Maintenance of chemical factories/Execution of Projects, piping
Resume:
V CHANDRAMOULY
Mobile: 096******** ~ Tel: 040-******** ~ E Mail: ************.******@*****.***
Aiming for senior level assignments in Projects / Maintenance with a growth oriented organisation in
Chemicals /Petrochemicals/ Power / Pharmaceuticals sectors.
Career Overview
A result oriented professional with 20 years of qualitative experience in Project Management and Maintenance management
in Chemical Industries. Presently serving M/S TCI Sanmarchemicals SAE,Portsaid, EGYPT as Senior Manager –
Maintenance and Projects. Proven abilities in enhancing production process operations, project execution, optimising
resource & capacity utilisation, escalating productivity & operational efficiencies; while curtailing costs & expenses. A leader
with strong skills in taking process improvement and cost reduction initiatives, project execution and implementing quality
systems for enhancing plant efficiency. Effective communicator & negotiator with strong analytical, problem solving &
organisational abilities. Knowledge of quality control and quality assurances norms and procedures as per standards;
upgraded ISO:9002:1994 system to ISO: 9001: 2000 quality system.
Areas of Expertise
Project Management
Managing activities right from the conceptualization stage to the execution; involving finalization of technical
specifications, store management & inventory control, scheduling, progress monitoring, site management and manpower
planning.
Establishing project review, monitoring and status reporting procedures to accurately report progress of the project to the
stakeholders and end user clients.
Handling activities involving working out various requirements & monitoring overall project operations for ensuring timely
completion within the budget.
Monitoring the activity at sites and review of project schedule, ensuring cost control within budget, planning for cash flow
requirements, etc.
Erection, Commissioning of Process plant equipment, Utilities equipment of chemical industries.
Operations & Maintenance
Identifying areas of obstruction/breakdowns and take steps to prevent/correct the anomalies of equipments through
application of trouble shooting tools.
Scheduling and planning predictive, preventive maintenance for process plants/utilities systems to improve the overall
reliability, availability of equipment for production use.
Monitoring plans/schedules to start maintenance activities and achieve plant targets, implementing maintenance
systems.
Preparing annual maintenance budget, planning for procurement and stocking of critical spares and consumables.
Undertaking repairs, refurbishment & overhauling of plant and machinery to improve its operational efficiencies and
reliability.
Maintaining and reviewing history records of key machines for repeated breakdowns to analyse and carry out necessary
preventive/corrective actions.
Organising activities for continual improvement & working towards cost reduction activities.
Man Management
Directing and leading the technical personnel. Imparting continuous on job training to the workforce for accomplishing
greater operational effectiveness / efficiency.
Working on talent pool and succession planning of the management cadre and workforce, appraising their KRA based
performance and providing feedback on the same.
Major Equipment handled
Process plant equipment:
• Reactors (GLRs, SS reactors, brick line reactors, rubber line) with/without mechanical seals
• Condensers, Heat exchangers, Columns.
• Tanks and weighing systems, Vessels.
• High Vacuum Distillation Systems, water/oil ring vacuum pumps.
• Hot oil systems, storage tanks.
• Centrifugal pumps with/without mechanical seals, AODD, metering and screw pumps.
• Spray driers, Centrifuges, rotary driers, pulverisers, micronisers.
• Belt conveyers, screw conveyers and bucket elevators.
• Packing machines.
• All glass systems, graphite exchangers, ejector systems.
Utility equipment:
• Cooling towers and accessories
• Water softeners, DM water/RO systems
• Steam boilers(oil fired and coal fired)
• Chilled water/Brine compressors
• Compressed air systems
• Dehumidification systems
Major Projects Handled
•
Project : Planning and Execution of 100meter steel chimney
• Synopsis : Planning, safe and successful execution of fabrication and erection of double skinned steel chimney
designed by (M/S Oomes Ittner of Germany) of 100meters height, 250tonnes weight and 4600mmx3200mm
diameter for the glass furnace within 120 days at a budgeted cost of INR 4,00,00,000.
•
Project : Development of local vendor for design fabrication of material handling systems
• Synopsis: Identifying, development of local vendor for successful fabrication and erection of bucket elevators, belt
conveyers’ equivalent to the design of M/S Zippe of Germany. It resulted in saving of INR 20,00,000.
•
•
Project : Refurbishment of existing utilities for energy conservation
• Synopsis: Replaced the existing pumps by selecting high efficiency pumps thereby considerable power saving is
achieved. Redesigned and replaced the existing water headers to reduce the pressure loss and conserve the
energy.
•
•
Project
: Effluent Treatment Plant
• Synopsis : This project aims at treatment of plant effluent water to pollution control norms of discharge of
effluent water on land. It also aims at achieving the global policy towards adherence of Statutory/Regulatory norms
of the region.
