Maintenance Plant

CURRICULUM VITAE

[pic] Ajay Kumar Biyani

B.E. (Mechanical,1985) with 24 years of experience in Plant and Project

Management, Engineering (including instrumentation, civil & electrical

jobs) & Planning in the Petrochemical, Fertilizer & Cement sector in India

and Gulf.

KEY COMPETENCY AREAS:

1) Maintenance Management Planning

2) Condition monitoring for increasing uptime(On-line/Off-line) of

Rotating Equipments for health, alerts and events monitoring for

Diagnostics Analysis & Predictive Maintenance

3) Process Capability Enhancement: Planning and executing daily,

preventive, shutdown maintenance schedule for increasing process

capability and consistency.

4) Engineering and Maintenance of all type of rotating equipments

like- Gas Turbines (GE-MS5002D & frame-5), Steam turbine

Compressors (Nuevo Pig none, MHI & Kobe co) & all type of Pumps,

HRSG, HVAC, Piping, etc.

5) Maintenance of kiln dryer and wet section

CORE COMPETENCY AREAS:

Process Plant Maintenance & planning

. Planning & effecting long run resulting parameters to effect

consistent operations & increase machine up time & equipment

reliability.

. Planning and implementing best combination of predictive /

preventive / condition based / shutdown maintenance schedule for

machinery so as to increase process consistency.

. Planning budget and controlling through continuous Cost Controlling

System.

. Material planning & management at write time, cost and reliability

with adequate vendor resource utilization.

. Identifying areas of obstruction / breakdowns and taking corrective

measures / steps to rectify the equipments through application of

troubleshooting tools.

. Usage of Industrial tools like 5S, QC, &TPM for enhanced process

performance.

TECHNICAL EXPERTISE

. Piping, Exchanger, Presser Vessel multistage Pump, and Compressor.

Turbine, Fans, Belt conveyors, High Angle Conveyors, Vibrating

Feeders/Screens, Jaw crusher, Cooling tower, D.M.Plant Agitators,

Overhead crane, HVAC and Heavy Lift Equipment Mobile Crane up to 120 t

cap, Forklift, Workshop machine, Safety valves etc.

IT SKILLS: SAP, ERP, MMS, M.S project, PPT

EMPLOYMENT NARRATION

Indian Experience:

(1)G.M (Engg.): Great Galleon Ltd. Dec '11 to

April'13

A unit of Kedia Group in dist Dh?r M.P engaged in Bottling and

distillation,

Handled erection and commissioning of INR 30 cores distillery project.

Oversaw 100 personnel in the production, quality assurance, maintenance,

HR, administration, stores,

. Reduced the team size from 75 to 60 personnel, introducing

automation which led to savings of INR 36 lakhs p.a. while

adding another line for 10 new products

. Decreased production cost by 10% through reduction in

process loss and raw-material cost as well as maximization

of production capacity

. Executed the erection and commissioning of three different

processing lines and machinery like boilers, compressors,

generators, ddgs systems etc.

. Introduced process efficiencies and automation which reduced

the number of contract workers from 140 to 100, with a

positive effect on the bottom line of INR 24 lakhs p.a.

.

(2)Head - Mechanical: India Glycol Ltd.

April 2007 to Dec2011

First and only company in the world to produce Ethylene Oxide (EO) / Mono

Ethylene Glycol (MEG)/ Performance chemical/ liquor Gurgum from renewable

agro route based on molasses in Kashipur, Uttaranchal India.

Deliverables: Best plant availability.

o Ownership of all improvement projects, 5S and QC for uptime Improvements.

o Timely execution of projects: Co-ordinate with various contractors and

consultants for smooth and timely completion.

o Interface with Electrical, Instrumentation and Civil section for projects

and maintenance to achieve set performance targets.

o Planning annual and day-to-day maintenance activities including man &

material within set budget.

Major Attainments

. Elemental analysis, MTBF, FMEA & RCA to achieve Operating cost within +/-

5% of target Cost as well maintenance cost within target BP cost

successively.

. Ensured Annual Shutdown predictions and adherence to quality, time &

completeness in shutdown activities.

. Identified debottlenecking projects and ensured quick implementation.

Achievements

. Implemented innovative solution for mechanical seal pumps by which the

chronic problem seal failure has been reduced.

. Timely re-commissioning of the plant after the shut down as per the

target: Carried out Annual shut down jobs in MEG/EO/GE plant with

proper planning in procuring the materials in time, mobilizing

required manpower and their effective utilization. The Successfully

executed and commissioned the project of manufacture of gurgum /

powder plant

. Maintenance procedures and their implementation in SAP System.

