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Maintenance Plant

Location:
Vasant Nagar, Karnataka, India
Posted:
December 20, 2020

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Resume:

SENIOR MANAGEMENT PROFESSIONAL- Over * Decades of Experience

Strategic Planning & Leadership Project Management Erection & Commissioning Operations & Maintenance of Iron Making Units like Blast Furnaces /Corex.

Expertise in championing organization values & vision and overcoming challenges with hands-on experience in instituting systems to enhance productivity & reduce cost

Executive Profile

Excellence in streamlining operations & maintenance, commissioning, and developing & implementing new systems within the plant

Rich experience of working on India’s largest Blast Furnaces (2 nos.) 4018 cubic meter and Blast Furnaces 1 & 2, Corex 1 & 2

Experience in maintenance schedule planning, budgets formulation, annual planning, troubleshooting, manpower planning and risk assessment analysis

Rich project management experience with expertise in developing project baselines, monitoring & controlling projects with respect to cost, resource deployment, & quality compliance to ensure satisfactory execution

Innovation-focused with success in managing erection, testing & commissioning and enhancing operational effectiveness of Blast Furnaces

Highly skilled in managing site operations, quality service and timely completion of projects along with testing and commissioning of various plants

Strategized techniques for maximum utilization of manpower with thorough understanding of industry & technology trends; implemented manufacturing techniques & methodologies to achieve product excellence

Successfully managed technical, financial and administrative issues; ensured adherence to safety, environment, regulatory and energy conservation norms

Excellent at establishing relationships with govt. departments, and acquiring govt. permits & clearances for successful execution of projects

Expertise in implementing cost saving techniques/measures and modifications to achieve reduction in all types of O&M expenditures

Skills

Skill set

Project management

Strategic planning

Contracts and commercial

P&L management

Business Development

Cost control & budgeting

Regulatory systems

Asset management

Revenue generation

Commissioning & take overs

Power system management

Education & Credentials

BE in Mechanical Engineering from Vijayanagar Institute of Technology in 1987 with 65%

Key Impact Areas

Project Planning & Management

Operations & Maintenance Planning

Decision-making Support /Process Enhancement

Strategic Planning & Leadership

Erection/ Commissioning

Budgeting/ Forecasting/ Cost Control

HSE/ Regulatory/ Compliances

Spares Management/ Procurement

Profit Centre Operations

Commercial Operations

Team Building & Training

Soft Skills

Communicator

Multi-cultural

Collaborator

Career Timeline (Recent 5)

Selected Highlights & Contributions

Merit of successfully:

oRevamping 4018 cub metre furnace bell less top equipment within record time of 48 hours

oDriving hot repair of hot blast main with the help of in-house resources within short span of 72 hours

oExecuting rebuild/repair of stoves within 6 months of record time (Danieli Corus design)

Steered:

oModifications in all de-dusting systems to ensure chimney dust emission parameter within stipulated limit of 10gm/NM3

oModifications in water systems to maintain specific water consumption of .6m3/THM

Implemented:

o5S housekeeping practices and mapping of 5S activities

oSpeed, agility and innovation mantra across/within the team

oTQM tools like 7QC tools to prepare for Deming award and grand Deming award

o0757 as the JSW TQM Mantra

Drove erection of coke drying projects to bring down the coke moisture by 3% from 8% (thereby achieving low hot metal production cost

Commissioned in-house developed platform in Paul Wurth Bell less top to use while replacement of upper seal valve for which earlier it consumed around 120 T of coke and delivered waste INR 20L

Built special tools to replace 36 nos. of blowpipes within 12 hours and replacement of BLT distribution chute within 8 hours

Delivered Fast Distribution Valve in cold blast line to save shut of the blast furnace in case of power failure

Preserved LTIFR .24 by following all the 10 safety standards on a daily basis

Conceptualized strategy & achieved 3 million man-hours in safety in each furnace and ensured zero fatal accidents

Worked as Chairman of Departmental Safety Committee; conducted monthly contractor’s safety meeting

Administered erection and commissioning of Top Recovery Turbine to produce 9 mw power/day

Conducted modification in drives to maintain the specific power consumption of 145kwh/THM

Played a key role in getting most precious TQM Award of Deming

Managed maintenance of sub units like Reduction Shaft, Melter Gasifier, Hot Metal / Raw Material Handling Systems, Coal Drying Plant

