Total years of experience :25+ years (04 No Green/ Brown Field Project
Resume:
RESUME
CHOKKAPU VENKATA RAMANA E-Mail: ************@*****.**.**
B. Tech (MECH ENGG) ************@**********.***
Mob: +968-********; +968-********
KEY ACHIEVEMENTS
• Total years of experience :25+ years (04 No Green/ Brown Field Projects and multiple Internal up-gradation projects, Operation & Maintenance of Complete Cement plant of different capacities, Capex & Opex Inventory management, KPI, API, IMS management in last 16+ yrs, 06+ Yrs
(Central Govt. Ministry of Defence-India) in Maintenance of Veh/Plant/Eqpt/Local Purchase) and 03+ yrs in Power sector Turbines, Compressors, Pumps (Steam & Gas). Operation & Maintenance:
• Presently Responsible for Maintenance of Complete (Clinkerisation+Grinding) Plant as Head of Sections (Mechanical & Civil) for overall maintenance including Mechanical, workshop & Methods (inspections, Planning & preparation, lubrication) also Co-ordination with Electrical, Instrumentation and automation, civil & utilities.
• One of Kiln Capacity 4000 TPD (Design 4500TPD) M/S Sinoma supplied Kiln achieved 5500TPD by internal Upgradations in Raw Mills-02no (180TPH to 240 TPH), Kiln Feed System & Cooler. Management appreciation with promotion as special achievement of Plant.
• Technology upgradations with modifications in plant for capacity enhancements, optimization of production costs & Reduction in power & heat consumption.
• ERP, SAP & S4HANA Implementation in the plant and maintaining for ease of cost, Inventory controls. Presently working on S4HANA and move from SAP system November 2022.
• Responsible for implementation of H&S standards and advisories in deptt
• Preparation of targets and objectives for deptt & Ensuring achievement of all departmental targets and objectives.
• Preparation for Opex and capex budgets for the deptt and Lean Management.
• KPI Implementation of all levels in the plant for monitoring of performances of personnel
• Operation and Maintenance of newly commissioned 4500TPD plant up to clinkerisation from Jan 2009 to Dec 2009.
• Operation and Maintenance In charge for Cement Mill and Packing Plant from Jan 2010 to Dec 2010.
• Operation and Maintenance of newly commissioned plant 5000TPD clinkerisation and Grinding Unit including Packing plant from Jan 2013 to Apr 2014.
• Quality execution of cement plant Unit-I up-gradation in the field of Preheater Cyclones, 2-stage Kiln Feed Elevator, TA Duct.
• Participation in one-week IMS training and qualified Internal Auditor for IMS system
• Involvement in production & process Optimizations for plant performances Improvement.
• Team leadership for Operation & Maintenance of Clinkerisation and grinding unit section since Jan 2009 to Dec 2010.
• Generation of manufacturing drawings at site for spare turbine rotor with dimensions to reduce import cost. Projects & Developments:
• Presently handling & Implementation of complete line expansion project (Brown Field) of 10000TPD capacity with capital investment of appx USD 350 Mn. Working out in the technical
& commercial evaluations and finalization of EPC supplier, P&I, equipment’s selection, GA, Plant Layout, Mass & Flow Diagrams of received Tenders from OEM of different cement plant OEM suppliers across globe in existing plant for line#4.
• Handled the new Green Field set up project of 5000TPD, layout selection, prepared Tender specifications & Documentations for new upcoming green field cement project In Duqm (Oman) Al sahawa Cement Plant EPC project from June 2019. All received tenders are comparing the specifications and technical details are under review for Vendor selection and further awarding (on Hold) due to restrictions of coal firing sanctions from govt authorities.
• Expansion Project of Grinding unit for capacity expansion of 150TPH (Flsmidth supplied) with Packing Plant
(Aug 2015 to March 2017).
2
• Execution of Internal Project Coal VRM (Gebr Pfeiffer supply) & Bag filters & Limestone linear stack yard domes erection & commissioning from initial equipment selection & difference auxiliaries’ selection by suitable vendors to hand over to operation (May 2014 to July 2015).
• Fabrication, Erection & Commissioning of a fully Brown field 1.5 MTPA /5000TPD (Flsmidth Supply) cement project within time with quality execution at Jaypee Sidhi Cement Project SUN-II (Jan 2011-Dec’2012) Including 3000TPD Grinding Unit & packing Plant (Flsmidth Supply).
