Power Plant Maintenance

T.S.R. MAHESH KUMAR

M.Tech -Electrical

Contact: ****-***** *****/944**-*****

E-mail: *******@*****.***;**********@*****.***

In quest of a senior management positions in maintenance management,

reliability centered maintenance,risk management,maintenance

planning,project management, Business analysys,Solution Architect-SAP

template implementation in Power plant, process, IT industries

Profile

Proven Expertise Superior Project life cycle Management,maintenance and

Operation and Maintenance production Planning,Team management, techno commercial

with excellent budget operation, Heading the business unit,business analysis and

controls. Industry best practices implementation through SAP,Asset

Reliability centered management, Reliability centered maintenance & spare

maintenance an spare otimization,peraion risk management,Quality Management &

optiiztion Client Service Acumen. Professional with over 23 years of

Reliability,Availability experience with wide international exposure in client

Maintainability analysis interaction, onsite operational and technical

Operatonal risk coordination

management and LOTO Experience includes:

implementation Project life cycle management of power and utility plants

SAP best practice over 1000 MW

template implementation Heading a business unit with industry best( operaton,

Project Management, maintenance and OSHE) practices under excellent budget

Erection commissioning of controls

power plants equipments. Excellent maintenance planing with proven SAP /CMMS

O&M planning software skills

Business Implementation of Reliability centered maintenance and

analysis&solution spares optimization

architechture. Experience in Reliablity Availability and Maintainability

Client interaction. (RAM)analysis, FMEA, RCFA,Asset reliability planning

Project Reviews, reports Maintenance management of Power and desalination R.O

and course correction. plants

Integrated management Implementation of Enterprise Asset management

system implementation Capacity Selection of equipments, techno commercial

6 Sigma, 5S, Kaizen, Poka discussion, procurements and contract dealings.

Yoke, OEE & RCM. Businss analysis,system architecturing, Five end to end

RCFA,FMEA,Fish bone SAP best practices Template Project implementation for all

analysis, Cause and business processes of Power and utility industries.

Effect Matrix, Why-Why Master in plant maintenance,work clearance module

analysis, Pareto charts. implementation from client end.

PDCA cycle to meet Fully conversant with ASAP methodology like,BBP,UAT,end

quality standards. user training,golive checks etc.

Administration, P&L Corporate Production and maintenance planning

management. Task risk assessment(HAZOP,HAZID,HAZRAS,HADRC),condition

SAP Project monitoring, predictive maintenance concepts, 6 Sigma and

implementation FICO,SD, 5S strategies.

MM, WM, EHS, HCM, PM,WCM,

PP,QM,DMS,BI-BW,PS

MS Projects,MS office,MS Significant Achievements

power point

Excellent Presentation NOMAC: First National Operation and Maintenance

skills Company-Jeddah-KSA

Inventory ABC analysis, Best handled Maintenance manager role of power and

control and cost desalination Barge plant

mitigation. Played project manager role to Implement Reiability

Excellent workshop centered maintenance and spares optimization for all

conducting skills projects of NOMAC.

Team Management through Optimized the task lists and Maintenance plans as per

Mentor Mentee principles FMEA data

& Leadership. Formulated Task Risk Analysis forms,conducted workshops

Training and development. to identify O&M activity risks and Implemented LOTO

system based on the task risk analysis output through

MIS & businesses SAP-WCM(Work clearance Management) module

reporting Handled proect manager role in Implementing SAP Plant

KPI & Objective Maintenance Module for effective maintenance processes

analytical ability Established Hazard Identifiction Risk Assessment and Risk

Control (HIRRC) and Aspect Impact Assessment to make the

Credentials plant industrially higene and environmentally friendly.

M. Tech -Power systems Established excellent condition monitoring and predictive

NIT- Warangal, India maintenance practices to increase the plant availability

B. Tech in Electrical & Established Centralized procurement and contract services

Electronics through service master to ensure the maintainability

VRSEC, Vijayawada,India Managed the Maintenance and production planning with

Note: consistently passed proven SAP/CMMS software skills

all exams with VEDANTA ALUMINIUM LIMITED:

distinction. Successfully commissioned 9 units of power plant

Training equipments.

