UJJWAL MANOJ KUMAR

Contact No.:+917********* ~ E-Mail: adczqc@r.postjobfree.com

Seeking Middle level assignments in plant, project,Engineering,Erection,testing & Commissioning/ Maintenance Management in Automation, Instrumentation & Control Department with an organization of high repute

PROFILE SUMMARY

• A result oriented professional with more than 20 years of experience in Erection & Commissioning, Maintenance Management, Instrumentation & Control, utility pump houses and water treatment plants/ waste water treatment and water sewage plants, Propane/LDO hydrocarbon plant, fire water pump houses,bar mill furnace, DIPplants.

• SAP PM Module End User for shutdown planning, preventive maintenance task list updation, etc.

• development of various programs related with equipments and planning of data sheet, I/O list, wiring diagram

and its simulation and testing for automation and instrumentation field devices.

• Equipment commissioning, testing and maintenance of major units of STEEL PLANT equipments in electrical automation/ instrumentation area.

• Maintenance Preventive Maintenance Planning &execution. Inventory and Spares Management Maintenance of L.T.

Equipments and Sub-stations Co-ordination with Statutory Authority.

• Failure Analysis of Equipments. Planning and Implementing Predictive/Preventive/Shut down Schedules for machinery to increase machine up-time/equipment reliability. Managing the Functions of Troubleshooting and Preventive/Breakdown maintenance of various Electrical LT and instrumentation systems.

• Preparing maintenance/services schedules, conducting regular calibrations to ensure the performance capacity of various

process control equipments. Instrumentation/ Control/ Industrial Automation Designing Automation & Control Systems

involving logic development, configuration, programming and testing of Human Machine Interface. Coordinating the entire

development including requirement analysis, finalizing specifications, selection of instruments, prototype development and

testing activities. Preparing Technical Drawings/ Wiring Drawings/ Field Termination Charts/ Installation Procedures and

Documents based on the functional specification and site requirements.

• Mentoring a maintenance team to take over the maintenance of the Field instruments instrumentation and DCS maintenance.

Process Improvement Analyzing various processes / applications and recommending process modifications and equipment calibrations to enhance operational efficiency.

• Foreseeing performance bottlenecks and taking corrective measures to avoid the same Maintenance and Troubleshooting.

• Planning and effecting preventive & predictive maintenance / overhauling / repair schedules of various machineries & instruments to increase machine up time and long term equipment reliability.

• Proactively identifying areas of obstruction/breakdowns and taking corrective measures / steps to rectify the equipments

through application of trouble shooting tools. Ensuring all the machineries work efficiently by conducting timely checks &

measures. Erection & Commissioning Preparing layouts for the project as per the process and material flow needs.

Foreseeing performance bottlenecks and taking corrective measures to avoid the same.

• operation and maintenance. Advanced maintenance management. Interfacing of equipment / electrical distribution system

with DCS, PLC. Implementation of ISO 9000, 14001, OHAS 18001 systems and ISO 50001 Energy audit.

Completed training course of Energy management system Auditor/Lead auditor course (ISO 50001:2011)by BSI.

SKILL SET

Strategic Planning

Erection & Commissioning

Project Management

Maintenance Instrumentation & Control Inventory Management

Vendor Management Electrical Automation Team Management

Energy Audit

WORK EXPERIENCE Presently designated as Assistant General Manager – Instrumentation & Control I&A dept at Electrosteel steels Limited (Vedanta Group company) Looking after Incharge Instrumentation and Control Department of steel zone section .

June 2015- till date

Company Highlights: Electrosteel Steel limited is 2.5 MTPA steel plant situated in Bokaro District of Jharkhand. Plant consists of 2X60 T BOF, 800 and 300 TPD BF, 800 TPD OXYGEN Plant, 0.75 MTPA BAR Mill, 0.75 MTPA WRM, SINTER PLANT, LIME DOLO Plant and DIP plant.

Responsibility:

1. Project commissioning of plant and stabilization of plant/ equipment in the area of Electrical/Automation/ Instrumentation area.

2. Checking of all field instruments and systems and control loops with proper automation logic as per P& ID list with proper safety interlocks.

