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Manager Maintenance

Fresh Meadows, New York, United States
January 21, 2018

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Current Address: ***-** **** ******, ***.1-A, Fresh Meadows, NY 11366

E -mail: /

Contact No.: (+1) 929 *** ****/ 929 *** ****/ 929 *** ****

Permanent Address: 36230 S. Huntington Drive • Solon, Ohio 44139

US Status: Permanent Resident of US (GREEN CARD)

Summary Profile

An ambitious and self-motivated, quality & schedule oriented professional with over three decades of experience in the field of Mechanical Engineering of large scale EPC and ODC projects, including proposal preparation, (EPC) execution, project management, facility engineering, operation, maintenance in oil & gas upstream and downstream industry. Vast cross functional work experience of developing and implementing, objectives, strategies and tactics for Project Procurement, Materials Management and also in Plant Maintenance for Oil and Gas, and Petrochemicals Industries.

As Procurement & Materials Manager and Maintenance Manager, optimized operating expenses by implementing material forecasting, ABC cost analysis, inventory utilization, and material inspection and quality compliance systems. Worked in a global environment, demonstrating success, in implementing cost engineering, maintenance, establishing equipment reliability and uninterrupted plant operations in high volume manufacturing industries by utilizing exemplary management, analytical, organizational and people management skills. I possess experience and capability of working in a competitive, goal and deadline oriented, multidisciplinary environment and believe in team work, continuous learning, delivering the quality output while holding safety as prime.


B.E Mechanical Engineer (1989 to 1993): With First Class: The Maharaja Sayajirao University of Baroda, Vadodara, India.

Diploma in Mechanical Engineering (1981 to 1983): With Distinction: The Maharaja Sayajirao University of Baroda, Vadodara, India

II Class Boiler Proficiency Certification (January2000: No expiry): issued by Indian Boilers Rules and Regulation Authority (IBR)

Key Skills

Materials Management & Supply Chain

oMaterial Procurement, stores / ware house and inventory Management, Vendor Development, Demand Forecasting, Lean/On-demand Material Mgt., Quality Control, working knowledge of SAP R3 – MM Module.

Plant Maintenance

oPreventive, Predictive, Breakdown and Shutdown Maintenance of Rotary and Static equipment of Gas Cracker (GC), Polypropylene (PP) and Power Plants. Working Knowledge of SAP R3 – PM Module

MIS Reporting

oSupplier Catalog, Materials Forecast Report, Cost Trend and Utilization Report

QC, Standards and Compliance

oSpecification and requirements of 6-Sigma, ISO 9001-2000, ISO-14000, OHSAS-18001, BS Five Star Safety, ANSI, ASTM, BS.

oVery well conversant with International Material, dimensions and testing standards like ASME, ASTM, ANSI, API, ISO, AWS, BS,ISI, TEMA, SHELL, standards, SAP and MESC item codes for various engineering items.

Microsoft Office & Soft Skill

oProficient in Microsoft Word, Advance Excel, Power Point, Access, Outlook Express, etc. Working on SAP R3 for PM and MM module

Significant Achievements (IPCL & PDO)

Successfully planned and scheduled Erection & commissioning activity of plant expansion project of Polypropylene plant in a Petrochemical Unit (Maharashtra Gas Cracker Plant-MGCC)

Successfully planned and scheduled Erection & commissioning of bagging machine of 4 working lines.

Successfully planned and scheduled Erection & commissioning of Boiler in Gas Cracker plant.

Implementation and enhancement of SAP- ERP system (Enterprise Resource Planning) for the entire materials group, & plant maintenance, resulting in a 58% improvement in on time delivery and inventory turns by 15%.

Identifying and developing alternate spares for imported equipment, achieving cost effective purchases of spares and reduction in delivery time, especially for the imported spares.

Performed physical and chemical lab tests of unused non MTC pipes and fittings under third party Inspection Agencies like LRIS, BVIS, to establish the MTC and standard Grade, rendering them usable. Saved over 50 million USD purchase in IPCL.

Preparation of Standard Operating Procedures (SOP).

