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IKPEGHEAKO ONYEBUCHI MICHAEL

IKPEGHEAKO ONYEBUCHI MICHAEL

Reliability and Maintenance Professional
Port Harcourt

Summary

Highly motivated Production Engineer with comprehensive experience in process improvement and ensuring equipment reliability. Successful at reducing downtime and improving production processes. Exceptionally talented at investigating and uncovering root causes to undesirable system issues that negatively affect production. Skilled at leading a team of engineers and technicians in troubleshooting complex rotating equipment issues. Hardworking, educated and willing to go extra mile to meet goals and exceed standards.

Overview

19
19
years of professional experience
1
1
Certification

Work History

EPST Member (Enhanced Problem-Solving Team), Production Engineer, (Reliability Engineering)

Shell Petroleum Development Company
Port Harcourt
01.2022
  • I am responsible for conducting root cause analysis (RCA) using causal learning investigation methodology for all reliability related incidents and trips for SPDC facilities
  • I also provide support to the HSE team in carrying out causal investigations with regards to high ticket HSE incidents
  • My role requires me to uncover the root causes of undesired plant and equipment behavior by using data driven processes and analysis; then provide solutions with a view to averting recurrence
  • Seeks to deep deeper into systemic and behavioral patterns contributing to these outcomes
  • I conduct learning sessions with relevant stakeholders and company leadership explaining leading factors and causalities
  • I drive recommendations and solution development workshops geared towards providing solutions and stopping recurrence of similar incidents
  • Examples of Causal Learning Solutions (root cause analysis) to Reliability incidents I led are: (i) Soku gas plant LP NAG compressor outage for 56 days Scope: Turbine driving compressor tripped and stayed down for 56 days
  • Compressor daily production was 200mmscf/d of gas
  • Revenue loss recorded was 11,800 mmscf of gas totaling $185m at $91/b
  • (ii) Hydrocarbon Vapour Release from Crude Oil Tanks leading to Plant Shutdown Scope: Terminal plant shutdown leading to delayed crude oil treatment and readiness for export
  • Loss of two crude oil storage tanks due to roof rim seal failure with a total repair cost of $1.3m Examples of Causal Learning Solutions to HSE incidents I led are: (i) Trans Ramos Pipeline Leak Scope: Pipeline rupture during pigging which caused a spill volume of 2700 barrels of oil affecting 3 communities land and water
  • Outage to production facilities producing into the trunk line for a period of 9 months
  • Estimated revenue loss of about $560m
  • (ii) Crude Oil Offtake Tanker Nearmiss Scope: Offtake tanker narrowly missed drowning 44 persons working in close proximity to tanker while proceeding to berth for crude oil loading.

Mechanical Team Supervisor (Bonny Oil and Gas Terminal/ Soku Gas Plant) Nigeria

Shell Petroleum Development Company
Port Harcourt
01.2014
  • Key responsibilities are: Maintain asset integrity for critical assets rotating & static equipment; Supervision of Mechanical Team Members & Contractors to achieve optimum plant maintenance; Planning and delegating responsibilities; Drives cost saving initiatives to reduce operating expenditure (OPEX); Provides guidance on troubleshooting skills; Motivate, mentor and coach team members
  • Scope: Manages budget size of $8m and 50 number of personnel including staff and contractors
  • Plant production output was 1.8bscf/d of gas and condensate
  • Maintenance and optimization of all mechanical rotating and static equipment like gas compressors, gas turbine generators (GTG), pumps (centrifugal and reciprocating); Ensures availability and maintenance of condensate export pumps; Coordinates shut down activities of all rotating and static equipment in line with scheduled maintenance calendar
  • Soku Gas Plant: I led many asset and process improvement initiatives
  • For example: I functioned as the lead and co-developed with plant support Reliability engineer permanent solution for frequently leaking seal packing for the condensate export pumps
  • Studied and charted performance indices for the export pumps, checked and corresponded with OEM and competitors on critical performance data
  • Assisted in fluid/ material compatibility design and finally selected a robust seal arrangement
  • Improved MTBF from 2 weeks to 9 months
  • Led the first onsite team to carry out intrusive troubleshooting of the gas turbine generator and resolve lube oil leak
  • Leak Closely working with the OEM rep
  • I replicated I replicated troubleshooting skills tapped from the OEM reps Replicating troubleshooting skills tapped from OEM reps, I led the first onsite team to carry out intrusive troubleshooting of the gas turbine generator and resolve lube oil leak
  • Leak Tapping lessons from OEM reps, I led the first onsite team to carry out intrusive troubleshooting of the gas turbine generator and resolve lube oil leak
  • Leak discovered to come from the fuel gas valve actuator
  • The leak was inimical to safe continuous production of the turbine
  • Saved Fuel gas valve to Equipment needs to be sustained in service while plan for the OEM rep to visit site Plans and implements Statutory Inspection and Risk Based Inspection (RBI) of static equipment like tanks and vessels
  • I am responsible for ensuring optimum maintenance of mechanical activities in the plant and overseeing all mechanical team members
  • Supervises pre-commissioning and commissioning of mechanical rotating and static equipment and integrating these with existing plant processes
  • Planned and prepared preventive maintenance cycle for equipment in line with OEM recommendations Assigns mandatory performance criteria to be met by all safety critical equipment (SCE) thus assuring asset integrity Ensures complete inventory of all maintenance items into the company’s maintenance database – computer maintenance management system (SAP) Liaises with the scheduler/planner and ensures roll out of equipment maintenance processes in line with assigned due date Follows up equipment milestone actions and proactively plan execution Ensures call-up of external vendors and contractors Liaises with gas receiving plant, NLNG and ensures adherence to start-up dates in order to meet contractual agreement.

