Essam Ramadan
C.E.1
Competency demonstration report
Career Episode 1
Introduction
Project Name: Sewage Networks & Pump Stations for Faisalia Plans project
Duration: (36 Months) January 2016 to Present Date
Location: Dammam – Kingdome of Saudi Arabia Employing Organization: AL-Yamama trading and contracting
Employing Position: Mechanical Engineer
Background:
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ALYAMAMA company, since its inception, it has executed hundreds of projects in operation and maintenance, construction, landscaping and irrigation. Driven by owner’s ambition, the company has diversified into several other fields.
After a long experience of working as a construction company for several decades, ALYAMAMA added other lines of business such as Environmental Services, Waste Water Handling, Water Treatment, Electric and Mechanical Works, Rail Roads, NDT and through its dedicated Subsidiary Saudi Pioneers, a wide range of Oil & Gas Services provided.
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‘The Sewage Networks & Pump Stations for Faisalia’ Plans project was, EXACAVATION, LAYING & REPLACEMENT OF PIPES with DIAM OF 300 to1600MM, 287 MAIN INSPECTION CHAMBERS, THRUST BORING WORKS WITH LENGTH of 850M and DIAM OF 400 to 900 MM, PUMPING LINES WORKS FOR PIPES WITH DIAM OF 1000MM and LENGTH OF 700 LM, 6 VALVES CHAMBERS & THRUSBORING WORKS OF 200M FOR PIPES WITH DIAM OF 700MM and LENGTH of 3500M
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There are 2 Pump Station, Main pump station works no. (1). 9 stations building under the normal level of the ground. Sewage pumping groups (submersed) with 3 pumps of T/Second with nanometer lift crane 45m, odder controller fan, and Guard chamber works, Generators and transformer chamber & SEC chamber, Voltage generating unit with diesel engine of 380/220v 3 phase’s 60F/S, Outer walls works with length of 200m pipes dimension of 700mm with length of 3500m, 3 valves chambers, Thrust boring works with length of 300m. Substation pump works no. (2): Station building under the normal level of the ground, Sewage pumping groups (submersed) 200T/S NO. Of 4 of lift nanometer crane 25m, Odder controller
Essam Ramadan
C.E.1
Competency demonstration report
fan, Guard chamber works, Generators & transformer works and SEC chamber, Voltage generating unit with diesel engine of 380/220V 3phases 60F/S, Outer walls works with length of 200m
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The total budget for the Sewage Networks & Pump Stations for Faisalia Plans project was SAR 400,000,000 (USD 106,666,666)
C.E.1.5 The Client and the Regulatory authority was Ministry of Water & Electricity General Directorate for Water, the consultant is ‘engineering and technical services office’ (Ali Hussein AlSagher). ALYAMAMA was the contractor and the designer of this project, and I am part of ALYAMAMA team on site
C.E.1.6 I am a Mechanical Engineer who was hired by AL-Yamama trading and contracting Company as a Mechanical Engineer. I started working in Sewage Networks & Pump Stations for Faisalia Plans project In January of 2016. My job was focused on Supervising and Inspecting in order to finalize the handing over of the project mechanical systems complying with design intent, project specification and international codes.
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My statement of duties:
‘ Research, evaluate, install, operate, and maintain mechanical equipment, systems and processes to meet requirements, applying knowledge of engineering principles ‘ Submits site daily reports, inspection requests, estimates and all applicable monitoring reports on regular basis or as required.
‘ Plan and manage project, and prepare material, cost and timing estimates, reports and design specifications for machinery and systems
‘ Designing and implementing cost-effective equipment modifications to help improve safety and reliability
‘ Investigate equipment failures and difficulties to diagnose faulty operation, and to make recommendations to maintenance crew.
‘ Coordinating maintenance and repair services; following manufacturer's instructions and established procedures; requesting special services .
