Engineer I - Mechanical Maintenance

About Emirates Global Aluminium

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry. EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

Supervise maintenance repairs and services for a combined Power Generation and Balance of Plant, to minimize downtime and increase availability and reliability of mechanical equipment that are delivered at cost effective, safe and efficient manner.

• Supervises effectively for timely completion of preventive, corrective and break down maintenance activities (Both planned and unplanned) including scheduled inspections with minimum equipment downtime and minimum interruptions to Power Operations.
• Maintains effective PM compliance rate and achieves the department KPI’s to meet the given targets.
• Attends corrective and breakdown maintenance repairs, in close coordination with Power operations team, as and when required (including “on call” duties), to restore the systems back to normalcy, as quickly as possible.
• Oversees that all aspects of maintenance works are carried out in adherence with EHS standards and plant operating requirements, to minimise workplace accidents / injuries.
• Investigates system failures and ensure prompt corrective action is initiated to minimize equipment downtime.
• Supervises all maintenance crew under his control ensuring they are and trained to perform their duties in a safe, competent and cost effective manner.
• Provides effective control over the maintenance costs including production & administrative overheads, overtime and contract labour administration.
• Manages the team ensuring they follow the TPM principles – moving away from breakdown/ corrective to more proactive maintenance approach
• Develops and reviews standard maintenance procedures related to mechanical maintenance function in line with OEM recommendations and best industrial practices.
• Develops 5S culture among the staff to ensure that all activities are performed in a safe, orderly, healthy and environmental friendly manner.
• Maintains plant and equipment, in accordance with recognized International Standards and spare part inventories are up-to-date to meet maintenance requirements.
• *Probability of significant exposure in various degrees to physical & sensory conditions inherent in the work environment, high pressure steam, high voltage, Arc Flash, high magnetic fields, high noise levels, Fumes, Hot, Humid, Dust, Height, splash of chemicals, Acid, Mineral oil and liquids is significant and avoiding risk of danger, accident or health issues becomes major challenges.

• The major challenge is to restore the power generating units, in an emergency situation, in a shortest possible time.
• The major decision making areas for the job holder are associated with trouble shooting, diagnostics and repair strategies in a breakdown situation; the allocation of jobs to competent persons; availability of spare parts and third party services and effective performance of critical PM activities while minimizing the impact on the Power operations.
• Responsible for all mechanical needs of the Power and Desalination Plant. Provides technical background and expertise to minimize breakdowns by identifying and eliminating the root causes. Responsible for assessing the overall effectiveness of the preventive maintenance programme and making changes as necessary.
• The major challenge in the job is analysing and generating corrective actions on non-routine problems occurring during emergency breakdown situations and the allocation of resources under conditions of competing priorities.
• Seeks approval from his Manager/Area Engineer / Superintendent for ordering spare parts and services outside his limit as per DOA.
• The job holder’s key contacts are Shift manager, Maintenance Planner, other maintenance departments, area owners and Supply departments.

Equipment in brief:

Jebel Ali site:

• Power Generation (Capacity: 2350 MW comprising 23 x Gas Turbines and 7 x Steam Turbines), Thermal Desalination plant (Capacity: 30 MGPD), Air compressors (110,000 Cubic meters/hour), Sea water pumping station (200,000 Cubic meters/hour, Electro chlorination plant.

Taweelah Site:

• Power Generation (Capacity: 3000 MW, comprising 9 x Gas Turbines and 4 x Steam Turbines), RO Desalination plant (Capacity: 3.75 MIGD), Fuel Gas compression station (430 mmscfd), Emergency diesel generators (10 x 2 MW), Air compressors, Cooling Towers and circulating water pumps (12 pumps x 170,000 cubic meters /hour), Sea water pumps (17 pumps x 133,000 Cubic meters/ hour), Electro-chlorination plant.