• Fabrication, Erection & Commissioning of a fully green field 1.5 MTPA /4500TPD (ThyssenKrupp Raw Grinding & Pyro& cement Grinding L&T supply) cement project within time with quality execution at Jaypee Sidhi Cement Project SUN-I (’2007-2009) including Grinding Unit of 3000TPD & Packing Plant (L&T supply).
• Involved six months for the erection of 35 MW Captive Power Plant (CPP) in house. Budgeting and Financial Planning:
• Ability to Manage the preparation, recommend the sectional budget, and monitor financial performance versus the budget while ensuring all sectional activities are conducted in line with the approved guidelines.
• Rich Skills in Planning of the spares & yearly budget requirement to optimize the cost of maintenance and increase the availability of equipment.
• Preparation for Opex and capex budgets for the Section. Continuous Improvement:
• Leader in the identification of opportunities for continuous improvement and sustainability of systems, processes and practices considering global standards, productivity improvement and cost reduction.
• Responsibility of all sectional reports are prepared timely and accurately and meet OCC requirements, policies, and quality standards.
Strategic Contribution:
• Expertise in effective cascading of the divisional strategy into sectional business plans to ensure vertical alignment and horizontal integration with other interfacing strategies.
• Ability to provide strategic direction and swiftly adapt the plans in line with changing trends People Management:
• Rich in ability in the effective achievement of assigned objectives through the leadership of the assigned section by setting individual objectives, managing performance, developing, and motivating staff to maximize sectional performance.
• Special skills in advanced leadership skills and ability to manage personnel in a multi-cultural work environment.
WORK EXPERIENCE:
Time
Period
Portfolio/
Organization
Job Profile
28 July
2015 - Till
date
Head of Section
(Mechanical & Civil)
Oman Cement
Company (S.A.O.G),
P O Box:560, Ruwi,
Postal Code 112
Sultanate of Oman
1. Responsible for Technical evaluation of Tenders received from OEM bidders of 10000TPD expansion Brown Field project Line#4 from April 2022 received from OEM of Cement plant suppliers. Technical Evaluation completed final Commercial and technical together review is in progress.
2. Feasibility study and necessary clearances, permissions & approvals for capacity expansion project in the existing plant of 10000TPD
(Line#4) capacity
3. Responsible for Complete Operation and Maintenance of Ball Raw Mills-05 no, Reclaimers (Circular-FAM & Linear-KP&BMH), Crushers
(Cone, Hammer and Impact) Preheaters, Rotary Kilns -03no
(2500TPD-Dia4.2x56.0m, 2000TPD & 4000TPD -Dia 4.8x74.0m) and Coolers- IKN & Pendulum Grate Cooler in Clinkerisation section, and Cement Mills-05no in Grinding section of 3.0 MTPA capacity plant 3
Including internal projects up gradations for optimization of plant and capacity enhancement. Materials and spares management for preventive maintenance, Budget planning of every year.
- Internal up-gradation projects for capacity enhancement, technology up-gradation and optimization of plant capacity
- Yearly business plan preparation with budget requirement
- Yearly Maintenance cost optimization per ton production basis
- Spares management and procurement through raising requirement.
- Serving as a team leader on technical strategic operation and maintenance related issues for the plants
- IMS system implementation in the plant
- Preparation of Tender specifications & Documentations for upcoming 5000 TPD new green field cement project In Duqm (Oman) Al sahawa Cement Plant EPC project.
- Self-feasibility study of ball mills of M/S Sinoma supplied and internals Modification for capacity upgradation of Ball mills-02 no from production capacity of each mill from design 180TPH to 240TPH. Which is enabled to possible to Kiln production increased from 4000TPD to 5000TPD achieved. This is special technical achievement in the plant.
- MAAG gear unit CPU 38 major overhauling complete in my supervision without MAAG specialist. Completed successfully and running. (This gear unit was installed in the year of 2016 and failed in 2020 due to lubrication safety logics failures)
- First time major overhaul of Flender DMG 2-22 gear units without any specialist. (1st time in the plant history)
- Repair technology developed for MAAG CPU 38 1st stage - cracked star gears
- To foster teamwork, provide a healthy work environment and keep the staff motivated.