Equipments Handled:

Air compressors, Gas Compressors, Root Blowers, screw compressor, dry gas

seal pump multistage, reciprocating. diaphragm etc Turbine, Cooling Tower

Chilling plant, 60Ton/Hr and 12 Ton/Hr coal fired IBR boilers 130 tons,

D.G. Set, Centrifuge, Agitators, Gearbox, EOT crane Glass lined reactors,

S.S Reactors, Tower, Turbine, D.M. Plant, Air Dryer, Distillation

Columns, Tanks, coolers, Condensers, Heat Exchangers, Belt and Bucket

conveyer, Material handling equipment etc.

(2)Sr. Engineer - Mechanical: India Glycol Ltd.

Dec'89-Mar'92

. Erection & commissioning MEG& ASU Plant; distillery, and boiler.

. Drafted spare parts manual, interchangeability manual, spare parts

management for reduction of spares and spare cost.

(3)MANGER (Mechanical): M/S Chambal Fertilizer and Chemical Ltd. 1992-

2005

Flagship Company of K.K Birla Group, engaged in production of AMMONA and

UREA from Natural Gas, having an installed capacity of two ammonia plant

2800TPD & four urea plant 5000TPD with H.T & TEC Technology.

Deliverables: Successful Commissioning of Projects and Best plant

availability.

Successfully commissioning of Urea and Ammonia plants:

. Planning, scheduling, liaising with vendors and supervising for

timely execution.

. Inspection of equipment, installation, commissioning, start-up.

. Authorized for witness tests/inspections :Factory tests of major

equipments like- GE Gas Turbines Frame-V, High Pressure Boilers,

HRSGs, D.G.Set, BFW pumps, Induced/Forced Draft Fans, heavy duty

Turbine pumps, heavy duty multistage centrifugal/ reciprocating

Compressors and various centrifugal/ reciprocating pumps for

various services.

Availability and Reliability of plant: After successful commissioning:

. Predictive maintenance for increasing availability and reliability.

. Failures investigation/ reporting

. Planning and execution of annual shut downs and

. Spare parts management

. Set up Mechanical & Electrical maintenance workshop

. SAP: Defining and implementing Maintenance procedure in SAP.

Achievements

. Maintenance procedures and their implementation in SAP System

. Set up mechanical & Electrical work maintenance workshop

. Successfully executed and commissioned the Expansion Gadepan -2

project for manufacture of Urea and Ammonia.

OVERSEAS:

Planning Engineer: M/S Al-Bayroni (SABIC) K.S.A April 2005 to

APRIL 2007

Major Attainments:

o Elemental analysis, MTBF, FMEA & RCA to achieve Operating cost within

+10% of target Cost as well maintenance cost within target BP cost

successively.

o Identified debottlenecking projects and ensured quick implementation

o Ensured Annual Shutdown predictions and adherence to quality, time &

completeness in shutdown activities.

o Achieved 15% conservation of energy by working closely with the

Operation and Maintenance Team.

o Implementation SHEM Procedure

o Strictly adhered to the safety norms and maintained the safety

standards.

o Planning of manpower and implementation of overhauling schedule

Equipments Handled

Pump, Compressors, Turbine, Gearbox, Belt conveyers, Work shop machine,

Safety valves, Heat Exchanger, Cooling tower, Piping etc

Others:

Asst. Engr. (Mech.) Lakshmi CementJ.K.Group Sirohi Plant (Raj)

Nov'86-Dec'89

Responsible for Repair and Maintenance workshop

G.E.T Diamond Cement Birla Group Damoh (M.P) Nov'85-Nov'86

Responsible for Shift Maintenance of kiln, cement mill & bagging plant

TRAININGS ATTENDED

. Repair and maintenance Welding Technique from BHEL, TRICHY

. Vibration Technique from BENTLY NEVDA

. RCM,RCA, MTBF,

. Operation and maintenance Gas turbine from BHEL HYDERBAD

. Repair and Maintenance of Pump and Compressor from BHEL HYDERBAD

. Lifting Tools and Tackles from IIT KANPUR

. Implementation PM schedule

PERSONAL PROFILE

Date of Birth : 6th August 1963

Pass port Details : E-713204

COMMUNICATION DETAILS

Present Address : 69-Ashirwad Villa, Nipaniya, near DPS, Indore

(M.P)

Alternate Address : 6CE, S-4, Scheme 78, Vijay Nagar Indore

M.P 452007

Email :

***********@*****.***,***********@**********.***

Cell no : 91-786******* & 919*********

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