project timeline and cash flow, coordinate with internal and external parties for execution, monitor progress and confirm completion against approved schedule.
• Interact daily with the operation team to interpret their needs and requirements and represent them in the field.
• Carry out and supervise all maintenance programs for critical and complex plant equipment including all types of mechanical equipment to ensure continuous plant availability and minimize equipment downtime.
• Confirm execution of all maintenance programs (Preventive, Predictive, Breakdown) with plant and shift supervisor to ensure high standards of plant and equipment operation with minimal production downtime.
• Communicate and coordinate with vendors, technology suppliers and third parties for all plant know-how issues, troubles, upgrading and modifications to ensure maintenance provision meets ongoing production process needs.
• Identify and recommend equipment and systems for procurement, provide technical specifications, perform technical evaluation of equipment and suppliers and ensure effective commissioning and follow-up where appropriate.
• Manage discrete projects and support or contribute to larger projects such as internal expansion from feasibility study through to implementation to ensure projects are delivered to time, cost and quality standards.
• Apply engineering technical knowledge and skills in mechanical maintenance across various applications.
• Identify and evaluate opportunities for import substitution for challenges such as high cost and obsolete spare parts to ensure asset reliability.

Planning

• Prepare maintenance annual plans activity to ensure high standards of plant and equipment operation with minimal production downtime.
• Plan, identify and recommend equipment, systems and spares for procurement, provide technical specifications, perform technical evaluation of equipment and suppliers and ensure effective commissioning and follow-up where appropriate.
• Prepare long-term maintenance plan for own area for management approval to ensure plant and equipment maintenance needs are met and production process availability optimized for the coming 5 years.

Budgeting & Inventory Control

• Prepare and propose annual budget OPEX and CAPEX figures for management approval that accurately represent anticipated costs and enable effective cost management.
• Review monthly budget consumption figures for mechanical to ensure alignment with approved budget consumption plan.
• Control record management systems to manage inventory holding including costs and ensure minimum stock is available at all times without unnecessary duplication.
• Review monthly shift schedule plan to ensure overtime is within approved budget.

Data Recording and Analysis

• Periodically review inspection results and perform data analysis to predict expected troubles and ensure plant and equipment data is available and well-analyzed.
• Ensure all data records follow relevant certifications such as ISO-9001, 14001 and 45001.

Reporting

• Prepare reports to management with data analysis and recommendations to achieve best performance in all areas.
• Report technical abnormalities with recommendations to management to ensure senior management has sufficient information to support decision-making and provide direction for appropriate remedial action and planning of future maintenance activity.
• Review delays and fault reports for root cause analysis and corrective actions.

Continuous Improvement

• Identify and develop improvements to operating standards, policies and procedures to support continuous improvements in operating performance.
• Lead and promote technical development in equipment and process maintenance to ensure continuous improvement in operation and achievement of maintenance KPIs.

Health, Safety & Environment

• Identify hazardous situations and evaluate relevant risk to conclude appropriate action to maintain safe working environment.
• Confirm compliance with all relevant safety, health and environmental procedures and raise HSE concerns and incidents to HSE with recommended actions to ensure safe work practices and environment and achieve corporate Zero Harm Objectives.
• Continuously review operating and safety standards and procedures (HIRA, PTW, LOTO, TBT) in DR-M area, updating and modifying as appropriate under direction of the Section Head.
• Contribute to all PSM and HAZOP studies in DR-M plants.
• Prepare annual plan for monthly safety meetings and attend all safety patrols and meetings.
• Review reported observations in monthly safety activities in the department including HES safety patrol, MRM, fire drill and environment audit and confirm closing action plan to ensure HES operating issues are understood and appropriate corrective action is taken.

Policies, Processes and Procedures

• Monitor compliance to applicable codes, practices, QA/QC policies, performance standards and specifications.
• Draft all Standard Operation Procedures for all maintenance activities in own area.
• Confirm continuous process of reviewing operating and safety standards and procedures, updating and modifying as appropriate under direction of the Maintenance Section Head.
• Identify and design system to ensure all operating, safety, environment and quality procedures are followed to ensure highest standards of operational integrity.
• Follow all relevant policies, processes, standard operating procedures and work instructions in the section so work is carried out in a controlled and effective manner.

Related Assignments

• Perform and carry out any additional assignments or tasks as required by management.

Qualifications & Experience

• University Bachelor degree in Mechanical Engineering.
• Minimum 7 years of experience in Midrex Direct reduction plant.

Skills & Competencies

• In-depth specialist skills and knowledge in own engineering specialism plus well-developed knowledge and understanding of entire production operation.
• Comprehensive understanding of DR process, associated function areas and all Steel Making Plants.
• Well-developed analytical skills.
• Complete knowledge in centrifugal compressors and rotary lobes blowers.
• Complete knowledge of static equipment (pipes, vessels, etc.) maintenance best practices.
• Complete knowledge of DR plant hydraulic system maintenance.
• Comprehensive knowledge and understanding of safety, environment and quality system procedures and standards.
• Comprehensive knowledge and understanding of HSE and quality procedures and standards.
• Complete knowledge and understanding of process calculations and computations.
• Ability to read and interpret technical drawings and documents.
• Planning and organizing skills.
• Ability to work both as part of a team and independently on own initiative.
• Problem-solving skills and decision-making capability.
• Ability to understand financial planning and budgeting processes.
• Communication skills in written and verbal forms.
• Technical and business report writing skills.