- Ensuring availability of Opex and Capex Budget and other resources for plant.
- To conduct Plant team assessment and ensuring succession plans and people development.
- Ensuring implementation of all SOPs at plant.
- Ensure implementation of annual appraisals, KPI’s and smart objectives at all levels
- Ensure implementation of Plant Operating Model (POM).
- Lean management techniques
Reporting to: GM- Engineering/CEO
13 May
2014- 20
July 2015
Dy. Manager (Mech)
Birla Corporation Ltd
Unit of MP Birla
Satna Cement Works
Satna, MP
Responsible for project execution works for up gradation and Modifications of Cement Plants since right from the start of layouts and technical specification for selection of equipment’s from various suppliers and drawings approval. Responsible for equipment selection and purchase from suppliers directly duly reviewed the plant operating parameters and technical specifications for cost control of projects. Contactors selection duly reviewed the feasibility of contractor.
Drawings approval after reviewing the technical and operating parameters. Along with the different up-gradation of plant technical feasibility activities
(like 60-year-old PH, cement mills & Packing plants) for plant up gradation, also responsible in the erection of Gebr Pfeiffer supplied MPS 2800 VRM Coal Mill and Limestone Linear shed supplied by M/S XUZHOU-China erection work
Technical tenders’ preparation, Floating of Enquiries, Technical offers evaluation, drawing checking. Correspondence with suppliers. Co-ordination with Purchase and stores. Project related activities like issue of Material, checking of Fabricated items. Execution & commissioning of Project. Checking
& Passing of Bills & Invoices raised by suppliers & Contractor. Presently looking after the BVC Coal VRM & Coal Washery by pass system Project Execution. Active participation in QC, kaizen/suggestion scheme & 5-S activities.
4
Reporting to : Sr. Vice President (Mechanical)
Sep 2012-
May 2014
Plant Engineer (Mech)
Jaypee Sidhi Cement
Project, Jaypee Vihar
SIDHI (M.P.)
Responsible for smooth operation & maintenance of complete newly commissioned (September’2012) clinkerization along with cement mill, packing plant, projects execution (new modifications), system-up gradation, implementation of TPM/ISO, & existing resource planning as In-charge
(Mech)
- Maintenance Planning for Man Machine & Materials for Smooth availability of all Centre line equipment.
- Mechanical section team leadership
- Reduction of Stores &Spares, Maintenance Cost, & Specific Power consumption/MT etc
- Formulation of Energy Conservation Committee
- Subordinate development
- Responsible for CAMM & Condition Monitoring Section
- Responsible for Mechanical Workshop Operations
- In-charge for Design/Drawing & Tech Library.
- IMS Qualified Internal Auditor for IMS Implementation of Organization Reporting to : Sr. Vice President ( Tech)
Jan 2011-
Sep 2012.
Plant Engineer (Mech)
Jaypee Sidhi Cement
Project, Jaypee Vihar
SIDHI (M.P)
Responsible as project In-charge for FLS supplied (5000TPD clinker production & 3000 tpd cement production) brown field cement project SUN-II
(clinkerization & post clinkerization) right from the start of project for mechanical fabrication of cement plant items i.e. PH cyclones, hoppers, feed bins & silos, Steel Structures, process ducting etc & then Erection of plant equipments, steel structures, ducting for
clinkerization: RM Hopper House, Raw Mill House & Complex, Bag House
,CF Silo & Kiln Feed System,PH cyclone tower, rotary kiln, clinker cooler, clinker transport & clinker silo with coal mill, firing system & Post clinkerization: cement mill hopper, cement ball mill house, main bag filter, product transport system to cement silo.
Mechanical Fabrication &Erection team leadership
Reporting to: Sr. Vice President (Tech)
Jan’2009-
Dec 2010
Plant Engineer (Mech)
Jaypee Sidhi Cement
Plant, Jaypee Vihar SIDHI
(M.P)
Responsible for operations-&maintenance (Mechanical) of newly commissioned (Jan’2009) clinkerization plant including Grinding Unit and packing plant along with projects execution, system-up gradation, implementation of TPM/ISO, & resource planning.
- Maintenance Planning for Man, Machine & Materials for Smooth availability of all Centre line equipment.