Successfully managed erection & commissioning activities of Corex C-2000 Module 1 Furnace in Oct 2000, Corex c2000 Module 2 in Apr 2002, 1250 Cubic Meter Blast Furnace in Aug 2004, 1650 Cubic Meter Blast Furnace in 2007 and 4018 Cubic Meter Blast Furnaces 2 nos.- one in Feb 2008 and second one in 2011 (one of the biggest Blast Furnaces in India)

Spearheaded erection and commissioning of Coal Grinding Mill for Pulvarised Coal Injection, Revamping of 4018 Cubic Meter Blast Furnace BLT System within 24 hrs

Attained:

o8% reduction in downtime through effective maintenance practices like condition monitoring, thickness monitoring, utilization of opportunity maintenance

o0.2% escalation in OEE & plant productivity due to major modifications like 10% of oxygen enrichment and 200 KG/TPH of coal fines injection through tuyers

oISO 9002 and ISO 14001 for the organization; maintained consistency in ISO related documents

Bagged:

oCertificate for excellence in performance improvement projects

oCash Award for best performance

Revived Chilled Melter Gasifier jammed DRI Screws and emptied reduction shaft within 48 hours and achieved high melting rate of 120 T/hour

Drove the implementation of indigenization / interchangeability of spares, adoption of CMMS to ensure availability of spares at any given point of time; reduced maintenance cost per ton of hot metal from INR 165 to INR 135 (RS 1300/THM and Rest 21000 product -HRC)

Delivered training programs like Hydraulics Training by Vickers India Ltd., Managerial Training Program by Kirloskar Technical Institute, and Karnataka for all employees in the dept.

Erected & commissioned two 250-m3 Blast Furnaces in 1995 and 1996

Organized training programs like Bearing Assemblies, importance of Lubrication System in Steel industry

Planned & led erection & commissioning of 4018 cub meter Blast Furnaces 2 nos/, 1650 cub meter & 2350 cub meter Blast Furnaces, Corex C 2000 Furnaces 2 nos., 3 Coal Grinding Mills and so on

Credited for executing capital repair (9 days) of 3 million tonne Pellet Plant

Monitored MTTR & MTBF of equipment; ensured equipment availability and furnace availability of 98%

Proved:

oSeventh ranking benchmark for with world steel association

oCoal fines injection of 150kg/THM

o100% availability of SGP given point of time

Organizational Experience

1st August 2019 to till date; Ashok Iron works Ltd Belgaum Karnataka, 590001 as Senior Vice President (operations)

Feb 1st to 31st July 2019 J Tech engineers and Fabricators-On Business (Self Employed) Belgaum Karnataka 590001

July 2008 till Jan 2019: JSW Steel Ltd., Bellary, Karnataka, India as Head of Iron Making 5 MT & 7 MT (4018 cubic meter Blast Furnace 2N0S,COREX C 2000 Furnaces 2 Nos,2350 cub mtr one furnace and 1650 cub mtr one furnace)

Role:

Erection and commissioning of blast furnace 3&4 0f 4018cub mtr capacity each since grass route level including site preparation & equipment selection

Heading operations and maintenance of Iron making 5 Million tonne and 7 Million tonne Furnaces

Working out various requirements, monitoring overall project operations and ensuring timely completion; setting up standards, ensuring optimum utilization of available resources to achieve organizational objectives

Monitoring the activity at sites and project schedule, ensuring cost control within the budget and plans

Planning erection, testing & commissioning as well as preventive & predictive maintenance schedule for the plant

Adhering to safety, environment, regulatory norms

Leading, mentoring & monitoring the performance of team to ensure efficiency in process

Implementing & maintaining all the activities in area of generation, maintenance & new facility planning; ensuring plant availability, reliability and generation as per the annual operating plans

Troubleshooting and driving preventive / breakdown / shutdown maintenance of rotary / static equipment, to reduce downtime to minimum

Spearheading site functions including execution activities involving laying foundations, installation of furnace shells, compressors, pumps, ID & FD Fans, hydraulic power packs, steel structures, piping

Managing commissioning of electrical substation, high and medium equipment, generators, civil works, erection & testing of equipment, commissioning of the plants

Previous Experience

July 2006 – July 2008: Suzlon Energy Ltd Coimbatore (SE Forge LTD foundry) as Head (Projects/Operations and Maintenance)

As a Project head of of biggest gray iron foundry in the country

Major responsibilities

Total involvement in plant procurement & lay out finalization of 40000T capacity castings and forgings.