•
•
Project
: Modification of existing plant and machinery for enhancement of production capacity
• Synopsis : Addition of new utilities to suit capacity enhancement and production of new range of products.
•
•
Project
: Fabrication, erection and commissioning of 60KTA Ethylene plant
• Synopsis: Fabrication, erection and commissioning of 60KTA Ethylene plant in a short span of 16 months. Since
April 2014 the plant is in continuous operation.
• The Process Designer – M/s Scientific Designs, USA.
• Detail Engineering Consultant – M/s IBIC Chematur, Mumbai, India.
Employment Scan
M/s TCI Sanmar Chemicals SAE,Port Said,Egypt, Senior Manager Engineering since May ‘13
Chief Responsibilities:
Review of P&I diagrams, UI diagrams, piping isometrics related to the project.
Cross checking the specifications of rotary and stationary equipment for finalizing the TOS before releasing it to the
vendors
Coordinating with the Detail Engineering Contractor to review the stage wise progress of fabricated equipment and
probable date of dispatch. It involves joint inspection also.
Follow up with the contractors for timely completion of foundations for equipment, structures.
Estimation of BOM of piping and piping items, finalizing the welding procedures, stage wise inspection procedures as
per the guidelines of the Detail Engineering contractors.
Control of piping fabrication progress, inspection, hydraulic testing.
Strict adherence of implementation of various safety permits during fabrication, erection and commissioning activities.
Convening daily meetings with contractors, consultants and suppliers to review the progress, identifying the bottlenecks
and resolving them so that the work will flow as scheduled.
To prepare reports and take part in corporate progress review meetings.
To cross check the bills submitted by various contractors for actual measurements, work completion. To raise necessary
service entries in SAP.
Commissioning of utilities and storage vessels, process equipment and piping.
Tuning of equipment to suit process requirements at various loads.
Monitoring of equipment for their efficiencies and reliability.
Preparing preventive and predictive maintenance schedules for all equipment in coordination with Production
Department and OEM guidelines.
Listing out the spares required, preparing a budget for procurement of spares and follow up for subsequent release of
necessary PO.
Implementation of preventive and predictive maintenance schedules to improve the reliability of equipment.
To plan and schedule the necessary modifications in coordination with Production department to improve the operating
conditions.
Notable Attainments:
Planning, scheduling and execution of 60 KTA Ethylene from Ethyl Alcohol project in a short span of 16 months. It
involves
• Fabrication and erection of 658 MT of equipment, structurals and pipe racks
• Fabrication of SS piping 30,000 inch diameter of various sizes
• Fabrication of CS piping – 62,500 inch diameter of various sizes
• Erection commissioning of Centrifugal compressor Ethylene Gas, make M/s Atlas Copco, 1.3MW, 6.6KV
• Erection commissioning of Screw Compressor – Ethylene Refrigeration, make M/s Austcold,
0.9MW,6.6KV
• Fabrication, erection and commissioning of 10,000 KL Ethanol Storage tank.
• Commissioning and successful maintenance of 60KTA Ethylene plant since April 2014.
AGI Glaspac., Hyderabad
Senior
Manager – Projects From April ‘11 to April ‘13
Chief Responsibilities:
Developing P&I diagrams necessary for the project in co ordination with Production, Technical services.
Preparing the budget estimates, technical specifications.
Floating enquiries, evaluation of vendors by analyzing the capabilities of them.
Preparing and review of project schedules at regular intervals
Follow up with vendors for ensuring quality work, timely delivery within the stipulated budget.
Inspection of equipments at different stages and attending to the performance runs conducted by supplier.
Planning for the execution of Preparatory works necessary for erection of equipments.
Erection of equipments, fabrication of connected piping and other utilities by complying to statutory requirements.
Testing and commissioning of equipments/systems
Documentation of all the related activities and collection of O&M manuals from suppliers.
Handing over of the project after successful run of the systems/equipments to operating departments.
Evaluation of the operating efficiency, consistency of equipments against the design parameters in co ordination with the
operating department.
Notable Attainments:
Planning, safe and successful execution of fabrication and erection of double skinned steel chimney designed by ( M/S
Oomes Ittner of Germany) of 100meters height, 250tonnes weight and 4600mmx3200mm diameter for the glass
furnace within 120 days at a budgeted cost of INR 4,00,00,000.
Identifying, development of local vendor for successful fabrication and erection of bucket elevators, belt conveyers’
equivalent to the design of M/S Zippe of Germany. It resulted in saving of INR 20,00,000.
TFL Quinn India Pvt. Ltd., Hyderabad, Manager – Maintenance Sep’03 – Mar ‘11
Chief Responsibilities:
Spearheading initiatives for planning and execution of all maintenance related activities, preparing annual maintenance
plans and budget.