General Management Headed the maintenance planning departments and

programme - 30 days in implemented Reliability centered Maintenance across power

XLRI-Jemshedpur-India plant

Finance for Non Finance Effectively Managed the plant Maintenance with proven

IOSH managing safely SAP/CMMS software skills

HR for Non HR Commissioned 220 KV switchyard, Boiler, Turbine generator,

Mentor Mentoring Generator HV/LV Transformer and offsite equipments - Coal

Six -Sigma by Wipro Handling Plant,Ash handling, DG sets, cooling towers,

TPM training PCC's & MCC's. as per the qualitative protocol

5-S Conceptual training Implemented the composite grid islanding and load

Reliability centered management system to avoid power black outs during grid

Maintenance conceptual disturbances.

training by GE, Meridium Established grid islanding and load management settings

SAP End user trainings. after extensive studies through RTDS( real time dgital

PLC and AC /DC drives by simulation) in Central power research Institute.

Siemens,ABB,schnider Established Hot line maintenance on 220 KV transmission

PMP Certificaton Training lines to reduce the plant shutdowns and increase plant

Availability.

Implemented risk assessment(HAZOP,HAZID,HAZRAS,HADRC) for

all power plant business operations and implemented the

risk controls through LOTO system.

Accomplished industrially Hiegiene in all areas of power

plant by implementing HIRARC

Implemented and Established the reliabiliy centered

maintenance and optimized the preventive /predective

/condition monitoring plans

Reduced the capital,maitenance expendeture by 20,12%

respectively with RCM spare optimization.

Reviewed and updated the maintenance procedures as per the

reliabiliy scores and FMEA data.

Achieved a plant scheduled availability of 99.98 % two

years consecutively .

Implemented the SAP-PM-WCM module and established task

risk management

Achieved a plant availbility for 748 days with out lost

time injury by implementing OHSAS stndards.

Implemeted process efficiency programs like kaizen,pokayoke

BALCO CAPTIVE POWER PLANT

Heading a business unit wth Best world class O&M, SHE

practices

Headed the maintenance planning departments and

implemented Reliability centered Maintenance across power

plant and improved the plant reliability by 27%

Excellent knowedge of handling Busines unit P&L figures

Managed the Maintenance and production planning with

proven SAP/CMMS software skills

Accomplished plant monthly PLF of 105 % and 98% yearly

PLF by implementing OEE concepts.

Implemented GE-RCM concepts across the plant and increased

the lant availabilityby by 27% and reduced th operational

spares expendture by 13%.

Ensured the BTG availability 99.999 limiting maximum

unscheduled outage period to 45 hrs for 4 units.

Implemented Pokayoke concepts and mitigated operational

unwanted mistakes.

Implemented 5S in three phases and reduced many occupional

and safety hazards.

Implemented 6-Sigma in 2 phases and improved the

operational efficiency of Boiler,turbine,coal handling,ash handling plants

Reduced the boiler tube leakages due to ash erosion from

60 to 20 per year.

Reduced Turbine - generator overhauling time to 9 days 2

hrs against previous record of 13 days by identification

of potential time saving activities & adoption of SMED

techniques and MS Project.

30 MW generation increase within 1 year with Over all

equipment effectiveness analysis(OEE).

Reduced the overall store inventory by 8%.by VED and ABC

analysis techniques.

Implemented GRID islanding & load management scheme to

save 300 Crores in potential damages.

Carried out HIRARC and Aspect impact studies and

established indusrial hygine all over the plant.

Carried out O&M activity risk assessment and implemented

the SAP PM-WCM module to ensure proper safety in all O&M

activities.

Received many cash awards for the outstanding performance

thorugh

out the carreer.

STERLITE INDUSTRIES LTD

Headed the Operaton and maintenance of Utilities of 250000

FKM plant

Headed the maintenance and production planning departments

and implemented Reliability centered Maintenance across

power plant

Managed the Maintenance and production planning with

proven SAP/CMMS software skills

Recognized as "star" performer of Sterile group through

ACT-UP to work

in BALCO after Sterlite acquired shares and management

control

Erected, commissioned and tested all utility equipments of

250,000 LFKM expansion.

Mitigated the per unit generation cost by Key Energy

conservation projects like power factor improvement

projects, and utilization of waste heat from 6 MVA DG set

by implementing the VAM Chillers & conversion of HSD based

DG sets to Super LDO based sets.

