Colman Mavhera

Major Inspection on 2 x GE C7 Steam Turbines at Basmaya Power Plant in IRAQ.

• Dis-assemble , inspect and repair turbine components and Steam Valves
• Take critical measurements on turbine components and steam Valve parts, like pre-lifts on valves
• Make critical adjustments to bearings, diaphragms, oil deflectors, Valve clearances and others
• Carryout critical lifts of Rotors, Casings and various turbine components
• Mentored junior technicians in advanced technical skills, fostering strong work ethic and professional growth.
• Replaced damaged, missing, or defective parts with new and refurbished components
• Tested newly installed equipment to determine proper functionality and compliance with regulations
• Prepared reports and documentation for Turbine parts and processes. Test Certificates
• Trained and supervised mechanical engineering technicians in installation and maintenance of turbines

Frame 9E Major Inspection

• Ensured safe working environment through strict adherence to safety protocols and guidelines.
• Disassembled and assembled equipment to perform repairs and maintenance i.e. Nozzles, Cans, Liners, Compressor Casing, CDC, Wrapper, Turbine casing, Exhaust Frame.......
• Resolved mechanical issues using both technical and manual skills.
• Read and interpreted technical drawings and schematics to understand equipment design and proper maintenance.
• Operated variety of tools and equipment to complete mechanical repairs.
• Steam Path Clearances on Compressor and Turbine
• Drilling of broken bolts and cleaning of threads

Frame 9E Crossfire Tube Repair

• Ensured safe working environment through strict adherence to safety protocols and guidelines.
• Identified mechanical problems and determined best solutions for correction on Crossfire tubes
• Disassembeling Nozzles and Cans to repair crossfire tubes

Major Inspection Frame 6B and Generator GEC Alsthom T190-240 42.337MVA

• Assembled and disassembled equipment to perform repairs and maintenance on Generator
• Alignment

Major Inspection on Combined Cycle Steam Turbine CC3 140 MW

• Ensured safe working environment through strict adherence to safety protocols and guidelines.
• Dis-assemble, inspect and repair turbine components and Steam Valves
• Take critical measurements on turbine components and steam Valve parts, like pre-lifts on valves
• Make critical adjustments to bearings, diaphragms, oil deflectors, Valve clearances and others
• Carryout critical lifts of Rotors, Casings and various turbine components
• Mentored junior technicians in advanced technical skills, fostering strong work ethic and professional growth.
• Replaced damaged, missing, or defective parts with new and refurbished components
• Tested newly installed equipment to determine proper functionality and compliance with regulations
• Prepared reports and documentation for Turbine parts and processes. Test Certificates

Engine Exchange on LM2500 DLE

• Dis-assemble Engine from package
• Rig old engine out of package and installed new engine
• Coordinated installation of systems, machinery, and components
• Operated variety of tools and equipment to complete mechanical repairs
• Ensured safe working environment through strict adherence to safety protocols and guidelines.

Major Inspection of Generator SGen5-1000A 282MVA

• Ensured safe working environment through strict adherence to safety protocols and guidelines.
• Disassembled and assembled Generator Set to perform repairs and maintenance
• Pulled out and in , Generator Rotor for Electrical inspection and Repair of Stator
• Disassembled Coolers to perform repairs and maintenance

Aero Mechanical Technician/ Turbine Mechanic/ Commissioning Technician

• Inspection of LM2500+ Aero Engine @ Mondi, South Africa.

Servicing and repair of engine, involving filter element replacements, strainer replacement, maintenance of VSVs, Starter and Clutch inspections and replacements. Boroscope inspections of compressor and package alignment.

Engine exchange on the LM 2500 and compressor cleaning.

