Professional Mechanical Engineer


Last Updated: 23rd May 2018 (over 4 years ago)

Address
Centurion, South Africa

E-mail
Locked

Phone Number
Locked

Qualification Level
Masters

Languages
Afrikaan, English

Summary

I have a Masters Degree in Mechanical Engineering and am registered as a Professional Engineer with ECSA. I have 24 years of engineering experience working on permanent and contract base in the Energy (Predominantly Nuclear) and Petrochemical sectors in South Africa since 1994.This includes finite element analysis, mechanical design, maintenance and plant ageing philosophy, general engineering and experience with various standards and ASME and API design codes with regards to their application in the areas of petrochemical, power generation and built environment.

I am currently involved with a number of energy efficiency projects aimed at improving the energy use in liquid fuel applications such as transport and logistics as well as power generation at mines and other large energy users in South Africa and sub-Saharan Africa.

In addition to the aforementioned I also consult as professional/senior mechanical engineer on all mechanical aspects of a current multi dwelling development in Mpumalanga.

My areas of expertise include:
• Engineering design (ASME and API design codes).
• System engineering.
• Liquid fuels – Transport and Logistics, Power Generation.
• Product Development.
• Computer Aided Engineering (CAE) incorporating CAD and Finite Element Analysis (FEA).
• Maintenance and plant health and ageing philosophy.

I am highly motivated, independent and driven by detail and quality. I have excellent reporting skills and communicate very well with colleagues and clients.

Education

Engineering Council of South Africa (ECSA)
Professional Engineer

   Jan 1998
— Sep 2003

I obtained the qualification of Professional Engineer from ECSA and have remained current to date. (Registration number: 20030217)

North West University (Formerly Potchefstroom University)
M.Engineering

   Jan 1993
— Dec 1997

I completed a thesis and four courses to obtain a Magister’s degree in Mechanical Engineering.

The Title of my thesis was: "An analysis of the interaction of a projectile with a rifle barrel during the firing process and subsequent movement down the barrel, using Finite Element Methods."

The four courses were:
Finite Element Methods.
Numerical grid generation.
Computational Fluid Mechanics.
Computational Air dynamics.

North West University (Formerly Potchefstroom University)
B.Engineering

   Jan 1989
— Dec 1992

I obtained my Engineering degree from North West University. I studied the effect of “Turbo-lag” in turbochargers as a final year project. I introduced and successfully implemented a process to rapidly increase the Enthalpy of the exhaust gas driving the turbine. The process virtually eliminated any “Turbo-lag” of the testing equipment.

Experience

Palace Consulting Engineers
Senior Mechanical Engineer

   Jan 2014
— Current

Background:
I was contracted by Palace Consulting Engineers to as Senior Mechanical Engineer to the Wilge residential development project.

Objective:
Wilge residential will house 1344 artisans working on the Kusile Power Station project. The project requires the development of 336 apartment units, canteen and a new sewerage pumping station.

My responsibilities:
As Professional Engineer, I am tasked with design on all new mechanical aspects of the project and to consult with the client (ESKOM) on existing design and proposed changes thereof. This includes, amongst others, pumps, piping, effluent handling, pump stations, storage tanks, water supply and fire design.

Pebble Bed Modular Reactor
Senior Design Engineer

   Aug 2013
— Dec 2013

Background:
I was contracted by PBMR to perform Care and Maintenance (C&M) actions for my body of work during my previous interaction with PBMR.

Objective:
The project required of me to re-package all work relevant to the Fuel Design program in a new format as prescribed by PBMR including the software platforms employed.

My responsibilities:
I was tasked to re-package all work relevant to the Fuel Design program in a new format as prescribed by PBMR, to re-link the information in Teamcentre in accordance to PBMR’s specifications and to do a presentation/interview on video for future reference. I also did C&M for the ANSYS suite of software as well as the CivilFEM add-on covering installation, software Verification and Validation and linking of all relevant information in Teamcentre.

M-Tech Industrial
Chief Engineer

   Mar 2013
— May 2015

Background:
I was contracted through M-Tech Industrial to ESKOM for the Design Base Back-fit (DBB) project under the Back to Basics program.

Objective:
The overall objective of the Back to Basics (B2B) program was to eliminate waste and create efficiencies through standardization, simplification and optimization of processes and systems in order to increase overall engineering performance across the ESKOM organization.

