Key Skills

Profile Summary

Installation & Commissioning

Testing of EIA Machineries

Maintenance of Plant & Machinery

Energy Auditing & Conservation

Project Management

Process Optimization

Cost Control & Optimization

Root Cause Analysis

Vendor Development

Six Sigma DMAIC Frame Work

A dynamic professional with B.Tech, M.B.A,PMP Certification and a Black Belt on Lean Six Sigma Methodology having over 24 years of rich experience in Project Management, Erection & Commissioning, Operations & Maintenance of Cement, Lime & Power Plants, Energy Conservation and Vendor development.

Proficiency in managing engineering, erection, testing & commissioning activities and ensuring completion of assignment within the time & cost parameters and effective resource utilization to maximize the output

Well versed in operation & maintenance of various Electrical & Automation machineries in Cement Plants & Lime Plants reducing downtime and enhancing operational effectiveness.

Specialist in maintaining the spare items stock for the line machineries and updating it periodically; Developing and rectifying new maintenance methodologies in the company to enhance availability of machinery.

A certified professional in energy efficiency implementing various systems & techniques for plant optimization with Energy conservation for cost savings.

Expert in Material Planning and developing vendors for timely procurement of materials and spare parts to ensure the smooth production operations.

Excellent communication & interpersonal skills with strong analytical, team building and problem-solving abilities.

Career Timeline

Working since July, 2010 as Head (Manager) of Electrical & Instrumentation Department with RAK Company for White Cement & Construction Materials, UAE

August1996 -

June 2005

July 2005 –

July 2010

July 2010 till Date

Sep’15-Apr’16

Mar’07 – Mar’10

Soft Skills

Education

Black Belt Certification on Lean Six Sigma from KPMG, India in 2020

PMP Certification from Project Management Institute, USA in 2015

PGPMX (MBA) from Indian Institute of Management Indore in 2013

B.Tech in Electrical & Electronics from M.G University, India in 1995

Work Experience:

Currently working with RAK Company for White Cement & Construction Materials, UAE as Head (Manager)- Electrical & Instrumentation since July 2010. Presently looking after all Project Management, Erection & Commissioning, and Operation & Maintenance of Electrical & Automation equipments in Cement plant & Lime Plant.

Major Accomplishments in RAK White Cement Company:

Retrofitting of old 6.6KV Panels in the plant with latest Vacuum Circuit Breakers and Protection Relays in 2021.

Up gradation of 33KV Panels in the plant with latest switch gears consist of SF6 Circuit Breakers and Protection Relays in compliance with FEWA requirements in 2020.

Electrical Power System Studies of the plant was carried out in 2020 with assistance of external agency.

Up gradation of the ABB make Plant Distributed Control System (DCS) that consists of different Servers and Human Machine Interfaces with latest software in 2020.

Made a major role in implementation of Lock Out Tag Out (LOTO) procedure in the plant.

Effectively implemented many energy saving initiatives such as installation of VFD panels, replacement of conventional lights with LED lights and optimization of electrical, automation and compressed air systems in the plant.

Successful implementation of a new cement silo project in 2018 that consists of engineering, installation and commissioning of electrical & automation system for the feeding and extraction system of the silo.

Successfully installed & commissioned electrical & automation systems of the new Petcoke firing system for Lime Kilns in 2017.

Effectively executed the energy auditing of Cement Plant & Lime plant in 2017 and also carried out the feasibility study for waste heat recovery in the cement plant.

Successfully completed the course assessment and examination for the Integrated Management System (IMS) Internal Auditor Training Course (Based on ISO 9001:2015, 14001:2015 & OSHAS: 2008 Standard) and implemented IMS in the department.

Successfully installed & commissioned electrical & automation systems of the new 2Nos. 30 TPH Petcoke Mills in 2016.

Successfully executed the capacity augmentation project of Line1 & 2 Kilns with engineering, erection, testing & commissioning of complete electrical & automation systems in 2013 & 2014.

Efficiently managed the entire testing & commissioning of electrical & control system for the new 600TPD Lime Plant that include 6.6 KV Panels, MCCs, Variable Speed Drives & Siemens PLC in 2011.

Successfully installed & commissioned electrical & automation systems of the new cement extraction system & Packing systems that include Rotary Packer, Automatic Truck Loader & Shrink Wrapper Machine in 2011.