‘ Be available to undertake off-site inspections of proposed equipment and materials as may be deemed necessary by the Project Manager
Essam Ramadan
C.E.1
Competency demonstration report
C.E.1.8 AL-Yamama trading and contracting team Organization Chart in this project:
Personal engineering activity:
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The ministry of Ministry of Water & Electricity General Directorate for Water announcement for the project and my company was invited to bid , The owner provided tender documents that includes preliminary design drawings and Specification and the scope of the company that will awarded the bidding will be ( Engineering ‘ procurements and construction)
To prepare the financial and technical offer I started by study the tender documents, i found a lot of uncertainties in the preliminary design so I held a meeting with client representative that was clarified by official agenda and issued the technical and financial proposal to the client in competitive bidding process. Eventually, my company awarded the contract due to our competitive offer plus our category classification advantage as first class company in the kingdom.
According to the material specification list and pressure temperature rating I start to choose and decide the suitable needed materials and equipments for the project
Project Manager
Senior Sructure Engineer
Structure Engineer For Pump Station 1
Structure Engineer for Pump Station 2
Senior Mechanical Engineer
Mechnical Engineer For Pump Station 1
Mechanical Engineer For Pump Station 2
Senior Electrical Engineer
Electrical Engineer For Pump Station 1
Electrical Engineer For Pump Station 2
Senior Architect Engineer
Architect Engineer For Pump Station 1
Architect Engineer For Pump Station 2
Resident Engineer
Essam Ramadan
C.E.1
Competency demonstration report
C.E.1.10
After site visit and designs study, I began to calculate direct and indirect cost of materials and equipment by Using Escalation Formula’s. And Because of my experience in the field of equipment the Senior Mechanical Engineer assigned me for that task. Being familiar with SAP program (System Applications Products) I asked the IT team in the company to apply that equation to the system so I can list all the materials and equipment used and calculate the cost by easier way
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After pipes installation we test the drainage and ventilation pipes and its welding in order to make sure there are no leaks of water or gases, there are two methods, by water or by Air and I recommend for the Senior Mechanical Engineer to apply air test
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during my calculation for cost by Escalation Formula’s I found that conduct water test for pipes needs more water tankers which will increase equipment, manpower and also a lot of in-direct cost, on the other hand using air test will be more cheaper and also easy and will give the same results, And that will be done by closing all Vents (except test vent) and connected to open the test to air compressor test-conducting pumped air up access to regular pressure capacity of 0.34 kg / cm 2 (5 lbs / square inch) or equal a bar of mercury height of 25.4 cm (10 inches), so no impairment can happen in this pressure for at least 15 minutes
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In excavation stage we should use dewatering pump to stabilize the shoring of the excavation thus avoiding the hazards of slides and caving plus to avoid soil stability at the bottom of excavation, I advise to purchase dewatering pump with ASME B73.1-2001 (Specification for Horizontal End Suction Centrifugal Pumps) and I recommended an international brand but when I asked in local market I found one local company called ‘Sykes’ can supply the same, I held meetings with them after project manager approval to check the best prices and also quality , i was satisfied as will they will covered the international code on the material and also will reduce the cost, otherwise as the client was the Ministry of Water & Electricity General Directorate for Water (government) I found it good chance to enhance internal invest
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During slab on grade construction the client requested more Guard chamber and a new design revision were issued. However the raft was already concreted which created a big problem for
Essam Ramadan
C.E.1
Competency demonstration report
the construction team. Installing the drainage network was the main issue. Therefore, I suggested a solution by making sloping of 1 % instead of 2 % through simple math calculation. In parallel I made verification for possible reduction of pipes dimension through running (Pipe Sizing Computer Program). But reducing slop will increase Accumulation of sediments on the pipeline which will cause more Odors emitted and that will considered as Environmental hazards from the sewage plant so I suggested to reduce the length of the stay of the sewage in pipeline under anaerobic conditions by minimize pumping distance and install additional dewatering pumps in the middle of the piping lane. I raised this issue and its corresponding solution officially to the high management and the construction division approved it after that submitted by submittal form to the consultant office, which approved it and executed installations accordingly.