My responsibilities:
I was tasked with defining the information that will be captured for the Design Base, specifically the Maintenance Base and Plant Health and Aging Base as part of the Information back-fit project. I provided inputs and helped to develop the Design Base Standard and relevant specifications and Manuals for the project, as a Subject Matter Expert. This included developing the processes to be used by ESKOM and their appointed contractors to find, verify and validate current design, maintenance and operational information and to populate it into the newly defined Design Base information structures in a data-centric format as required by the B2B Systems & Tools Stream. I further engaged with the relevant Business Process development teams to ensure alignment between the requirements from DBB and the Process Control Manuals that specify how Design Base information will be created and managed by ESKOM in future.

Pebble Bed Modular Reactor (Pty) Limited
Senior Design Engineer

   Oct 2002
— Jun 2010

Background:
In 2002 I was offered a contract at the Pebble Bed Modular Reactor Company (PBMR) as a specialist finite element analyst in the Structural Analysis Group. I was tasked with all the structural analysis work of the fuel design group. As a result I was involved in the PBMR fuel design software development process.

Objective:
It was envisaged that the Fuel design software suite would, once fully developed, verified and validated allow PBMR to collate all measured fuel performance data, optimize fuel manufacturing parameters and deliver accurate predictions of current and new fuel configurations’ behavior under irradiated conditions from pre-irradiated characteristics.

My responsibilities:
I was responsible for model- and code generation for all components forming PBMR fuel. This entails creating “smart” parametrized geometry and meshing input decks, building user coding into commercial of the shelf software packages to describe material behavior under neutron irradiation, and managing the flow of data between different fuel component models to ensure correct transfer of loading data and material responses.

I was responsible for the interfaces between the software models I develop and real-life material data and behavior obtained from external contracts describing material behavior of our fuel from atomic lattice level by means of SEM, TEM and atomistic calculation software such as VASP, Gaussian and Crystal.

Further responsibilities, partially in support to the above, included the following:

1. Finite Element Analysis of the PBMR fuel design
I performed all the Finite Element Analyses on the PBMR fuel design as well as design work on certain aspects of the fuel itself. This has resulted in international patents for fuel designs for PBMR with me listed as co-inventor.
2. Design optimization of the Safari reactor fuel sphere test rig
In order to test the survival rate of PBMR fuel spheres under irradiated conditions.
3. Finite Element Analysis of Magnetic Scrubber design
I am listed as co-inventor on the PBMR magnetic isotope scrubber. (MIS) The MIS is passive hardware situated in the reactor outlet duct that uses magnetic fields to force any radioactive isotopes present in the Coolant stream to impinge on a special deposition layer that effectively captures the isotopes for the duration of the plant’s life. The MIS prevents plate-out of, amongst others, radioactive Silver and Cesium on the turbine blades thereby allowing safe (In terms of irradiation dosage delivered to personnel) maintenance procedures on the turbines.
I performed all the Finite Element Analyses on the magnetic scrubber design.
4. General support functions for the PBMR Structural Analysis Group
At structural analysis group I created and maintained an internal database for automated material property inputs for the MSC.Patran software. This was implemented by means of the Patran Command Language. I was also tasked with managing change control of the database data.
5. General consulting engineering for the PBMR Technology programme
I was tasked with performing project development for the start-up phase or feasibility of the following projects under the Technology programme of PBMR:
• The Fuel Sphere design program and software,
• Nuclear fuel characterization project,
• Graphite reclamation by means of Bio-remediation,
• Nuclear waste minimization by means of Bio-remediation,
• Artificial graphite ageing to stabilize nuclear moderating graphite in the PBMR core,
• Core cavity conditioning by means of heat pipes,
• The magnetic scrubber project.
6. Patents for inventions at PBMR
I am listed as a co-inventor of the following PBMR patents:
• Magnetic Isotope Scrubber
• Nuclear waste minimization by means of bio technology
• Graphite aging for reactor core materials
• Certain advanced fuel design patents.

SASOL Chemical Industries (SCI)
Consulting Engineer

   Jan 1997
— Jul 2002

Background:
I negotiated a service contract with SASOL AGRI for Finite Element Analyses and general consulting Engineering work on behalf of Raventech CC. In my capacity as consulting engineer and chief analyst for Raventech, I embarked on a statutory compliance project at SCI at the Thermal Oxidation-, Ammonia plant and Sasol Agri business units of both the Sasolburg and Secunda plants.

Objective of Project:
A Technical Risk Profile was performed by SASOL AGRI to identify all critical plant equipment. The objective for the project was to apply CAE/FEA methods to the equipment to:

• Obtain the stress distribution for each piece of equipment, for operating loads.
• Calculate Minimum Allowable Thickness (MAT) values specifically related to the stress distribution patterns for equipment.
• When equipment failure occurs to find the origin of the problem.