Implemented many innovative projects like electrostatic

filteration

system to achieve cl.10,000 system in the fibre

manufacturing plant in place of traditional HVAC system

Core Competencies

Operation & Maintenance

. Effective Maintenance planning techniques with reliability cantered

maintenance concepts

. Effective execution of maintenance processes like, corrective,

preventive, breakdown, calibration, condition monitoring, condition

based maintenance, reliability cantered, refurbishment maintenance,

overhauling maintenance with optimum spares planning & execution of

maintenance activities with proper spare planning

. Effective maintenance history data up keeping through SAP ECC 6.0.

. Total plant maintenance performance monitoring using advanced software

like SAP ECC 6.0

. Optimum Budgeting, & execution of Overhauls of power plants with

advanced software like SAP project systems.

. Ensuring the plant machine availability close to 100 % with proper

preventive, condition monitoring & maintenance .

. Preparation of maintenance budgets and budget tracking & executing

cost saving, energy saving techniques/measures and modifications to

achieve substantial reduction in O&M Expenditures and work within the

budget

. Expert in new generation maintenance and improvement techniques like six

sigma, kaizen, fault analysis techniques; Over all equipment

effectiveness, asset optimization concepts.

. Project leader in implementation of SAP ECC 6.0 for all business

processes of power plant.

Production Planning

. Preparation of well achievable Business / production plans.

. Planning of Raw Material, resources, close follow up in up-keeping of

generating equipments to plan for maximum utilization in available

period.

. Close follow up with operations team, various types of analysis reports

to increase the utilization factor.

. Preparation Variance analysis reports with plan Vs Actual productions

and variance in raw material consumption, reasons wise breakups.

. Facilitation of operations people to improve the productions with new

generation concepts like, over all equipment effectiveness, capacity

gap analysis, Asset optimization concepts.

. Preparation of optimum and well executable maintenance plans to achieve

best availability factor.

. Generation of maintenance and production performance reports.

. Generation of maintenance analysis reports to guide the maintenance

teams in right direction.

. Effective Maintenance planning techniques with reliability cantered

maintenance concepts

EPC-Project Management

. Played a key role in project life cycle management of 1215 MW power

plant

. Evaluation of bidding documents and the scope of supply and advising for

the necessary corrections.

. Leading the project activities to ensure completion of project within

the time frame & cost parameters and effective resource utilization to

accelerate the project progress.

. Leading a team of engineers for various types of job and evaluating

project progress, through MS-Project

. Preparation of projections of expenses, Managing cash flow and cash

control, Project bill settlements.

. Involving in the Installation, testing & commissioning activities of

various plant equipments and analysing the commissioning results and

taking up necessary corrections from EPC.

Quality Assurance

. Preparation of quality,environmental, health safety policies,

procedures, work instructions as per ISO standards

. Implementation of ISO standards through renowned ERP system -SAP-ECC6.0

.

. Fair experience in Implementing ISO QMS, EMS, OSHAS.

. Team leader in 2 certification audits and 7 surveillance audits of ISO

9001,14001 and 18001 for power plants.

Techno Commercial Operations

. Evaluation of power plant,Bidding documents for cost effectiveness

. Taking care of all the tender works from offer phase to till payment to

vendor.

. Tapping /identifying new projects, preparing/submitting the proposals

for the smooth movement of operations.

. Good knowledge in Scope of work preparation and cost benefit analysis of

the projects identified and payback calculations after project

implementation .

Team Management

. Excellent team building strengths and completing the job by motivating

the teams.

. Good knowledge in Setting up skill set, scheduled skills evaluation,

identifying training needs & organizing OJT.

. Organising of mentor-mentee couples, to ensure optimum performance and

increase the employee retention period.

. Maintaining cordial relations with all legal authorities and also

within the organisation through initiating settlement proceedings and

enabling employees to voice their opinion on a common platform.

ERP(SAP-ECC-6.0) Software Implementation & Utilization

. As business analyst& Project leader mapped all the world best business

processes of power and water plant through SAP-ECC6.0

. First organization in the KSA to implement all power plant business

processes through SAP and ensure full utilization by all employees

across the organization.