• Major servicing on combined cycle steam turbines at Ciprel (2022) and Azito (2021 Cote D’ivoire). Alignment of diaphragms using piano wire, Lube oil system servicing, Steam Valves servicing i.e., MCV and SV valves including blue checks and lapping. Blue checks on bearings, bearing keeps and scrapping as required. Taking critical measurements on centre line i.e., axials, radials, oil clearances on bearings and oil baffles/deflectors.
• Nozzle replacement at Koeberg Nuclear Power Station
• Major services on Sasol Secunda Frame 9E Gas turbines
• Turbine Lead Commissioning at Medupi Power Station, South Africa

Lube Oil flushing on , Unit 3,2,1 on the Lube oil system (MAV), Control Oil System (MAX) and Jacking Oil System. Preparation for barring involving pressure settings on the lube oil valves, control oil valve, and jacking oil pumps. Setting jacking oil lifts in preparation for barring. Oil sampling and testing using the PCM100 Oil testing machine. Filter replacements on the lube oil system.

Final commissioning of Unit 5, 4, 3, 2, and Unit 1 for Grid synchronisation

• Running tests on stop valves and control valves. Testing turbine protection systems. Also worked on barring gear, gland steam condenser, non-return valves on steam exhaust pipes, oil purification systems, pneumatic valve actuators.
• Inspection of Gas Turbine Generator bearings at Sasol Secunda (GT 2). Installation of gas turbine nozzles, pipes and turbine shaft alignment
• Pre-assembly of Kriel Power Station Retrofit, that’s involves setting up of Blade carriers in cylinders (LP1 and LP2). Setting up of clearances between bottom half and top. half, grinding of sealing strips on blade carriers
• Kriel Retrofit installation at Kriel power station, Unit 6, 1, and 5.
• Overhauls on steam turbines.
• Taking critical measurements on turbine, white metal bearings, journals and gear mechanisms using micrometers, telescopic gauges, slip gauges, clock gauges and special measuring instruments.
• Bolt heating process using different types of induction machines.
• Overhauls on steam governing valves and emergency stop valves (ESVs).
• Tightening and loosening bolts and nuts using hytorc machine, Arc of turn system and bolt stretching equipment. Basic fitting and bench work involving tapping, filling, grinding, removal of broken bolts and studs, rigging.
• Doing risk assessments (HIRA) before commencing work. Overhaul and servicing of auxiliaries on turbines.

• Facilitated strong communication between maintenance personnel and other departments to ensure seamless coordination during planned outages or emergency situations.
• Reduced downtime by quickly diagnosing and repairing issues with machinery, electrical systems, and facility infrastructure.
• Coordinated scheduled shutdowns for major equipment overhauls, minimizing disruption to production schedules while maximizing asset longevity.
• Assisted in planning and execution of facility expansions, ensuring proper installation of new equipment and seamless integration with existing systems.
• Conducted root cause analysis on recurring equipment failures and implemented corrective actions to prevent future occurrences.
• Prioritized preventative measures such as lubrication programs and vibration analysis that helped extend equipment life cycles and reduce overall costs.
• Managed inventories of spare parts and tools to ensure availability of necessary resources for timely repairs.
• Analysed and identified equipment failure root causes and initiated correction actions.
• Completed partial or full dismantling of equipment to quickly repair or replace defective components and restore functionality.
• Procured pricing information from various vendors to support cost-effective purchasing.
• Coordinated preventative maintenance schedules, verifying equipment safety and function. PRAGMA
• Scheduled and oversaw maintenance, repair and installation activities. SHUTDOWNS
• Assisted in training junior mechanical fitters on proper techniques, fostering effective teamwork and skill development within the department.
• Performed maintenance and repair work on Winding Machines (Horizontal & Vertical), Spray Painting Pumps, Air Compressors, Vacuum Pumps, Shot/Sand Blasting equipment, Zinc Spray Equipment. Dust Suction Systems( Venturi ), Oil Heating Systems, Heating Ovens, Oil Filtration Plants Hydraulics and Pneumatics
• Supervised 6 employees and scheduled shifts.