Played a major role in commissioning of 33/6.6KV, 30MVA substation in compliance with FEWA requirements in 2012.

Major Achievements in Energy Conservation Front:

1. Reduced the power consumption of Cement Plant and Lime plant to the tune of 700KW with the implementation of following activities during 2015- 2020.

Installed Variable Frequency drives for 15 process fans and removed the inlet vane dampers of all these fans.

Replaced 5 Nos. low efficiency centrifugal fans by latest high efficiency fans.

Optimized the usage of air compressors & positive displacement blowers in the plant and installed variable frequency drives for 2 Nos. underutilized compressors.

Optimized the usage of air conditioners used in the plant and administration buildings.

Replaced conventional light fittings by LED light fittings in some areas of the plant. The replacement in remaining areas in progress.

Replaced old type field instruments (Around 30 nos. of Pressure, Temperature and Flow) with latest instruments so as to enhance the operational efficiency of the plant to reduce energy consumption.

Enhanced the accuracy of weighing systems of Kiln Feeding and Kiln firing (fuel) by up gradation and new installations (6 systems) in the plant so as to enhance the operational efficiency of the plant.

Made many alterations in the operational sequence of equipments installed in the plant so as to minimize the idle running of equipments.

Introduced many PID loops for equipments such as Bag filter fans so as to reduce their speed to reduce energy consumption.

Played a major role in enhancing the awareness of operation & maintenance personnel on the need for Energy conservation.

2. Feasibility study for Waste Heat Recovery for the Cement Kilns was carried out in 2017 and technical interactions with various suppliers are in progress to implement the same.

3. Feasibility study for Utilization of solar energy in the plant was carried out in 2017 and technical interactions with various suppliers are in progress to implement the same.

4. Effectively executed the energy auditing of Cement Plant & Lime plant in 2017 conducted by an external agency and the implemented many of these proposals.

Career Growth in RAK White Cement Company:

Joined RAK White Cement Company as Head - Electrical & Instrumentation of White Cement Company in July 2010 in 5-1 Grade, reporting to Technical Director (Plant Manager).

Promoted to 6-3 Grade as Head - Electrical & Instrumentation of White Cement Company in March 2013.

Given additional responsibilities of Lime Plant as Head - Electrical & Instrumentation of White Cement Company & Lime Company in December 2015.

Promoted as Manager - Electrical & Instrumentation of White Cement Company & Lime Company in March 2016.

Given additional responsibility as coordinator of cost committee of the factory since April 2016 responsible for all energy conservation activities of cement plant & lime plant.

Working as acting Technical Director of White Cement Company & Lime Company since February 2017 during the absence of Technical Director.

Worked with Lafarge Surma Cement Limited, Bangladesh as Manager – Electrical from July 2005 to July 2010.

Major Accomplishments in Cement Plant:

Successfully carried out erection, testing & commissioning of complete electrical system for the 1.2 MTPA capacity Cement plant of FLS Design as per Lafarge standards in 2007. The plant consisted of 9 Nos. 6.6KV Substations and a ABB make Distributed Control System (DCS)

Established electrical maintenance department in Lafarge Surma Cement Limited as per Lafarge standard with recruitment and training of suitable manpower and procurement of necessary machinery spares and tools.

Implemented LOTOTO (Locked out Tagged out Try Out), worked at Height (WAH) procedure in the plant as per Lafarge Safety Standards.

Implemented various modifications in the electrical system of the Cement Plant.

Implemented various maintenance tools like Maximo, ADAP, etc. in the plant.

Major Achievements in 30MW Power Plant during 200 5- 2010:

Successfully carried out erection, testing & commissioning of complete electrical system for the 30MW, Wartsila make Power Plant as per Lafarge standards in 2007. The Power Plant consisted of 4 Nos, 8MW Wartsila make Gas Turbine Generators and 2 Nos. 6MW Wartsila make Diesel Engines.

Responsible for the Operation & Maintenance of the Power Plant in co-ordination with the O&M contractor M/s.Wartsila.

Implemented various modifications in the electrical system of the Power Plant and Cement Plant to increase the reliability of the Power Plant.

Reduced the specific fuel consumption of Gas Turbine Generators & Diesel Engines by proper load management and operational techniques.

Worked with Associated Cement Companies (ACC Ltd) From Aug’96 to Jun’05 as Assistant Manager-Electrical

Major Accomplishments:

Worked in Cement grinding section as In charge of Operation and Mechanical maintenance from 2001 – 2005.

