Christopher Kalaba

Reporting into the steering Committee, accountable for the preparation and execution of the TA.

Highlights:

Delivered the first NSRP refinery TA which was classified as complex:

a) HSSE: 1 MTC case for the TA which peaked at 5100 workforce

b) Quality: Leak free start up. Minor flange leaks picked up during Ops leak testing and were resolved with no impact. Weld reject rate of < 3%

c) Schedule: Delivered the TA in 48 days vs the business plan of 55 days

d) Cost ($ 5 mil below budget of $154 mil)

Advisory role for the 2023 Turnaround team (on Scope, Technical matters and TA process improvements).

Creating efficiencies within the TA work process to ensure seamless preparation.

An interface between the TA group and the Site's Leadership team and the sponsor's Technical committee.

TA strategy formulation, Capital Projects execution, Minor Projects, Engineering Design, Pressure equipment integrity (PEIM), maintenance support

• Develop TA Long range plan and Site's Solomon benchmarking Credible Path to Top Quartile. As Leadership team, provided steer to the site teams on future and current TA events
• Provide technical direction on Capital projects & maintenance to project engineers, designers and maintenance engineers
• Provide an Assurance role on standards and on asset integrity
• Liaise with production, maintenance and Technical department, facilitating delivery on site targets incl. keeping stakeholders updated on project developments
• Pressure equipment Integrity Management (PEIM)

• Work force: 101 Full Time employees excluding Full Time Contractors & Fluor

Accountabilities:

• Turnarounds planning and execution
• Development of Capital Projects (Green and Brown field)
• Pressure equipment integrity management
• Engineering Design incl. Assurance on critical processes and standards
• Provision of support to maintenance and operations on complex problems
• Developing master plans and ensuring these are budgeted for (by maintenance or included as part of projects) and phased aligned to the risk

Accountable for the following:

• Turnarounds and projects development and execution
• Upkeep and enforcement of Engineering standards
• Asset integrity management: Integrity Operating window management, Risk Based Inspection implementation & driving catch up programs i.e., Corrosion Under Insulation, Corrosion Under Supports, paint the refinery program, corrosion review, injection points and dead leg inspections
• Failure analyses & ensuring learnings are driven within the department & organization to prevent repeat failures
• Designs, Fitness for Service assessments, Finite Element Analysis and technical support for maintenance/ operations
• Data Assurance - ensuring the systems and quality of out records for all systems (Applications) carry quality data

• Re-design and implementation of Maintenance Execution (ME) process. Being a Complex process; ME implementation involved used Change Management tactics
• Crafted the "As Is" and "To be"; defined the "How" plus the associated "Assurance process" to sustain the process
• Scope coverage: 5 Refinery production zones and cutting across different stakeholders namely operations, maintenance (in-house and contractors), and projects
• Successes: Rolled out ME that brought a structured planning that led to efficient execution

• Accountable for the following: Turnarounds and capital projects development, planning and execution
• Asset Integrity management (pressure equipment) incl. Tankage maintenance
• Managed project team of Mechanical, Electrical, Civil and Instrument engineers, Designers, Estimators and Cost controllers
• Provided technical guidance, peer review and mentorship to junior engineers

• Accountable for driving the 2011 & 2013 Turnaround events through milestone compliance for the key phases namely: Strategy development, Organization, Scope development, Detailed planning, and pre-turnaround activities
• Contractor selection and management for the TA events
• Getting the site to rally behind the TA events which were Mission critical for the sustainability of the business

• Accountable for the day to day maintenance activities & delivery of shutdowns within my area of responsibility. Units under my area included the FCCU, Gas tail, Merox, SRG and PPS Conversion units (Platformer, HDS units) Alkylation and Penex.
• Developed/ Optimized prevent maintenance plans and drove execution of PM's on time and to the right quality
• Execution of zone plant shutdowns. For major shutdowns (Turnarounds), became the Shutdown leader for the designated areas
• Failure investigations and driving field solution implementation to prevent repeat failures
• Reported equipment performance (e.g. equipment uptime)
• Manage delivery via day to day central planing (primavera)
• As appointed General machinery regulation 2.1, accountable to protect people & assets from equipment related failures

• Business Improvement Project (Serbia) at two refineries - Novisad & Pancevo HSE Asset management Operational excellence Turnaround process Contracts & Procurement
• General Consultancy: Reliability Centered maintenance (RCM) Risk Based Inspection (RBI) Root Cause Analysis (RCA) Turnarounds process Countries where I consulted while with Shell (UK) Maintenance Strategies using SRCM: Stanlow (UK), Corus (UK), Yansab (Saudi), Kaduna/ Warri (Nigeria), Rhineland (Germany), Reichstett (France), Criterion (USA), OMSK (Russia), NAM (Holland), Bergen (Norway) Turnaround execution: Oman, Scotland, Serbia Risk Based Inspection: Germany Root Cause Analyses: Norway, United Kingdom, USA, Nigeria

Area Maintenance engineer in several zones; Central Zone (Cat Cracker, Alkylation, Platfomer, Hydro-desulpgurizing, Penex units); South Zone (Crude, Visbreaker, Hydro-desulpgurizing, Sulphur recovery and Utilities); North Zone (Crude distiller, Hydro-desulpgurizing and Base Oil units)

• Undertook planned shutdowns and in major events, took upon the role of Turnaround block lead
• Accountable for the planning and execution daily maintenance activities
• Accountable for the preparation and management of the zone maintenance budget
• Managed contractor workforce within the zone
• Accountable for the safety of the employees within my area of responsibility

• Project costing, planning & execution in Pulp & Paper industry; installation were both for new machines and refurbishments
• Turnaround planning and execution in Oil and Gas (at SAPREF and Engen refineries in Durban and Chevron refinery in Capetown)

• Maintenance engineer for the day to day maintenance of Copper Charging machines, Conveyors, Furnaces, Overhead Cranes, Rolling Stock, Rotating Equipment (compressors, Pumps & blowers), Piping & Lead tanks, pneumatic starting machine for cutting finished copper sheets for exporting
• Developed preventive maintenance (PM) plans and ensured their execution