Responsible for execution of projects for new processes and refurbishment projects for old plants.
Preparing P&I diagrams for new processes in consultation with production people.
Identifying of unsafe conditions / practices and improving to safe work environments.
Ensuring implementation of ISO 9000 in engineering departments and focusing on reducing the breakdown time by
implementation of preventive maintenance.
Planning AMC’s from external service providers.
Notable Attainments:
Demonstrated abilities in achieving rated capacity utilisation, improving the reliability of O&M of spray driers which
resulted in increased productivity by more than 40% and savings of about 1 million per year.
Anchored erection and commissioning of new equipment and facilities to suit production of new range of products worth
Rs. 10 Crores project cost.
Undertook planning, selection and procurement of new chilled water plants of 2 x 55 tons capacity and successfully
completed erections and commissioning in a record time of 45 days.
Achieved the reductions in break downs from 6% to 3% by effective implementation of preventive and predective
maintenance practices.
Siris crop sciences limited.,Gummadidala, Medak Dt Manager – Maintenance Jul ’03 – Sep ‘03
Chief responsibilities:
Planning execution of reconditioning of all plant & Machinery of Chloripyriphos plant
Reconditioning of plant Utilities cooloing towers, Chilling plants, Boiler, Nitrogen plant
Notable attainments:
Chloripyriphos plant was completely overhauled in a record time of 45 days
All Utilities were Streamlined in 30 Days.
Parsin Chemicals Ltd., Hyderabad Manager Maintenance Mar’99–june’03
Chief Responsibilities:
Steering a gamut of tasks entailing implementation of processes for energy conservation, cost reductions, complying the
audit findings
Improving dust extraction system by strict implementation of preventive maintenance schedules.
Planning and inspecting blenders at regular intervals for safe work environments resulted in increased productivity (from
65 MT / month to 100 MT / month).
Notable Attainments:
Registered reductions in fuel consumption of boilers by heat recovery from condensate and proper tuning of burner
resulted in savings of Rs 65000 / per year continuosly for 3.5 years.
Executed in house modification of existing equipment to develop and produce new products.
Developed quality systems, which resulted in certification of ISO – 9000 in the year 2000.
Successfully recduced of breakdowns from 8% to 4% by effective implementation of preventive and predective
maintenance practices.
Bakelite Hylum Ltd., Hyderabad Assistant Manager Engineering Dec’96–Mar’99
Chief Responsibilities:
Supervising mechanical maintenance activities of utilities and resin plant.
Identifying necessary spares required; raised procurement requests, followed up for purchase.
Allocating work to all subordinates, coordinating with all concerned for safe and timely execution of maintenance works;
also preparing annual maintenance plan.
Taking servicing and overhauling of valves in house.
Notable Attainments:
Executed minor modifications in house, involved internal resources, resulted in substantial savings
Took part in technical discussions for all modifications up gradation; coordinating with all service providers for timely
completion of works.
Conducted energy study at pump house, identified the inefficient pumps and replaced them with new pumps which
resulted in power saving of about 25% and reduced buy back period to 6 months.
Previous Assignments
Jul’95–Dec’96 with Medicorp Technologies, Hyderabad
Assistant Manager
Notable Attainments:
Erected, Maintained the following:
o Existing reactors, GLRs with Mechanical seals, and its condensers, all glass systems, pipings.
38 TR chilling water system, 1 MT/ hr boiler, hot oil system.
o
D.M water system, air compressor, microniser.
o
Handled successful trail production of flucanazole, alprazolum drugs for the first time at Hyderabad.
Aug’92–Jul’95 with VBC Industries, Sri Kakulam, AP
Engineer
Notable Attainments:
Executed the following tasks:
o Safety in erection, resolving site problems.
Pressure test of piping, made trial runs of equipment
o
Commissioning equipment, utility systems like boilers, cooling towers, DM water plants, air compressors, etc.
o
Troubleshooting and resolving the bottle necks of 230 Tons dehumidification system.
o
Identified requirement of spares and procured them.
o
Planned and executed all mechanical maintenance jobs; certified contractor bills for such jobs.
Took part in succesful completion of project worth Rs. 45 crores.
Essayed a key role as in charge for erection, commissioning of Ammonium Nitrate plant and utilities.
Planned and implemented preventive maintenance of AN plant and utilities.
Education
1990 B.E. (Mechanical Engineering) from College of Engineering, Andhra University
Trainings Undergone: Internal Auditor Training Program
Personal Details
Date of Birth : 4 June, 1962
th
Address : Flat 302, Vijaydurga Estates, Block–B, Nizampet Road, Hyderabad–500072
Linguistic Abilities : English, Hindi & Telugu.
Contact this candidate