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For the wastewater pumping station in site, it was expected according to specifications that over than 70% of the tributary flow will delivered by off-site constant-speed. That mean we need pumps at several pumping stations with large-capacity and variable-speed (V / S), to be capable of reacting quickly because no storage could be provided in the wet well. But while reviewing the Sewage pumping groups issued by supplier, and the submitted service manuals and catalogues for pumps, and after verifying its specification, I found that the pumps which he supplied were with a high shut-off head and a steep head-capacity curve. Which will not achieve the min requirements, therefore I requested to change the pumps with all its related connection to fit the project requirement. I raised the problem officially to the Senior Mechanical Engineer and in his turn he got approval from the project Manager for the new selections
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I adapted a strategy to accelerate the production of reviewing layouts issued from our design section.
I requested from them to issue an advanced copy of coordinated drawing activities and dewatering pumps for critical selected areas, So that when we get a mechanical layout it would be easier task for other trades to check and verify, moreover the margin of errors would be much less.
Also, in parallel meetings held for coordination, I always try to lead my colleagues to achieve proper coordination maintaining mechanical requirements.
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Essam Ramadan
C.E.1
Competency demonstration report
I start learn English as a subject since I was in Grade 6 in 1991 at my school, and all my study in the faculty was also by English, and that enhance my English language, but as a professional user that start in 2007 in my first job.
To prove my efficiency in English I attend IELTS exam in January 2017 and my results were in listening 8.5/9, Reading 6.5/9, Writing 6/9, Speaking 6.5/9. And that is demonstrating my skills in language. 10 years now I am sending formal and informal emails, reports, asking for quotations’…Etc to my managers, colleagues, suppliers’.Etc. or reading service manual for the equipment from many sources , so that I can clarify to the users, drivers and technicians. Despite of my company in Saudi Arabia but it has various manpower from different nationality with difference language but English are common between managers, engineers and supervisors staff on the other hand drivers and technicians staff usually not perfect in this skills and have less knowledge so many times I must use body language or show them physically what I want and make sure they understood what I mean
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I had in that project various types of equipment heavy and light, so I made service schedule for each equipment regarding its model and used. For example I have some equipment I should make periodic maintenance service as per hour and other equipment as per kilometer, and I linked this service with daily check list which I provide to users earlier. And in daily basis I send this report to the Senior Mechanical Engineer after analysis from my side and decide the route case of problems and offer the solutions
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Equipments were one of my duty in the project and we can say that it were the major element of the project, so keep this equipment in working condition without breakdown as much as I can was one of my challenges, in order to do that, and as my previous study and experience, I create daily check up list for all equipment, user should follow it before he start his duty and in case he found any difference between the check list and the reality he must contact me to analyze the case and prevent the equipment from breakdown
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I used to review a mechanical shop drawing submitted and discusses it with architect engineer my colleague to review it from architectural point of view and he will note his remarks on it and sign it. In parallel during that time I would read and understand the mechanical designer concept/intention as per the latest mechanical design revision so that later on if it is a well coordinated drawing it would be a fast and accurate review. All of this is done to save time and at the same time insure that the layout was fully coordinated with all other disciplines.
Essam Ramadan
C.E.1
Competency demonstration report
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One of ideas which I got from my project manager in the Sewage Networks & Pump Stations for Faisalia Plans project is strategy called Earned Value Plan (EVP), in one of our meetings he shows us a report about the difference between Actual Values of the project and the Planned Values.