• Reduced downtime for essential machinery by swiftly diagnosing and repairing mechanical issues on slitting machines, cut to Size machines, Punching machine & guillotines.
• Adhered to stringent environmental regulations during all maintenance tasks, minimizing potential impact on surrounding ecosystems.
• Maintained strong communication with Area supervisors throughout the Plant, ensuring expectations were met or exceeded.
• Mentored junior fitters, fostering supportive learning environment that enhanced overall team productivity.
• Enhanced equipment reliability by conducting thorough preventative maintenance and routine inspections on bearings, rollers, conveyers, hydraulics & pneumatics, drive shafts, gear boxes, couplings, chains & sprockets, clutches, brakes, pumps
• Increased production efficiency with timely repairs and implementation of proactive maintenance practices.
• Worked closely with engineering teams on equipment repairs that resulted in increased efficiency and reduced operational costs i.e. repairing and servicing of hydraulic & pneumatic cylinders
• Improved safety standards within facility through regular hazard assessments and implementing corrective actions.
• Worked with Maintenance managers to assess ongoing needs and plan preventive maintenance and cleaning schedules.
• Quickly responded to internal service calls ( Day & Night) regarding malfunctioning equipment and completed repairs.
• Completed partial or full dismantling of equipment to quickly repair or replace defective components and restore functionality.
• Completed daily, weekly, and monthly checklists on building equipment to maintain records of scheduled maintenance procedures.
• Troubleshot equipment breakdowns and performed preventive maintenance.
• Followed work orders and specifications for machine and equipment replacement, repair, or maintenance.
• Followed safety protocols to minimize workplace accidents.
• Operated varied hand and power tools to complete repairs.
• Replaced worn or defective parts and adjusted settings to improve performance i.e. blades on guillotines
• Cleaned, lubricated and calibrated machinery components to maintain peak operating performance.

• Contributed to cost reduction efforts by identifying opportunities for process improvements within manufacturing environment
• Managed multiple projects simultaneously, prioritizing tasks to meet deadlines while maintaining high-quality work standards.
• Collaborated with quality assurance team to resolve discrepancies and implement corrective actions for non-conforming parts.
• Improved workplace safety by performing routine maintenance on machinery and ensuring all equipment was in proper working order.
• Maximized machine uptime by efficiently scheduling jobs based on priority level and resource availability.
• Maintained detailed records of completed jobs, tracking materials used and time spent on each project for accurate billing purposes.
• Enhanced production efficiency by setting up, adjusting, and operating various machines according to specifications.
• Manually set up machinery, lathes, and grinders.
• Studied daily work instruction, sketches, drawings, blueprints, and manuals to determine dimensions and tolerances accurately.
• Utilized micro meters and callipers to measure and verify precise tolerances.
• Operated Radial drill presses, lathes and milling machines to produce required parts.
• Inspected completed parts to verify compliance with specifications and quality standards.
• Read and interpreted blueprints, technical drawings and schematics to determine parts dimensions.
• Used various precision measuring instruments to check workpiece accuracy.
• Developed jigs, fixtures and tooling to meet production requirements.
• Measured, examined or tested completed units to check for defects and verify conformance to specifications using precision instruments such as micro meters and GO- & NO-GO gages

Sites worked on , Koeberg Nuclear Power station, Camden Power Station, Kendal Power Station, Majuba Power station

• Collaborated with team members to complete tasks on schedule, maintaining high standards of workmanship.
• Enhanced production efficiency by accurately interpreting blueprints and specifications for various projects.
• Increased workplace safety by adhering to strict guidelines and protocols during daily operations.
• Assisted in training new employees, sharing technical knowledge and best practices for efficient operations.
• Followed safe work practices, which included fall protection and personal protective equipment.
• Worked on Centre Line & Generator- measuring of rotor, bearings, oil wipers, any other components on the machine.
• Disassembly & Assembly of Turbine and Generator
• Pump / Shaft Alignment
• Rigging of diaphragms,
• Measuring of LP rotors, bearings, oil wipers,
• working on Locating & Anti-Rotating Keys, Steam Bellows, Gland Boxes & Gland Box Segments,
• Lead sizes between diaphragms and LP rotors, LP rotors and bearings