Successfully completed the Procurement cycle for 10+ large size EPC projects and completed procurement cycles for the ODC projects with 99% material receipt before schedule and NIL rejection item.

Work Experience

I.Petroleum Development Oman through Al Turki Enterprises, LLC (Muscat): (Feb. 2007 to Jan. 2017)

Designation: Manager Project Procurement Reporting: Director Oil & Gas / ED/ MD

For last one decade worked for Petroleum Development Oman, -PDO: (an Oman Government undertaking Oil and Gas company) through Al Turki Enterprises LLC, a big name in Oman as EPC contractor. Worked as Manager Project Procurement, for ODC and EPC Projects, handling the purchase of Project Items as well as infrastructure development Projects in south of Oman.

Lead the procurement and planning team ensuring availability of critical equipment and parts as per the project demand and production schedule.

Professional Profile

Very Well Experienced in

Tendering, Procurement, Demand forecasting, Planning, Reporting, Inventory management for various Heavy Engineering projects of Oil and gas industries, Gas pipeline Projects, Oil Hook up wells, Oil field projects.

Development of procurement related strategies, procedures and bidding processes for various projects.

Handling import of goods, establishing Letter of Credit (LC), Wire transfer payments and various negotiable instruments.

Vendor development, assessment and evaluation. Created Checklist and Scorecards to improve supplier analysis and enabled efficient procurement decision making with the help of Critical Inventory Lists Catalog (CILC) ensuring on time delivery of materials.

Optimized inventory budget through implementation of Lean Principles and implemented on-demand supply/ delivery model to reduce the Inventory Carrying Cost.

Developed strategies to mitigate impacts of the market volatility of high cost items through ABC Analysis.

Identified opportunities in the new product design through target costing, and managed cost drivers to improve the design decision making to drive short and long-term materials cost reduction improvement.

Audited warehouse physical inventories by maintaining 99.9%+ inventory accuracy.

Supervised development of standards and inquiry packages and technical documents to be sent to suppliers.

Carried out forecasting and reporting for procurement cost, material reconciliation, and project surplus.

Involved in ISO 9001:2000 and ISO 14000 activities, SIX SIGMA,OHSAS – 18001

Responsibilities Include:

Procurement of Pipes (GRE, CS, Alloy steel), Valves (including MOV & Surge Relief Valve), Flanges, Pipe Fittings, consumables, structural material capital items like Generators, Compressors, Pumps etc.

Co-ordinate with Project Manager for the material requirements and assure timely delivery as required.

Review of specifications, Drawings, material take off (MTO) for ordering, progress monitoring.

Preparation of bidders list (BL) and selecting potential supplier from contractual vendor list, given by client.

Assembly of Inquiry packages of equipment/ materials- attaching technical requisition documents (MR) and general procurement documents. Expediting bid from inquired suppliers with in due date of Bid.

Transmission of technical proposal to specialists, and answers to Technical & commercial clarification required by bidders.

Manages the Procurement and logistics activities of an assigned project adhering to established guidelines of company policies and procedures. Preparation of Purchase Orders and Amendments. Purchas of material/equipment in the most cost effective manner. Expedite material/equipment to ensure delivery schedules are maintained or improved. Obtaining inspection schedule and notification in advance and arranging client inspection/ TPI Third party inspection in time. Expediting of Drawing and QC documents like ITP / QP as per PO documents. Deal with the supplier for the delivery of the defective / damaged / non confirming material and arrange for the suitable replacement of the same.

Organizing a kick-off meeting (KOM) with the supplier along with Project Team / Engineering team and Quality team. Obtaining manufacturing schedules/ engineering & QC documents schedule from suppliers and confirm the same after verification with projects requirements. Close monitoring with vendor for their Engineering/ Procurement / manufacturing activities. Receiving Monthly/ weekly progress report from suppliers and updating in the project schedule.

Issuing a detail status report with forecast of inspection and delivery and ongoing technical issues to client/project once in fortnight

Preparing procurement cost report, material reconciliation, project surplus material report etc.