- Clinkerisation section team leadership
- Reduction of Maintenance Cost & Spares
- Formulation of Energy Conservation Committee
- Subordinate development
- Responsible for CAMM & Condition Monitoring Section
- Responsible for Mech Workshop Operations
- In-charge for Design/Drawing & Tech Library.
Reporting to: Vice President (Tech)
Oct ’2007-
Jan ’2009
Sr. Field Engineer
(Mechanical)
Jaypee Sidhi Cement
Project, Jaypee Vihar
SIDHI (M.P)
Responsible for green field cement project since right from the start of project for Mechanical Fabrication of Cement Plant Items i.e. Steel Structures, Ducting’s etc & then Erection of plant equipment’s, steel structures, ducting for LS Crushing Section, RM Hopper House, Raw Mill House & Complex Bag House, CF Silo & Kiln Feed System & Coal Mill House. Mechanical Erection team leadership
Reporting to: Sr. Joint President (Project)
July 2001-
Oct 2007
Charge
Mechanic/Supdt
(E&M)/ JE (E&M)
Overhauling and Maintenance of Vehicles, Equipment and Plants related to Roads, Bridges & Tunnels construction works.
5
Border Roads
Organization (BRO),
Central Govt Organization
(Ministry of Defense-
India)
a. Repair Maintenance and Overhaul of Heavy Earth Moving Equipment such as Dozer BEML D80A12, D15A15, Paver finisher Apollo Model RM-3, BG-220 with sensor, Hot Mix Plant make Apollo Model DM-30 Capacity 30 to 45 TPH, Wheel Loader BEML Model BL- 1420, Motor Grader BEML Model- BG605,Air Compressor Atlas Copco Screw Type 250Cfm JCB Excavator Loader 3 DX, Road Roller Static(Jessop Britannia,Speed Craft) and Vibratory Road Roller (L&T 752 Vibromax) Stone Crusher (Marshal, Sisco, Laxmi) Capacity 6 to 10TPH etc related to Road Construction. b. Overhaul of Light Vehicles such as TATA 1613,1612,1210,407,207 Maruti Gypsy,
c. Independently handled Local Purchase Section for spares procurement from Authorized Dealer, Local Market, and OEM through DGS&D Rate Contract
d. Computer knowledge related to office works and Net Working (LAN) e. Development & Establishment of Fabrication activities of Steel Super Structure Bridges in base workshops first time of different span and material requirement calculation. Fabrication of Super Structure Steel Bridges
f. Worked as Mechanical Transport Officer (MTO)
Reporting to: Superintend Engineer (E&M)
May1998-
Feb 2001
Junior Engineer
Turbo machinery Group
of Industries- Chanda
Nagar, Hyderabad -
500050
1. Overhauling of steam & Gas Turbines, Compressors (Syn gas, NH3, Air, N2), Rotating Pumps, Turbo Charges and other accessories at site leading by a team of people.
2. Major Inspections, Hot Gas path inspection of Gas Turbines at site GE Frame-5 &6
3. Trained Repair procedures and methods of Combustion liners, cross fire tubes and transition pieces by M/S Thomassen Internationals- Netherlands
4. Drawings generation (Reverse Engineering) of above spares at site as well as in workshop to reduce import/repair cost of spares from OEMs. 5. Quality Assurance activities, NDT Tests (UT, MT, PT & HT) as per International Standards.
6. Active participation in ISO 9001 & 9002 Certification of Organization. 7. Maintained inter departmental relations, Co-ordination with different sections like PP&C, Materials etc.
8. Customer co- ordination & Relations while working at erection/overhaul site.
9. Dynamic balancing of Turbine rotors, Compressor rotors and Pump Rotors
Reporting to: Manager (Design & QA)
EXPOSURE:
- Basic and detailed project Engg, erection and commissioning of-plant Civil, Mechanical & Process.
- Techno-commercial comparison and negotiation for Mechanical equipment.
- Planetary Gear Boxes of MAAG, Flender & RENK
- Vertical Roller Mills of Krupp Polysius AG,Loesche AG & FLS Atox mills for Limestone & Coal Grinding
- KP, Sinoma, L&T and FLS Ball Mills for raw meal & Clinker Grinding
- Chain & Belt Elevators BHP, Kowey, Beumer & Aumund
- Process Centrifugal Fans TLT, Flakt woods, Reitz, AEC Boldrocchi & Venti Olde.