. played business analyst/solution architect/project Manager role in 5 end

to end implementations in 11 functional modules.

. Successfully mapped and implemented SAP functional modules - Plant

maintenance and work clearance management (PM-WCM), Quality

management(QM),Environmental health safety (EHS)

. Making use of 20 years of functionalexperience well defined the

Enterprise Asset organization Structure, Functional locations,

equipment, classification, Classes & Characteristics, work centers, BOM,

measuring points, inspection routes, counters and object types

. Well defined Notification & Work Order Processing for Corrective,

Preventive,break down,condition monitoring condition based

maintenance,calibration order,refurbishment modification, inspection of

lifting tools and tackles and ressure vessels,modification processes,

overhauling /unit outage planning with proper budget control in project

systems. Implementation of Task Risk assessment and Risk based

maintenance

. Formulated the Task Risk Analysis forms and conducted workshops to

analyse operational and maintenance risks involved.

. Implemented the Lock Out Tag Out system through SAP-WCM (Work Clearance

Management ) Module based on the Task Risk Analysis work shops

. Carried out Centralized Maintenance planning for the different projects

of an organization and optimized the maintenance Plans Through RCM

. Effective resource utilization through SAP-ECC 6.0

RCM-Reliability Centered maintenance Implementation

. Project leader in implementing the Reliability Centered maintenance and

spares optimization concepts through SAP-ECC6.0 across all power plants

of NOMAC.

. Good knowledge of reliablity enginering methdologies and cocepts.

. Through knowledge in Reliability availability maintainability (RAM)

analysis

. Maintenance Spares optimization as per the reliability matrix scores.

. Excellent workhop conducting skills to formulate reliability matrix

. Excellent workhop conducting skills to get Equpment Failure modes and

mitigation plan data as per the reliability scores

. Tracking of availability of the equipments as per the reliability scores

. Good knowledge of failure analysis techniques like Rootcause falure

analyis,cause ad effect matrix,fishbone analysis

. Review &Optimization of maintenance strategies as per the reliability

scores.

. Tracking of maintainability of the individual equipmens as per the

reliability score

. Preparation of budget for the emergency spares and required

modifications and controls as per the Reliability matrix.

. Review and upgrading of of preventive, predictive and condition

monitoring maintenance plans as per the reliability scores.

. Analysis of MeanTime BetweenFailure (MTBF)and MeanTime To Repair

(MTTR)reports and improving the condition monitoring.

. Formulated the Task Risk Analysis forms and conducted workshops to

analyse operational and maintenance risks involved .

. Implemented the Lock Out Tag Out(LOTO)system through SAP-WCM (Work

Clearance Management ) Module based on the Task Risk Analysis work shops

. Through knowledge and implementation of Industrial Hygiene (HIRARC) /

Environmental Aspect impact /Occupational health and safety /waste

management in SAP-EHS module for any Organization. Certified by

Institution of Occupational safety and health-IOSH

ERM-Enerprise Risk Management:

. Project leader in implementing risk management concepts

. Preparation of risk register covering operational, Envirometal,health

safety,production,maintenance task risks,supply chain,

financial,contractual,legal,stakeholders risks for all business

functions of the organization.

. Formulation of dependent risks and Evaluaton of the risks based on risk

ratings

. Conducting f workshops for Root cause analysis and identifying controls

for mitigation of the risk to acceptable range

. Identifying the residual risks

. Monitoring the risk controls through reports and presentations to the

Executive board

Technical Expertise

. Captive power plants ? PF fired Boiler ? 135 MW Turbo generator,220/11 KV Generator Transformer and offsite equipments ? Coal Handling

Plant ?Ash handling,? DG sets ? cooling towers? HT/LT Motors,HT/LT

switchgear,PCC's & MCC's.