3. Managing critical Spares expenses within provided ABP budget.

4. SOP /SMP maintained in shop floor.

5. TPM/ISO/5S compliances.

6 Calibration of equipment, as per system requirements.

7. Weigh bridge commissioning and maintenance.

8. In house training to subordinates for their skill enhancement.

7. Vendor development as per requirement.

8. RCA of breakdown and its analysis and permanent solution.

Achievements:

Successful Erection, Commissioning and stabilization of Wire Rod Mill furnace field instruments and its automation system.

Commissioning and stablisation of equipments in finishing line # 3 (Zinc coating machine, High pressure testing machine, Cement lining machine) in ductile iron plant.

Successful execution of recommissioning work of cold box in oxygen plant.

Commissioning of Turbo Blower system in power plant.

Commissioning of Boom Barrier at main gate and railway siding area.

Design, engineering, commissioning of signal isolator panel for new oxygen compressor.

Load cell commissioning in weigh bridge.

HT camera system commissioning in WRM and Bar Mill furnace.

Developing Technical specification of systems, equipments for indigenization and vendor development according to specification.

Root cause analysis of problems in plant for automation/Instrumentation related breakdown and its permanent solution.

Safety and technical training to juniors and workman on safety and technical for skill development.

Instrument calibration and trouble shooting in steel zone.

PREVIOUS WORK EXPERIENCE

As Manager - Electrical/ Instrumentation - Central Utility, Jindal Steel and Power Limited Angul, Odisha

Company Highlights: JSPL Odisha is 5 MTPA steel plant situated at Angul Odisha. It comprises of Blast Furnace, CGP, DRI, BOF shop, SMS, BF, Plate Mill, Bar Mill and accessories plant.

• Handled a team of 20 members and simultaneously worked for commissioning of utility department

• Served as overall In-charge of all electrical/ instrumentation systems of central utility department comprising of 30 members

• Monitored all automation system contract finalization, procurement, vendor selection, erection, testing and commissioning of all

Central Utility projects

• Played a stellar role in engineering/ layout/ equipments/ erection/ commissioning and scope of raw water treatment plant/ HTSS

electrical system

• Ensured effective erection/ testing/ commissioning of pumphouses, SCADA (GE) system, programming for auto system,

Instrumentation system of RWTP, LDO plant and propane plants Siemens system.

• Essayed a key role in finalizing the layout/ equipments/ erection Commissioning and scope of propane station/pump house

electrical system

• Carried out:

o Party finalization for automation/ instrumentation system in new plant

o Commissioning/ maintenance of automation system in central utility department

o Material inventory management

o Breakdown and shutdown maintenance related with central utility department

o Construction power maintenance as per requirement

As Manager - Electrical/ Instrumentation - SMS Projects, Patratu, Jharkhand

• Played a stellar role in finalizing the technical specification and scope of 2X200T BOF/ Billet caster electrical & automation part

• Ensured effective preparation of scope list for new caster and BOF shop

• Carried out discussion with vendor with detail specification of equipments

• Essayed a key role in:

o Party finalization for automation system in new plant

Commissioning/ maintenance of electrical system in Bar Mill

PREVIOUS WORK EXPERIENCE

Aug2006 to Aug2010 with Ispat Industries Limited, Dolvi-Pen-Maharashtra

Company Highlights: Ispat Industries Ltd, is now JSW limited at Dolvi, Taluka Pen Maharastra. It is 5 MTPA steel plant comprises of blast Furnace, Oxygen plant, SMS, Caster, Plate mill, sinter plant.

Last designated as Deputy Manager - Electrical/ Instrumentation – Maintenance planning inventory and cost control department

Responsibility:

• Shutdown planning and scheduling of works of electrical department maintenance sections.

• Breakdown analysis and making Root Cause Analysis of .major problems.

• Preparation of SOP and SMP for the work procedure.

• Preparation of Maintenance presentation of plant regarding major problems, Inventory management, Utilisation of resources.

o Maintenance and material planning RCA why- why analysis

o Weekly maintenance S/D planning and compliance

o Spare planning for schedule preventive, shutdown and breakdown maintenance.

• Liaised with end-user and SAP key-user for development work in various SAP transactions for PM & MM modules.

• Functioned as Leader of Innovation and IFC Pillar of TPM in department for implementation of various development activities

PREVIOUS WORK EXPERIENCE

Nov’93 to Aug’06 with Tata Steel Ltd., Jamshedpur

Company Highlights: This is well known Steel plant of India, Founded by J N tata in 1907. This is now 10 MTPA steel plant situated in Jamshedpur Jharkhand. Plant consists of BF, LD shop, Plate Mill, Lime Dolo, BRM and WRM etc.