- METSO cone crusher, TITAN hammer crushers, L&T Impactor Crusher APPM 1822 & TENGL Apron Feeders
- Material Handling Equipment; Stackers & Reclaimers FAM, KP & BMH, & Conveyor Belts
- Roto Packers of EEL make of 120TPH each and HAVER IBAU make 240TPH.
- SKF & FAG Bearing & Housings
- Deep Drawn Pan Conveyors Beumer & Aumund
6
- Clinker Coolers Folax, Cross Bar Cooler M/s FLS, ETA 877 M/s CPAG with L&T Hammer Crushers & IKN Cooler
- Power Transmission Devices I.e. Fluid/Rigid Coupling &Lubricants & Lubrication System
- Flakt woods Reitz Cooler Fans
- Alstom & FLS Airtech Reverse Air Bag House & Pulse Jet Bag Filters & ESP
- AIA Sinter Casting & Hi-Cr Castings by Firth Rixon, Megatteaux
- Roller Mill hydraulic system & gear boxes forced lubrication system
- Auto Cad& MS office windows
- Conversant to ERP & SAP System
- Rating of subordinates by KPI analysis method
PROJECTS EXECUTION:
• Presently working/exercising in tender documentations and equipment selections of fully green Field Cement Project 5000 TPD in Duqm- Al sahawa Cement project (A unit of Oman Cement Company (S.A.O.G)
• Grinding unit Expansion project in existing running plant to meet market demands in Oman Cement Plant
(S.A.O.G)
• Birla Corporation Ltd from basic engineering, equipment’s selection, Vendor development, Erection & commissioning – Mechanical/Civil/Electrical
• Jaypee Sidhi Cement Project SUN-II: basic and detailed engineering for brown field project (mech/civil).
• Jaypee Sidhi Cement Project SUN-I: Basic and detailed engineering for green field project (mech).
• Border Roads Organization: First Time Developed Super Structure Steel Bridges Fabrication Technology.
• Turbo Machinery Group of Industries: Developed Reverse Engineering of complete manufacturing drawing and dimensions at site for spare Rotor manufacturing to reduce import cost. MANAGEMENT TRAINING:
• Man-machine relationship.
• TQM &TPM awareness program
• 5S System certification development
• Organizational Behavior
• ISO 9001 & 9002 audits and certification programs
• Time management and self-development
• Stores & Inventory
• Managerial Motivation in Leadership by IIM Indore
• Team Building & Leadership
• Integrated Management System (IMS) Internal qualified auditor TECHNICAL TRAINING:
• VRM Maintenance & Optimization
• VRM Planetary Gear Boxes Maintenance
• Cement Manufacturing Process & Optimization
• Energy conservation for cement industry
• Condition Monitoring for Cement Plant Equipment
• Bearings & Housings: Operation & Maintenance by SKF &FAG
• Castings Performance & Output by M/s AIA Ahmadabad
• Technical Competency program
• Lean Management programs
EXPECTED EMOLUMENTS: at par to the best in the industry. PERSONAL DETAILS:
Name : CHOKKAPU VENKATA RAMANA
Father’s Name : SHRI LATE CHOKKAPU GOPALAM
Mother’s Name : SMT CHOKKAPU LAKSHMI
Age/DOB : 44yrs. (1st July 1979)
Nationality : INDIAN
Marital Status : MARRIED; [02 Daughters (11 years & 07 Years)] Contact Address : C-02, Oman Cement Housing Complex, Po No:560, Ruwi, Postal Code 112, Sultanate of Oman. Permanent Add : Bobbili (PO & MD), Bose Nagar, Military Colony, Vizianagaram (DT), Andhra Pradesh-535 558 E-mail ID : ************@*****.**.**; ************@**********.***; Skype ID : chokkapu20042
Mobile No : +968-********; +968-********; +91-739*******: 7
Passport No : M4727304 Valid up to- 18.12.2024
Academic record:
B. Tech (Mech): First class, B.Tech (CCC) in Mechanical Engg from Jawaharlal Nehru Technological University- Hyderabad with 66.91%
Diploma in Mechanical: Govt. Polytechnic- Narsipatnam with 88.00% (SBTET-Hyderabad) 10th : First class (Distn), 80.33%, Board of Secondary Education- AP Date:
Place: Muscat, Oman (Chokkapu Venkata Ramana)
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