I took the idea and start to apply the same on my department particularly in equipment service. I study a lot of researches through the internet and the ways of applying that theory and how does it works .Already I had a plane for equipment service dates, time, material and cost, and in weekly basis I start to calculate the actual values of equipment usage (hour or kilometer) from daily service reports, after two weeks I surprised by the results when I found the equipment usage in project is less than planned about 20 %.
regarding this new values I made a new plan for service which shows less cost depending on previous reading, in the begging I had some debate to show this report to my Senior Mechanical Engineer but since I used to be honest and realistic in stating claims or estimates based on available data I told him and he appreciated that and grateful my efforts
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‘Manpower’ for me means ‘power comes from human’ and that is my strategy with my team, my company has various manpower from different nationality and here is the challenge, most of them has good knowledge but there are some problem related to nationalities between them, (for example Indian and Pakistanis technicians sometimes have some hassle due to political dispute between the two countries ) and my plan was first, divided them into groups each group has various nationality to make sure that there will be co-operation together from the other hand I advise camp manager to do the same while he accommodate them even more I give him the names I need them to be together in the same room.
In lunch break time I divided them also and sometimes I join each group to listen form them and solve the problems with friendly way. In the beginning I face problems with their attitude and behaviors together but day per day my plan succeed
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I attended daily, weekly and monthly meetings with my manager to present the project progress report. In these meetings, I used to discuss safety issues, quality control and time schedules for the quality delivery of work. There was a weekly meeting with architectures, mechanical, and electrical engineers for coordinating the project activities and brainstorming any highlighted problems. Also, I have a monthly meeting with consultant and clients to discuss approval status for work done and also got their advice about changes and technical issues.
Essam Ramadan
C.E.1
Competency demonstration report
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I managed my team successfully and achieved the required goals of the project. I prepared a weekly look ahead schedule for activities that needed to be done in the upcoming week and monitored their work regularly. In the weekly meeting, I discussed the project status with them and if there was any issue that they were unable to resolve, I used to discuss the details and asked the team to participate in providing a suggestion for its solution and jointly we resolved the issue.
I advocate and support the extension of ethical practice, engage responsibly in public debate and deliberation, select, and provide opportunities for, all engineering practitioners on the basis of merit, promote diversity in engineering leadership, provide clear and timely communications on issues such as engineering services, costs, outcomes.
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I know very well that Communication is very crucial especially in large projects and it is the key to success in a team based environment, so with the abundance of new advanced technology it was very sensible to use mobile applications that fairly save my time. In many situations the top management asks for instant photographic dated reports about certain subjects such as housekeeping or health and safety issues. Also in other cases like important internal MEMOs should be distributed to my team of engineers while they are at the job site. So it was of great idea, and was followed by others, to create what's-app group since all of us, me and my team, own smart phones. It helps all of us to be on the same page, making the reports preparation has become quicker. This mean was very powerful in situation like an instant photographic report to me with any incidents that take place on site or any defects work of the contractor that requires immediate corrective action.
Summary
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The Sewage Networks & Pump Stations for Faisalia Plans project was a challenge for me because I had lots of tasks that I had to accomplish. One of them is site tasks to supervise
Essam Ramadan
C.E.1
Competency demonstration report
installation of the pump station with its component and make Inspection and operating tests as per design and international codes aside from keep all equipment in working condition.
In parallel office duties I had to full fill like reviewing submittals for shop drawings, material supply and service reports. Weekly meetings I had to attend to highlight major problems on site with the project manager and my colleagues to adopt acceptable solutions generated by me.. Moreover, to obtain better results in work and in coordination I treated my subordinates friendly and respectfully for all of the above I think that I greatly contributed in project progress.
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I handed over the project to the consultant and received positive feedback. They then allowed us to invoice all the work done and balance our company cash flow. Project met its requirements and finish within budget ahead of schedule and started educated people and added a great value for Saudi Arabia infrastructure. My role was vital to deliver the project in the time constraint. This was one of my first projects, I gained a lot of experience and knowledge in design, execution as well as management and communication skills, also it gave me a lot of self-confidence and my manager and client appreciated me for my quality performance. The project was completed within the provided time limit.
I had the following objectives in this project, AND I do it:
‘ Innovate a new technique for execution
‘ Work in accordance to a specific budget.
‘ Work in accordance to the codes and standards.
‘ Directing, supervising and managing my team.
‘ Work in a specific time frame.