Karim K.

Experience

• Freelance Senior Simulation & FEA Consultant Independent Contractor (Remote Consulting) · Freelance Jul 2014 – Present 12 yrs 1 mos Alexandria, Alexandria Governorate, Egypt Provide expert structural simulation, advanced finite element analysis (FEA), and mechanical design validation services for international industrial clients and mechanical engineering sectors.
  
  Key Consultation Projects & Technical Focus:
  • Design by Analysis for Storage Tanks: Executed comprehensive structural evaluations for large-scale storage tanks (ranging from 15m to 106m in diameter) according to API 650 and ASME Section VIII Division 2 standards.
  Analyzed structural integrity for critical sub-assemblies including dome brackets, walkways, and shell nozzles using ANSYS Mechanical.
  • Extreme Loading & Environmental Simulations: Formulated advanced wind and seismic load case simulations for massive squat water storage tanks, defining intricate boundary conditions to validate structural stability under extreme environmental threats.
  • Buried Pipeline Assessment: Evaluated structural safety factors, stress distributions, and buckling resistance for high-diameter underground piping systems (e.g., DN 2200) subjected to severe soil settlement and soil-structure loading interactions.
  • Pressure Vessel Validation: Executed structural design verification and code compliance checks for large-scale industrial pressure vessels and fire-tube boilers (e.g., 2800 mm diameter x 10m length).
• Senior Mechanical Design & Simulation Engineer EZDK (Al-Dekheila Steel) · Full-time May 2014 – Present 12 yrs 3 mos Alexandria, Alexandria Governorate, Egypt Lead complex mechanical design validation, structural integrity assessments, and advanced numerical simulations (FEA/CFD) for heavy industrial utilities and plant assets at one of the region's largest steel manufacturing complexes.
  
  Key Responsibilities & Engineering Achievements:
  • Executed full-scale structural and seismic analysis for large-scale industrial storage tanks (up to 106-meter diameter) in strict compliance with API 650, ASME Section VIII Div 2, and ASCE 7 codes.
  • Directed forensic engineering and root-cause failure investigations (RCA) using explicit dynamics and fatigue models to resolve structural issues in heavy plant machinery, including 500 kN pendulum shears and high-capacity lifting units.
  • Modeled and optimized transient fluid-thermal systems using ANSYS CFX and Fluent, including EAF spray-cooled roof return water circuits, high-precision calibration laboratory HVACs, and hazardous chemical ventilation networks.
  • Investigated shearing forces and thermal distribution models for industrial steel coils and strips (580°C and 650°C), factoring in temperature-dependent material degradation.
  • Conducted transient dynamic and structural safety evaluations for plant utility assemblies subjected to high-impact loading forces up to 150,000 N.