FIELD OPERATIONS SUPERVISOR

Shell
Bonny terminal, Shell
01.2019 - 01.2020
  • Coordinates Bonny Terminal Activities in order to safely meet business target for hydrocarbon processing and export
  • Integrates with maintenance teams to resolve plant issues ensuring availability and reliability of plant equipment
  • Provides supervision to plant operations staff in order to operate safely plant critical rotating/ static equipment
  • Ensures first-line maintenance of plant equipment
  • Responsible for meeting production assigned targets (crude oil export volumes) for the team
  • Ensures on-time loading of crude oil tankers in order to avert incurring demurrage.

Contracting & Procurement Role

Shell Nigeria
01.2012 - 01.2013
  • Responsibilities of this role were:
  • Build an effective interface with the Maintenance Asset teams
  • Facilitates procurement & minimize material lead time
  • Assumed business advisor role to up-skill mtce/production staff for spares ordering.

Work Preparer/Scheduler

SPDC Nigeria
01.2008 - 01.2012
  • District custodian of plant maintenance management blueprint; Compliance advisor to O&M discipline; Planner- maintenance activities to align with district’s budget; Facilitated third party and milestone inspections.

Mechanical Team Member

Shell Nigeria E&P
01.2001 - 01.2007
  • Maintenance, troubleshooting & repair of rotating equipment (pumps, compressors, turbines); Maintained inspection records for milestone maintenance; Proactive monitoring and trending rotating equipment performance.

Education

Bachelor of Technology - Mechanical Engineering

Rivers State University of Science And Technology
Port Harcourt, Nigeria
04.2001 -

Skills

Maintenance Integrated ExecutionRotating and Static EquipmentReliability EngineeringBusiness Performance ManagementContracts & Procurement ManagementRoot Cause Analysis (Causal Learning Investigation and Solutions)

Skills Professional Training

  • Shell Contract Management - ECMII
  • Leadership Development Training
  • GE Turbines FAT & workshop experience GKN Trollhattan, Sweden
  • Influence Reliability Training
  • Conflict Management Resolution Training
  • PM (Production Maintenance) Library Maintenance
  • Production and Interpretation of Engineering Drawings
  • Causal Learning Facilitators Course
  • Survival at Sea/ Helicopter Underwater Escape Training
  • Hazard & Effect Mgt. Process (HEMP Tools Learning Event)
  • Solar Gas Turbine Troubleshooting
  • SAP MIE (Maintenance Integrity & Execution) Shell
  • SAP Super Schedulers/ Users Training Shell
  • Siemens Demag Delaval Compressor Training
  • Breathing Apparatus & Gas Testing Course NISP
  • PM:06 Mechanical Seal
  • ISO 14001 EMS Training
  • PM03 - Caterpillar Diesel/Gas Engine Troubleshooting
  • SCI Breathing Apparatus Course, Safety Centre Int’l
  • Machinery/Bearing Lubrication Training
  • Oil Spill Response (OSR) Training
  • EASY LASER Machinery Alignment Course

Education Certification

  • Bachelor of Technology, Rivers State University of Science & Technology, Port Harcourt
  • Certified Maintenance Reliability Professional (CMRP), 2021
  • Council for the Regulation of Engineering in Nigeria, COREN (Eng.), 2021
  • International Vocational Qualification (IVQ), Nigerian Society of Engineers (MNSE), 2021

Personal Information

  • Date of Birth: 07/12/77
  • Gender: Male
  • Nationality: Nigerian

References

  • Yisa Tairu, Terminal Superintendent, tairu.yisa@shell.com
  • Onyejekwe Chimuanya, Production Unit Manager, chimuanya.onyejekwe@shell.com

Affiliations

Nigerian Society of Engineers (MNSE) 2021

Council for the Regulation of Engineering in Nigeria, COREN (Eng.) 2021

International Vocational Qualification (IVQ)

Certification

Certified Maintenance Reliability Professional (CMRP)

Work Availability

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Timeline

EPST Member (Enhanced Problem-Solving Team), Production Engineer, (Reliability Engineering)

Shell Petroleum Development Company
01.2022

FIELD OPERATIONS SUPERVISOR

Shell
01.2019 - 01.2020

Mechanical Team Supervisor (Bonny Oil and Gas Terminal/ Soku Gas Plant) Nigeria

Shell Petroleum Development Company
01.2014

Contracting & Procurement Role

Shell Nigeria
01.2012 - 01.2013

Work Preparer/Scheduler

SPDC Nigeria
01.2008 - 01.2012

Bachelor of Technology - Mechanical Engineering

Rivers State University of Science And Technology
04.2001 -

Mechanical Team Member

Shell Nigeria E&P
01.2001 - 01.2007
IKPEGHEAKO ONYEBUCHI MICHAELReliability and Maintenance Professional