II-Indian Petrochemicals Corporation Limited (IPCL) (Now Acquired by Reliance Industries Limited) (October 1984 to January 2007)

Designation: Maintenance Manager (Mechanical)

The INDIAN PETROCHEMALS CORPORATION LIMITED –IPCL, is the pioneering Petrochemical company in India, now taken over by Reliance Industries Limited (RIL), India’s fastest growing and most admired private sector group for OIL GAS and Petrochemicals.

Growth Path in IPCL:

Joined as Trainee in 1984, (IPCL, Vadodara Complex) and got two promotions in 1989 and 1993.

Promoted as Maintenance Engineer in Sept.1996 (IPCL, Maharashtra Gas Cracker Complex – MGCC).

Promoted as Senior Maintenance Engineer in Dec 2000, Deputy Manager in July 2003 & Maintenance Manager (Mechanical) in Sep 2005 to January 2007.

Maintenance Handled in the following plants:

1-GAS CRACKER PLANT (GC) and Power Plant’s Boilers.


Worked using SAP Plant Maintenance Module – helped configure B2E maintenance management systems

Managed complete plant maintenance for Gas Cracker and Polypropylene plants.

Developed and executed comprehensive Annual Plant Shutdown Plan.

Established Maintenance Contracts to ensure sufficient manpower during high workload time periods.

Supervised boiler maintenance with Site Operations Manager and IBR Inspectors

Coordinated with Safety Engineers to ensure proper Compliance with HSE policies and ISO regulations.

Hands on experience of maintaining varieties of Rotary and Static plant equipment,

Plant Maintenance: Responsibilities:

Determine maintenance schedules, sequences, and assignments for work activities, based on work priority, quantity of equipment and skill of personnel. Develop, implement, and evaluate maintenance policies and procedures. Coordination with various internal departments like RMC, Fire and Safety, C & I for the maintenance activities

Monitor employees' work levels and review work performance as per KPI. Counsel employees about work & safety related issues and assist employees to correct job-skill deficiencies. Conduct or arrange for worker training in safety, repair and maintenance techniques, operational procedures, or equipment use.

Monitor tools and parts inventories and the condition and of store to ensure adequate working conditions.

Investigate accidents and injuries, and prepare reports of findings.

Recommend or initiate personnel actions, such as hires, promotions, transfers, discharges, and disciplinary measures. Compile operational and personnel records, such as time and production records, inventory data, repair and maintenance statistics, and test results.

Technical advice for the management of special projects or new assignments in other sections.

Maintenance Purview at IPCL Vadodara and MGCC

Reciprocating and Diaphragm Compressors:

Reciprocating Gas Compressor: Make: Dresser Rand, India. 4 stage, double acting

Diaphragm compressors: Burton Corblin (France), Activities – Complete maintenance and overhauling.

Pumps: All type of maintenance including preventive maintenance, predictive maintenance (condition monitoring) & breakdown maintenance, and complete overhauling of the RC Pumps, CF Pumps, Gear Pumps, Screw Pumps of various brands. The job involves bearing replacement, mechanical seal development/ replacement (single and double seal), alignment.

Extruder: Make: W & P. Germany. Model: ZSK 220 Capacity: 15 MT/Hr. Screws: Intermeshing Twin Screw/Die Plate: Insulated with Oil Heating and steam heating.

Dryer: Make: Gala. The activity involves complete overhauling.

Agitator: Maintenance of Mechanical Seal and gearbox of different make of agitators like Miscenard –Quint France, samic Italy, and standard engg. India etc.

Blowers: The overhauling of centrifugal blowers & lobe type rotary blowers from M/s Arzener, M/s Waeschle, Germany, Hibon

Rotary Valves: Overhauling of Rotary valves, feeders, multi way feeders & other equipment of Waeschle and Buhler pneumatic conveying system.

Bagging lines and Palletizers Machines: Make: Moller, Gmbh: Model: EZ3 & EZ 4/Capacity: 15 tons /hr

The complete overhauling of vibrating screens, weighing machines, bagging machines, belt conveying & palletizer section. Also done the Erection & commissioning of bagging machine.