My responsibilities:
I was tasked with updating design drawings to as-built status, analyzing and in some instances reverse engineering all critical plant equipment, propose design alterations to increase equipment life expectancies, liaising with the applicable SCI inspection sections to focus their respective inspection actions and generating risk profiles and life expectancy forecasts for all said equipment.

I analyzed the following equipment types as per the requirements above:
• Ammonia Nitrate Neutralizer.
• Scrubbers.
• Pre-Neutralizer.
• Pipe Reactor.
• Various storage tanks.
• Pressurized Ammonia storage vessels.

Megkon (Pty) Ltd
Mechanical Engineer

   Apr 1994
— Nov 1996

I joined Megkon Pty. Ltd. contracting for the South African Utility ESKOM, at Lethabo Power Station in Gauteng, as an engineer-in-training in 1994.

During my career at Megkon I worked on the change control management system (CCMS) as part of a team creating a complete hardware breakdown structure of Lethabo’s plant equipment. From there I progressed to team leader of a joint ESKOM services team to implement a change control management system for all electrical switchgear schedules at Lethabo. After successful completion of said projects I was deployed to the Industrial services branch of Megkon in Midrand as design engineer where I was tasked with the design, fabrication, assembly and maintenance of the Autoster project and its auxiliary production line components.

Project:
AutoSter.

Background:
AutoSter project consists of various equipment modules that, as an assembly, automate the sterilization process of Intravenous (IV) fluids packed in a variety of containers.

Objective:
I was seconded to the project by Megkon Industrial support section to assist in the design, fabrication, assembly and maintenance of parts of the AutoSter project.

My responsibilities:
I was tasked with:
1. Refitting prototype Intravenous-bag filling machines. I had to re-configure and/or re-design certain parts and cycles of the prototype IV bag filling machine to accept different Intravenous components as specified by prospecting clients according to their native countries’ medical standards and equipment. Typical modifications included:
• Re-design of gripping heads,
• Adding additional degrees of freedom to gripping heads,
• Modifying Radio Frequency welding heads and
• Programming changes to the machine cycles to accommodate design changes.
I worked in close association with the CAD team and the Computer Numerical Control-machinist to assure rapid implementation of any changes.
2. Assisting in the design update of Megkon’s proprietary AutoSter machines, I re-designed the pressurized main connecting chamber vessel. The vessel performed extremely well and resulted in significant savings in terms of:
• Material cost.
• Manufacturing cost.
• Weight of vessel.
• Installation time.

Project:
Implementation of a Change Control Management System (CCMS) at ESKOM Lethabo Power Station for Electrical Switchgear Schedules.

Objective:
Cross-link all the Power station switchgear schedules to the electro-mechanical plant equipment and update the CCMS database accordingly.

My responsibilities:
• Lead an ESKOM team of Engineers, Electrical Technicians and plant Operators.
• Verify switchgear schedules by on-site inspections, cable numbers and/or commissioning.
• Update all defective or modified drawings in cooperation with Lethabo’s drawing office.
• Append all the information on the switchgear schedules to the CCMS database, cross linking it to all relevant drawings, procedures, mechanical plant equipment and any additional information deemed relevant by the database administrator.
• Assist with the administration of the CCMS database.
• Assist Lethabo IT-Department with CCMS user log-ins and information.
• Act as first point of contact for ESKOM, on behalf of Megkon, for any queries and problems arising from the project.

All the Switchgear schedules were verified, updated and cross-linked. The schedules were successfully incorporated into the CCMS database. This database was, in turn, successfully integrated into the ESKOM IGIS information database. The project was completed December 1995.

Project:
Implementation of a Change Control Management System at Lethabo Power Station for Mechanical components. (CCMS)

Objective:
Create a database containing the Hardware breakdown structure of the complete Power Station.

My responsibilities:
• I was part of an on-site team of Megkon at Lethabo Power Station.
• The Power Station was sub-divided into sections by service and or process and I had the following responsibilities regarding his allotted sections and the total project:
• Verify Plant Piping & Instrumentation Diagrams by checking against the physical hardware on site.
• Update all defective or modified drawings in cooperation with Lethabo’s drawing office.
• Transform the P&ID into linear flow sections and tag every plant equipment piece with a unique area code as determined by a joint Megkon/Eskom procedure.
• Append all equipment area codes to the CCMS database, cross linking it to all relevant drawings, procedures, switchgear schedules, repair history and any additional information deemed relevant by the database administrator.
• Assist with the administration of the CCMS database.

The Mechanical plant section of the CCMS database was completed successfully at the end of December 1994.

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