Karim K.

Experience

• Freelance Senior Simulation & FEA Consultant Independent Contractor (Remote Consulting) · Freelance Jul 2014 – Present 11 yrs 11 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 1 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.