Karim Mohamed Kamal
Senior Condition Monitoring & Inspection Engineer
Beheira,,Egypt
Summary
Mechanical Engineer with 6+ years of experience in vibration analysis, thermography, and inspection across cement and mining industries. Specialized in rotating equipment diagnostics using Emerson CSI 2140, field balancing (one & two plane), and NDT crack testing. Reliability-focused with strong involvement in shutdowns, overhauls, and maintenance planning for crushers, mills, kilns, gearboxes, compressors, and fans. Certified in vibration analysis and skilled in predictive maintenance practices, with proven ability to improve equipment reliability, reduce downtime, and ensure compliance with ISO 10816/20816 standards.
Overview
6
6
years of professional experience
1
1
Certification
Work History
Senior Vibration Analysis & Inspection Engineer
Unity Cement Company
Yemen
11.2021 - Current
- Configured and implemented the CSI 2140 vibration analyzer software, setting up a complete database of all plant machinery to enable full-scale vibration monitoring across the cement plant.
- Collected vibration data from critical rotating equipment (Motors, pumps, fans, compressors, gearboxes) on a regular basis, ensuring accurate trending and baseline condition monitoring.
- Analyzed vibration spectra and waveforms to diagnose mechanical issues such as misalignment, imbalance, bearing defects, and looseness, providing actionable insights for maintenance teams.
- Prepared detailed diagnostic reports with maintenance recommendations, communicating findings to reliability and inspection teams to support corrective and predictive maintenance planning.
- Monitored vibration trends over time, comparing results against baseline data to detect early-stage deterioration and ensure timely corrective action.
- Participated in Root Cause Failure Analysis (RCFA) by integrating vibration data with inspection findings, identifying underlying causes of repeated failures and recommending long-term solutions.
- Successfully performed extensive field balancing on a wide range of fans using the one-plane method, and carried out advanced two-plane balancing on large equipment such as cement plant separators, achieving significant vibration reduction and smoother operation.
- Carried out inspection activities in the crushers area, covering hammer crushers, conveyor belts, stackers, and reclaimers, ensuring safe and reliable operation of critical material handling systems.
- Documented inspection findings in detailed reports and communicated critical issues to the maintenance team, ensuring timely corrective actions and proper follow-up on equipment conditions.
- Conducted detailed shutdown inspections on crushers, bearings, and gearboxes, ensuring accurate condition assessment and early fault detection.
- Participated in major shutdown overhauls, including crusher rotor replacement and disassembly of vertical mill planetary gearboxes , gaining hands-on experience in heavy equipment maintenance.
- Monitored equipment performance through plant SCADA system, tracking key parameters such as temperature, pressure, and vibration to support proactive maintenance decisions.
Condition Monitoring Engineer
Centamin PLC
01.2021 - 09.2021
- Collected vibration data across the entire plant — including crushers, mills, pumps, compressors, apron feeders, belt conveyors, etc. — using the Emerson CSI 2140 analyzer to ensure comprehensive condition monitoring of mining equipment.
- Analyzed vibration spectra and time waveforms to identify both mechanical issues (imbalance, misalignment, bearing defects, looseness) and electrical faults (stator and rotor problems), ensuring accurate fault diagnosis for mining equipment.
- Generated detailed diagnostic reports and followed up on equipment condition to verify corrective actions, ensuring compliance with international standards such as ISO 10816 for vibration severity assessment.
- Conducted thermography inspections on a wide range of static and rotating equipment — including storage tanks, bearings, electrical panels, and motors three-phase cables — to detect abnormal temperature patterns and early signs of failure.
- Performed thermography surveys on transformers, kilns, and girth gear/pinion assemblies, assessing temperature distribution to detect hidden faults, misalignment problems, and potential safety risks.
- Generated detailed thermography reports and followed up on equipment condition after corrective actions, ensuring issues were resolved effectively and equipment operated within safe limits.
- Performed crack detection tests on welds as part of NDT inspections, ensuring structural integrity and identifying defects across different types of equipment.
Preventive Maintenance Engineer
Royal Cement Company
03.2019 - 01.2021
- Conducted systematic inspections on a wide range of rotating equipment — including crushers, raw mills, cement mills, kiln main drives, fans, compressors, pumps, conveyors, separators, and — ensuring reliable operation and early fault detection.
- Participated in major shutdown and overhaul activities, including rotor replacement for crushers, disassembly and inspection of gearboxes, kiln girth gear and pinion replacement, and fans installation.
- Documented inspection findings and prepared technical reports, coordinating with maintenance teams to plan corrective actions and verify proper execution.
- Contributed to improving equipment reliability and reducing downtime by applying proactive inspection practices and supporting plant-wide maintenance activities.
Education
Bachelor of Science - Mechanical Engineering
Alexandria University
Alexandria, Egypt07-2017
Skills
Certified in vibration analysis (CAT II) using Emerson CSI 2140
Infrared thermography assessments
Predictive maintenance
Root cause analysis expertise
One-plane and two-plane field balancing
Skilled in machinery inspection techniques
Shutdown and overhaul collaboration
Compliance with ISO 10816/20816 standards
Documentation of maintenance procedures
NDT expertise in weld crack testing
Certification
Vibration Analysis: Category II - ISO 18436-2.
Timeline
Vibration Analysis: Category II - ISO 18436-2.
03-2025
Senior Vibration Analysis & Inspection Engineer
Unity Cement Company
11.2021 - Current
Condition Monitoring Engineer
Centamin PLC
01.2021 - 09.2021
Preventive Maintenance Engineer
Royal Cement Company
03.2019 - 01.2021
Bachelor of Science - Mechanical Engineering
Alexandria University