Frank Bwalya
Kitwe
Summary
Results-oriented Mechanical Engineer with a decade of experience in the mining industry, specializing in industrial pumping systems, mine dewatering, and multi-disciplinary mechanical engineering infrastructure. Proven track record in conducting technical and financial feasibility studies, authoring business cases for infrastructure upgrades, and designing high-capacity pumping solutions to enhance operational efficiency. Expertise in fluid hydraulics, pump curve analysis, and CAPEX/OPEX optimization ensures reliable troubleshooting of complex dewatering systems while prioritizing safety and risk mitigation. Recognized for innovative problem-solving and effective communication skills, consistently driving team success through collaboration and adaptability in fast-paced environments.
Overview
11
11
years of professional experience
Work History
Pumps & Dewatering Engineer
Mopani Copper Mines Plc
Kitwe, Zambia
02.2021 - Current
- Performed detailed feasibility assessments aimed at optimizing capital investments and operational efficiency for dewatering chamber improvements.
- Directed and coordinated dewatering system operations, utilizing 18-inch steel pipe columns and rock rising mains for efficient water management.
- Analyzed hydraulic data and tested pump performance through curve analysis to effectively ascertain system head loss and select appropriate pumps for significant dewatering projects.
- Executed installation and commissioning of centrifugal and submersible pumps at various stations, enhancing discharge performance across a range of 80m to 894m.
- Supervised maintenance activities and operational workflows for high-head multi-stage pumping systems, ensuring team efficiency and system reliability.
- Streamlined maintenance processes for an 80-pump fleet, managing a variety of brands including Sulzer, Grifo, Harland, Flygt, Grindex, C5, Amandhla, and Warman to ensure operational excellence.
- Conducted thorough preventive maintenance assessments to ensure equipment reliability and optimize maintenance budgets.
- Coordinated efforts with cross-functional teams to identify and implement improvements in production efficiency.
- Analyzed operational processes and implemented engineering solutions to drive efficiency enhancements.
- Mentored junior engineers, fostering skill development and knowledge sharing within the team.
- Conducted thorough analyses of system performance, identifying areas for improvement.
Shafts and Winders - Sectional Engineer (Mechanical)
Mopani Copper Mines Plc
Kitwe, Zambia
03.2016 - 02.2021
- Conducted thorough maintenance on mechanical and electrical systems, significantly improving the reliability of surface and underground winders, diesel/oil filling stations, and firefighting systems.
- Conducted thorough assessments and optimizations of mechanical systems to ensure effective operation of shaft loading complexes.
- Utilized evaluation frameworks to analyze operational and infrastructural modifications, ensuring adherence to compliance standards and identifying associated risks.
- Collaborated with team members to troubleshoot operational issues and enhance productivity.
- Operated and maintained mining equipment to ensure efficient extraction processes.
Risk Coordinator
Mopani Copper Mines Plc
01.2015 - 03.2016
- Conducted comprehensive risk assessments by integrating risk data into pre-feasibility and project planning phases.
- Oversaw systematic data management in Mopani CGR software, preserving a detailed risk and control register that spans all engineering disciplines.
- Examined historical data on HPRI injuries and property damage, implementing adjustments to safety and maintenance controls.
- Oversaw creation and implementation of training materials and assessment tools aimed at improving risk management practices.
Education
Degree - Mechanical Engineering
University of Zambia
Lusaka, Zambia07-2013
Skills
- Technical Engineering: Centrifugal, Submersible, & Positive Displacement Pumps; Electric Drive Systems; Fluid Hydraulics & Pump Sizing
- Operations & Design: Dewatering System Design (Sump & Wellpoint), Pipework Layout & Valve Manifolds, Cascade Pumping Systems
- Project Strategy & Economics: Pre-Feasibility & Feasibility Studies, Business Case Development, CAPEX & OPEX Optimization, Equipment Specifications & OEM Selection
- Maintenance & Reliability: Root Cause Analysis (RCA), Preventive Maintenance (PM), Vibration Analysis, Pump Rebuilds
- Risk & Governance: Quantitative Risk Assessment, Statutory Compliance, Risk & Control Registers, Health & Safety
- AutoCAD (Piping & Instrumentation Diagrams)
- MS Project
- Mopani CGR Risk Software
- Technical reporting
- Data analysis
- Project planning
- Project management
- Critical thinking
- Quality control
Accomplishments
- Feasibility-Driven Cost Reduction: Reduced operational energy costs by 15% through feasibility-backed, timely replacements of defective valves and low-efficiency pumps.
- System Availability: Successfully increased overall plant availability from 50% to 90%.
- Reliability Optimization: Improved Mean Time Between Failures (MTBF) to 4 hours, averaging only 1–2 equipment breakdowns every 30 days.
- Safety Record: Achieved zero Lost Time Injuries (LTIs) during all major engineering and dewatering projects to date.
- Data Integration: Collaborated with civil engineers and hydrologists to interpret hydrogeological data and optimize pumping capacities.
Timeline
Pumps & Dewatering Engineer
Mopani Copper Mines Plc
02.2021 - Current
Shafts and Winders - Sectional Engineer (Mechanical)
Mopani Copper Mines Plc
03.2016 - 02.2021
Risk Coordinator
Mopani Copper Mines Plc
01.2015 - 03.2016
Degree - Mechanical Engineering
University of Zambia
Project Delivery & Execution Oversight
- Feasibility to Handover Support: Provided senior engineering support during procurement, construction, and commissioning phases, ensuring deliverables met strict scope, schedule, and quality criteria.
- Technical Evaluations: Led thorough technical and commercial evaluations for major mechanical equipment packages, feasibility reviews, and OEM selections.
- Design & Quality Assurance: Supported the resolution of design and site engineering issues, participating directly in Factory Acceptance Tests (FATs), Site Acceptance Tests (SATs), and commissioning sign-offs.
Key Deliverables Produced
- Mechanical Engineering Basis of Design and Standards
- Technical Assurance, Feasibility, and Design Review Reports
- Equipment Specifications and Selection Reports
- Engineering Governance and Compliance Documentation
- Commissioning and Handover Assurance Reports