REACTOR (High Pressure): Fluidized bed reactor of L Max working pressure 24 bars Polymer Reactor Circulation Pump of Polypropylene Plant.

Make: David Brown, U.K. /Model: 24x24 HLTE. Operating parameters: Liquid Propylene: 33 KG. / g at 70 DEG.C. Sealing: Triple Mechanical seal (John Crane Make), Complete overhauling of David brown pump and de-laval compressor.


Heat Exchangers: Fixed head, floating head shell & Tube exchangers, Plate type exchanger, Double pipe type exchangers. Job involves hydro test of shell and tube side, hydro jetting, complete overhauling & reconditioning, including replacement of tube sheet.

Other static equipment with extensive maintenance carried out is: High pressure, MP, LP Vessels, Silo, Dryer and storage tanks. Cooling Tower operation and maintenance. Medium pressure /low pressure Filters/High pressure/ low pressure Piping and structures and steam traps. Hydraulic / manual operated valves maintenance, Safety valves and Rupture discs,.

Vapor Compression Refrigeration Package System.

Boiler Maintenance: Maintenance of Gas Fired and Oil Fired boilers and accessories.

Field Fabrication Jobs and Workshop jobs:

Fabrication, welding and Machining jobs related to regular Plant Maintenance, preventive and break down maintenance, in the Central Work shop.


Promote accident prevention and safety awareness by conducting pre-shift briefings, job safety audits, lockout/tag out compliance and accident investigations as needed.

Provide direct supervision of union represented employees to ensure safety, company policy and contract compliance and schedule compliance.

Responsible for making sound, timely decisions with little or no supervision.

Follow quality control procedures including ISO 9001 requirements and monitor shop personnel for quality procedure compliance.

Track personnel Fire and safety and equipment training to ensure timely completion.

Perform housekeeping assessments, assure shift cleaning and housekeeping assignments are completed, and direct work assignments to maintain acceptable shop conditions.

Participate in a team environment to develop work scopes, resource allocations and schedules in conjunction with the work management procedures, Process Specialists and Station Management.

Assist specialists like RMC or Corrosion & Inspection department with root cause analysis on component failures.

Supervise projects at multiple work locations, plans, directs, and monitor maintenance work to assure the most efficient/effective use of company resources and the timely completion of projects within the budget.

If required, control Capital/O&M project(s) and budgets within the incumbent’s scope of responsibility and monitor expenditures to ensure cost effectiveness and predictable cash flow.

Perform special assignments within the incumbent’s areas of responsibility.

Supervise employees to protect tooling, vehicles, equipment, and facilities assigned to the department.

Establish the highest standards of business conduct, discipline, and ethical behavior to insure continuing compliance with company policies and procedures.

Coordinate contractor activities as required.

Responsible for the inspection of QA materials received through stores.

Responsible for the procurement of work related materials that are not commonly stocked items.

Materials Inspection:

Visual, Dimensional Inspection, MTC review and lab testing of the engineering items like pipes, pipe fittings, flanges, valves, fasteners, bearings, rubber items, steam, air and water hoses, mechanical seals, pumps, vessels and all other items purchased by the company.

Knowledge of various material testing and dimension standards like ASTM, ANSI, BS, ISI, IBR, TEMA. and other standards related to manufacturing and inspection of engineering items. Various ferrous and non-ferrous engineering materials and relevant ASTM and ANSI standards, Hydro and Pneumatic Testing of valves body and Seat. Can use the measuring instruments like veneer caliper, micrometer, bore gauge, thread gauge, filler gauge, ring gauge, hardness tester, thickness gauge etc.

Seminars & Trainings

Several seminars and short training programs for Supply Chain Management, Inventory Control, SIX SIGMA, ISO 9000, personality development, safety, finance etc.

Trained for Operation & Maintenance of Mechanical Seals by EPIL, Pune. Assembly, operation, and maintenance of reciprocating gas compressors at Ingersoll Rand (Dresser Rand) at Naroda, Ahmedabad.

Fire and safety hazard management, at IPCL.

H2S training at PDO.

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