. 220 KV,33,11 KV Switch yards and associated equipments ? transmission

lines ? HSD based DG sets ? Super LDO based sets (11X400 KVA) UPS system

(Invensys make) along with associated back up battery (2500 AH) system

. HVAC system: Air handling units, Blue star ? Voltas make 500 TR

centrifugal ? 125/250 TR reciprocating chillers ?, class100 / class

10,000 systems ? 240TR VAM chillers

. Scrubber / DM water/soft water plants: Thermax culligan make ?gas

scrubbing plant ? Ion Exchange make soft water plant

. Fire alrm systems,Fire rotection systems,PAsystems

. Compressors/Air driers: Kirlosker ?GEC ? Khosla make compressors

. Diesel generator sets of Cumins, Detroit,caterpillar, Wartsila

. AC/DC ? Regenerative ? Non-regenerative ? Drives of Siemens/ABB ? PLC's

of Siemens/ABB ? Substation equipments ? HT/LT switchgear ?LT/HT Motors

up 2000HP control systems of Oil fired Boilers? DG sets ?Wartsila-ABB

make multiple 6 MVA ?,HFO based sets ? AVR systems Grid synchronization

? SCADA system and load shedding system

KRAs and KPIs across career span

. Handling the O&M,SHE,procurement, logistics,P&L,Human capial

management,legal,contracts of the plant as business unit head

. Erect Test, Commission, Operate and Hand over completed projects.

. Manage end to end implementation of SAP PM-WCM,QM,EHS

. Establish Reliability centre maintenance and spares optimization (RCMO)

. Commission units of power plant electrical, i.e., commissioning of 220

KV switchyard, Boiler, Turbine generator, Generator Transformer and

offsite equipments like, Coal Handling Plant,Ash handling, DG sets,

cooling towers, PCC's & MCC's.

. Review performance at the appropriate level and frequency to ensure

effective control of project budgets.

. Carry out energy conservation projects in the plant like power factor

improvement, improvement of cooling tower efficiencies, installation of

vapour absorption chillers, electrostatic filtration system.

. Draw up business plans, optimize resources, drive process utilization &

adherence to environmental regulations.

. Handle business plan preparation, power plant operation, process and

resource optimization

. Review of P&L and variances reports and initiat course corrections where

required.

. Identify the business risks, operation show stoppers and preparing the

action plan to run the business smoothly.

. Ensure Hazard identification, risk assessment and establish risk

control measures.

. Undertake initiatives like 6 sigma, OEE, Asset optimization & RCM,

Kaizen, Poka Yoke, 5 S to sustain high availability

. Conduct environmental aspect impact assessment implement and establish

control measures to reduce the impact to comply with environmental acts.

. Manage motivate and train project teams to deliver quality servces.

. Handle internal training programmes like Finance for Non finance, HR for

Non HR, change management & commercial for Non commercial thereby

identifying the individual potentials and aspirations to develop them as

business partners.

. Quarterly review of the the performance of the employees

. Oversee corporate production and maintenance planning .

. Drive implementation of Best operation & maintenance practices across

the group power & water companies

. Maintenance, repairs and overhauling Power plant units as per scheduled

plan.

. Proper preventive, condition monitoring, reliability centred maintenance

practices implementation and establishement to increase the equipment

availability and reduce the shutdowns.

. Handling of Centralized contract services.

. Material requirement Plan and monitor procurement process included RFI

and RFQ packages.

. Check, test the QC (quality control) and endorse the QA (quality

assurance) report.

. Preare and establish procedure to monitor and improve contractors

erformance

. Inspect the work of EPC contractors & subcontractors to ensure quality

and that it was up to required standards.

Career History

SEP'1999-MAR'2009

Head Maintenance - VEDANTA ALUMINIUM LIMITED -

. Managed commissioning of power projects, equipment testing, handle

contractors and service providers

. Managed the O & M of 9X 135 MW power plant/ash handling/coal handling

plant/balance of plant /220 V swith yard equipments

Head Operation & Maintenance - BALCO (Bharat aluminum company) Captive

Power Plant - Korba, Chhattisgarh

. Handled business plan preparation, power plant operation and maintenance, process and resource optimization

HEAD OPERATION AND MAINTENANCE- Utilities - STERLITE INDUSTRIES LTD-

Aurangabad

. Head maintenance of equipment and utilities

Early Career

1992-1999 - Sr. Engineer (Maintenance) - M.R.F. Ltd - Sadasivpet, Hyderabad

1991-'92 - Project Assistant - Western Regional Electricity Board-Mumbai

Personal Details

Date of Birth : 8th July 1969

Languages : English, Hindi, Telugu

Passport No : H 0547048 - ( expiry: 03/09/2018)

Notice period : Immediate

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