Last designated as Shift In-charge (Electrical and Instrumentation) – LD#2 & SLAB CASTER (Continuous casting plant)

Growth Path: Junior engineer- shift in charge

Highlights:

Process Control Instrumentation:

• Incharge of trouble shooting, maintenance and calibration of pressure,flow, temperature measurement system in different units in LD# 2 and Slab Caster.

• Played a stellar role in troubleshooting, maintenance and calibration of pressure, flow, temperature measurement system as per instrument data sheet and P&I diagrams

• Level measurement, Position measurement, Flow Control Valves,Pressure Control Valves,Servo controllers,Ultrasonic flow and level measurement ( Yokogawa) system,Magnetic flow meters, and their close loop control system,PID loops and interfacing with PLCs.

• Liquid steel temperature measurement system at LF, caster,RH( Auto temp-sample measurement system), and its interfacing with PLC and Level II.

• Analysers - Measurement and calibration of off gas analysis i.e CO, CO2,Oxygen,hydrogen measurement.

• Weighing System – weighing system maintenance and calibration in cranes,transfer cars,conveyor system, hoppers, scrap weighing systems of ABB, Philips make.

• Servo controller system – servo controller system maintenance and calibration in hydraulics system. Programmable Logic Controllers ( PLC/DCS):

• TDC-3000 ( Total Distributed Control) Honeywell system, LCN/UCN,LM,PM based logic control system for different process and Instrumentation.

• Preparation and implementation of logics in PLC and their checking.

• ABB PLC MP-200 system maintenance, and interfacing with different control loops for process and Instrumentation.

• SIEMENS automation/Instrumentation system maintenance

RAC LAB ( Rapid Analysis Centre) or Express Lab :

• XRFS ( X ray fluorescence spectrometer 8680 ARL make), for metallic and non metallic sample analysis. The maintenance and calibration of different element’ s monochromator and Goniometer. Sample transporter system, primary and secondary vacuum system maintenance.

• OES ( Optical Emission spectrometer ) for metallic sample analysis, maintenance and calibration.

• LECO CS-244 ( For carbon/sulphur measurement) CS-444 (For carbon/sulphur measurement)

TC-136 ( O2 and nitrogen measurement) Its maintenance and calibration.

Sample transport system maintenance

• Successful commissioning of the following:

o Liquid metal temperature system in LD#2.

o Argon purging system Forbes Marshall in LF

o Argon purging system in all 6 tundish car in Caster

o Implementation of delay booking system in RMHS JETTY area through SAP

Inventory control system development for Electrical Department

Water treatment plant and waster water treatment plant commissioning.

TRAININGS

• Two week training/ seminar for operation and maintenance philosophy in BSW at Kehl Steel Plant, Germany on the following:

o Study of operation and maintenance philosophy

o The KEHL Steel plant Layout and steel making procedures

o Planning for S/D and other connected issues

o Inventory management system

o Skill enhancement of people

• TDC-3000 LCN/UCN Maintenance and Implementation (One month training program) in Pune

• Small group activities like QC, Aspire, TQM and TPM

• Just In Time in Department

• Primavera – Project Software

• Siemens PLC S7-300/ 400

• Industrial Instrumentation in Forbes Marshall, Pune

• Gas Analysers (Special Training) conducted by Addage Automation, Mumbai

• Plant Operations and Maintenance in KEHL STEEL Plant Germany

IT SKILLS

• Well versed with MS Office (Excel/ Word/ PowerPoint), MS Project, Primavera Project Planner and Internet Applications

ACADEMIC DETAILS

BE in Electronics & Communications Engineering from AMIE The institution of engineers (India), India, 1993

EPGDM (Executive Post Graduate Diploma in Finance Management) from South Indian Education Society Navi Mumbai, Mumbai, 2010

AITT ( SNTI) - Electronics & Communication 1990

Matriculation – 1985-

EXTRAMURAL ENGAGEMENT & ACCOLADE

• Accredited with various Merit Prize Award given by Institution of Engineers, Jamshedpur

COMMUNICATION ADDRESS

Plot 347, Co operative colony Bokaro steel city, Dist Bokaro Jharkhand

Manoj Kumar Ujjwal

26.02.2020

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