Actively participated and finalized plant layout

Charging cranes and systems erection and commission

Mould shop with various pits and risers for pressurised mouldings so as to avoid cavity and blow holes in the castings

Sand preparation units with various equipment and hematite/magnetite material addition so as to have proper bonding of the core

Core shop equipment erection/commissioning

Installation of heat treatment bay with top hat annealing furnaces

Fettling section with automatic swing frame grinders with hydraulic systems

Dedusting systems with dedicated compressors

Painting bay with computerised programmed painting of castings.

Actively involved in technical discussions of procurement of all foundry equipment like 8nos of 8T capacity induction furnaces with robust cooling systems with level 2 automation

Planning of basic raw material to start the foundry.

Recruitment of maintenance /operation team to run the foundry

Setting up of full-fledged maintenance systems with SOPs and SMPs

Quality circles/kaizens/OPL/5S implementation

December 1996 – July 2006: JSW Steel Ltd., Bellary, Karnataka, India as Assistant General Manager.

Major responsibilities

Involved in erection and commissioning of two nos of grass root projects COREX 1&2 including procurement of various indigenous and international. Setting up of maintenance dept.

Undergone Management training at POSCO STEEL PLANT POHANG, South Korea to operate & maintain the COREX plants

Erection and commissioning of 1250 cub mtr blast furnace since grass root level and maintenance of the same

Erection and commissioning of 1650 cub mtr blast furnace 2 since grass root level and maintenance of the same.

October 1994 – December 1996: Kirloskar Ferrous Industries Ltd., location as Senior Engineer

Major responsibilities

Erection and commissioning oh 150 cub mtr 2nos of mini blast furnaces since grass root level

Maintenance of 2nos of blast furnace including setting up of full-fledged maintenance department.

June 1992 – October 1994: Sesa Goa Ltd., India as Maintenance Engineer

Major responsibilities

Erection and commissioning of 2nos of TATA KORF technology mini blast furnaces since grass root level including equipment procurement

Setting up of maintenance department including recruitment of maintenance team

Formation of SOP& SMPS /Spares planning.

October 1989 – June 1992: Deccan Cements Ltd., India as Junior Engineer

Major responsibilities

As a front line engineer handled responsibilities of maintenance and operations of packing section/Kilns/Cement mills and raw mills.

October 1988 – October 1989: ACC Babcock Ltd. as Management Trainee

Major responsibilities

As a management trainee handled responsibility of foundry maintenance including manufacturing of cement industry crusher hammers/induction furnace maintenance/fettling section equipment maintenance etc. including tube shop maintenance to manufacture boiler tubes.

Trainings

1 month Middle Management Program from Kirloskar Institute of Advanced Management Studies, Karnataka, India in 1995

Computer Orientation Program by Belhos Infotech Pvt., Ltd., Karnataka, India 1997

Extensive training in O & M of Corex Plant at Pohang Iron & Steel Co., Ltd., Pohang, South Korea in 1998

Senior Management Training program in JFE Korasaki Steel Plant, Japan for 2 weeks (2011-2012)

3-month Intensive In-plant Training Program conducted by JVSL and complete operations & maintenance knowledge about all SBUs like Pellet Plant, Sinter Plant, Coke oven, BOF/CCP, HSM, HRD, logistics, raw material handling system, lime plant, oxygen plant, power plant, transport and security

Positive Leadership Programmes conducted by Harvard University Faculty

adit23@r.postjobfree.com

adit23@r.postjobfree.com +91-944*******

+91-973*******

R S KULKARNI

Ashok Iron works Ltd Belgaum Karnataka, 590001 as Senior Vice President (operations)

JSW Steel Ltd., Bellary, Karnataka, India as Head of Iron Making

JSW Steel Ltd., Bellary, Karnataka, India as Assistant General Manager

August 2019-till date

Feb 2019-july 2019

Since 2008- Jan 2019

Suzlon Energy Ltd., (SE FORGE LTD) location(Coimbatore) as Head Projects and Maintenance

J Tech engineers and Fabricators-On Business (Self Employed)

1996-2006

2006-2008

Personal Details

Date of Birth: 1st June 1965

Languages Known: English and Hindi

Permanent Address: 410 Sanika Landmark B Wing 9th Cross Bhagyanagar, Angol, Belgaum-590006

Expected CTC: negotiable.



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