Achieved the distinction of restructuring the Electrical System by replacing 22 KV Distribution System by 6.6 KV Distribution and old SDBs by MCCs in 2001.

Successfully handled following erection & commissioning projects like Electrical Systems for 150 TPH capacity Cement Mills & Auxiliaries in 1998.

Involved in the initial designing of 15MW coal based Thermal power plant.

As a member of Energy Audit Team, conceptualized and implemented the following electrical energy conservation steps:

Enhanced Power factor by commissioning of Capacitor Banks; the Plant power factor improved from 0.8 to 0.92.

Installed variable Speed Drives for 16 Number fans & 12 Number pumps.

Converted 30 Number under loaded motors from delta mode to star mode of operation.

De Rated 10 Number reciprocating compressors to reduce power consumption.

Replaced old low efficiency motors, fans & pumps, around 30 Nos. Old motors were replaced by new high efficiency motors. 6nos. low efficiency fans were retrofitted. 8 Nos. low efficiency pumps were replaced by new high efficiency fans.

Documented of ISO 14001 and ISO 9001 manuals for certification purpose.

Implemented Total Productive Maintenance (TPM) in the plant as an Apex Committee Member.

Trainings Attended:

Underwent trainings on:

o CII Certified Professional in Energy Efficiency (Cement Sector)in 2021.

oLean Six Sigma Black Belt course by KPMG India in 2020

oContinuous Emission Monitoring System (CEMS) in 2019.

oField Instruments by E&H in 2018

oTraining on Leadership & People Management in 2017.

oInternal Auditor Training on Integrated Management System ( ISO 9001,14001 & 18001) in 2017

oInternal Auditor Training on ISO 9001 in 2016

oABB PLC – AC800M by M/s.ABB in 2016

oCemtech Technical Workshop in Malaysia in 2014

oUp gradation of ABB PLC – 450 in 2013

oABB PLC – ACS450 by M/s.ABB in 2012

oSiemens PLC – Step 7 & WIN CC by M/s.KIMA, Germany in 2011

oDevelopment of Facilitator by Lafarge, France personnel in 2009.

oSafety topics like LOTOTO,WAH,PPE, etc. in 2008 by Lafarge Management

oMV motors by M/s. BHEL in Lafarge Surma Cement Limited in 2007.

oPCS by M/s. ABB in Lafarge Surma Cement Limited in 2006.

oMV & LV drives by M/s. ABB in Lafarge Surma Cement Limited in 2006.

oHT Motors conducted by BHEL in 1998.

oElectrostatic Precipitators by Research & Consultancy Directorate (RCD) of ACC Ltd. in 1998.

Root Cause Analysis in 2005 by APOLLO Associated Services.Inc, Texas,USA

Obtained AOTS Certificate in Total Productive Maintenance.

TPM at ACC Ltd. In 2004 by M/s. Techno Solutions.

Commercial Skills enhancement at ACC Ltd. in 2003

Analytical Skills Development at IIT, Kharagpur in 2002.

Optimization of MILLS at ACC Ltd. in 2002.

OHSAS. ISO 18001 Standards by DNV in 2001.

Fan Engineering by RCD of ACC Ltd. in 2001.

Energy Conversation in Industries conducted by Environment Training Institute, Chennai in 2000.

Electrical Risks in Industries conducted by Loss Prevention Association in 1999.

Protective Relays by Power System Consultants in 1999.

IT Skills:

Oracle Based ERP system

AutoCAD

MS Project

MS Office

Internet Applications

Maximo Maintenance Management System

Personal Details:

Date of Birth : 24th May 1974

Permanent Address : Poicadu House, Ramankary P.O, Alappuzha-689595, Kerala, India.

Passport Details : K8772047, Date of Issue: 31/12/2012 at Dubai, UAE

Marital Status : Married with 2 kids

Languages Known : English, Hindi, Malayalam & Tamil

Driving Licenses : Of UAE since February 2015 & of India since 2007

Gireesh Nandakumaran Pilli- B.Tech, MBA & PMP

Head of Electrical & Instrumentation in Cement, Lime & Power Plants

+971*********,+971********* adnppw@r.postjobfree.com

RAK Company for White Cement & Construction Materials

ACC Limited, India

Lafarge Surma Cement Limited, Bangladesh

Communicator Innovator

Thinker

Collaborator Intuitive

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