T.S.R. MAHESH KUMAR

M.Tech –Electrical

Contact: +91-837*******

E-mail: adzl9d@r.postjobfree.com/adzl9d@r.postjobfree.com

In quest of a senior management positions in maintenance management,reliability centered maintenance,maintenance planning,project management,in Power plant, process industries

Personal Details

Date of Birth : 8th July1969

Languages : English, Hindi, Telugu

Passport No : S 7635296 valid up to 24/10/2028

Notice period : 30 days

Cuttent CTC : 53 LPA+14 LPA (Variable)

Expected salary : 30 % hike

Proven Expertise

Operation and Maintenance with excellent budget controls.

Reliability centered maintenance an spare optiiztion

Reliability,Availability Maintainability analysis

Operatonal risk management and LOTO implementation

SAP best practice template implementation

Project Management, Erection commissioning of power plants equipments.

O&M planning

Client interaction.

Integrated management system implementation

6 Sigma, 5S, Kaizen, Poka Yoke, OEE& RCM.

RCFA,FMEA,Fish bone analysis, Cause and Effect Matrix, Why-Why analysis, Pareto charts.

MS Projects,MS office,MS power point

Excellent Presentation skills

Inventory ABC analysis,control and cost mitigation.

Excellent workshop conducting skills

Team Management through Mentor Mentee principles &Leadership.

Training and development.

KPI &Objective analytical ability

Credentials

M. Tech –Power systems

NIT- Warangal, India

B. Tech in Electrical & Electronics

VRSEC, Vijayawada,India

Note: consistently passed all exams with distinction.

Training

GeneralManagement programme - 30 days in XLRI-Jemshedpur-India

Finance for Non Finance

IOSH managing safely

HR for Non HR

Mentor Mentoring

Six -Sigma by Wipro

TPM training

5-S Conceptual training

Reliability centered Maintenance conceptual training by GE, Meridium

SAP End user trainings.

PLC and AC /DC drives by Siemens,ABB,schnider

DCS CS-3000

PMP Certificaton Training

IMS Internal auditor

Profile

Multi talented Electrical Power systems Master degree Professional,over 29 years of experience with wide international exposure in client interaction, onsite operational and technical coordination

Experience includes:

Capacity Selection of equipments,technocommercial comparisions,techno commercial discussion, procurements and contract dealings.

Errection,commissioning testing of all power plant electrical equipments including Generator,GT,ST,UAT,brushless and Brush type excitation systems,boiler, turbine,BOP auxillaries.

HVAC and related auxilarries

Installation,testing,commissioning of static protection relays of Generator/GT/UAT/ST/Busbar/Transmission lines

patrolling &maintenance EHV transmission lines and associated auxilarries

maintenance of EHV switch yard(including GIS) and associated equipments like CV/CVT/LA/Sf6 CB/off load breakers and protection systems

AC/DC,Regenerative /Non-regenerative Drives of Siemens/ABB,PLC’s of Siemens/ABB,

Excellent maintenance planing with proven SAP PM,WCM,MM,EHS/CMMS software skills

Implementation of Reliability centered maintenance and spares optimization

Experience in Reliablity Availability and Maintainability (RAM)analysis, FMEA, Asset reliability planning

Very good turnaround planning with latest turnaround techniques

Master in SAP plant maintenance,work clearance module implementation from client end.

Task risk assessment(HAZOP,HAZID,HAZRAS,HAZRC),condition monitoring, predictive maintenance concepts, 6 Sigma and 5S strategies

Preparation of quality,environmental, health safety policies, procedures, work instructions as per ISO standard

Fair experience in Implementing ISO QMS, EMS, OSHAS.

Significant Achievements

VEDANTA- BALCO 1740 MW POWER PLANT SINCE DEC 2022

Working as Head O&M – COAL HANDLING PLANT -1740 MW

Handling OPERATION AND MAINTENANCE OF COAL HANDLING PLANT which includes coal unloading through rake/road,yard management, coal feeding to bunkers,physical verification

Leading a team of 980 manpower

JINDAL INDIA THERMAL POWER LIMITED DEC2020-DEC2022

Worked as Head - Electrical in 2 x 600 MW JINDAL INDIA thermal power plant, Angul,Orissa, India

Handling the plant maintenance including BTG/BOP,AHP/CHP/400 KV SWITCHYARD /72 KM OF 400 KV TRANSMISSION LINE

Leading a team of 200 manpower

STEAG ENERGY SERVICES LIMITED May 2017-NOV2020

2 X 600 MW SINGARENI THERMAL POWER PLANT -JAIPUR,MANCHERIAL

ADDL.GENERAL MANAGER ELECTRICAL

Working as Head - Electrical in 2 x 600 MW Singareni thermal power plant, Mancherial,Telangana, India

Established Various worlds best maintenance practices after the date of COD

Reduced forced outages due to electrical from 19 to zero with in 1 year with excellent technical and target oriented leadership qualities

UNIT 1 RUNNING WITH OUT ANY ELECTRICAL FORCED OUTAGE from SINCE JULY 2018

UNIT 2 RUNNING WITH OUT ANYELECTRICAL FORCED OUTAGE SINCE NOVEMBER 2018

Established 99.98 % plant reliability with focussed reliability centered maintenance approach

Leading a team of 125 manpower

POWERMECH PROJECTS LIMITED JULY 2016-Feb2017

SITE HEAD

Worked as site head for 2 x 600 MW coal based power plant at cuddalore, Tamilnadu

Worked with MAS Powermech Arabia- Riyadh office on turn around project of power and desalination units in Saudi Arabia.

SABIC-JUBAIL -KSA AUG 2015- May 2016

Worked for SABIC on Process knowledge Assurance and Business process data quality project

Updation of Process documentation as per the current processes and training the end users

On SAP Plant maintenance

NOMAC:FIRST NATIONAL OPERATION AND MAINTENANCE COMPANY-JEDDAH-KSA

PROJECT MANAGER APRIL’2009– AUG’2015

Best handled Project manager role of power and desalination plant

Managed the Maintenance planning with proven SAP/CMMS software skills

Applied VED analysis to all O&M spares and Ensured the spares best availability through SAP MM functions

Created best MRP planning in SAP MM function and automized the total procurement cycle of critical spares

Created the service master for all routine and overhauling services and established standard service rates for all plants.

Implemented Reiability centered maintenance and spares optimization

Optimized the task lists and Maintenance plans as per FMEA data

Formulated Task Risk Analysis (TRA) forms,conducted workshops to identify O&M activity risks and Implemented LOTO system based on the TRA output through SAP-WCM(Work clearance Management) module

Lead the Implementation of SAP Plant Maintenance Module for effective maintenance processes

Established Hazard Identifiction Risk Assessment and Risk Control (HIRRC) and Aspect Impact Assessment to make the plant industrially higene and environmentally friendly.

Established latest condition monitoring techniques and carried out predictive maintenance to mitigate the potential failures

Established Centralized procurement and contract services through service master to ensure the maintainability

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.

VEDANTA ALUMINIUM LIMITED: Sep’1999-Mar’2009

VEDANTA ALUMINIUM LIMITED- CPP

HEAD ELECTRICAL MAINTENANCE

Established Various worlds best maintenance practices in condition monitoring and maintenance of switchyard and generator

Best handled patrolling and maintenance of EHV Transmission Lines

Established Hot line maintenance on 220 KV transmission lines to reduce the plant shutdowns and increase plant Availability.

Implemented the composite grid islanding and load management system to avoid power black outs during grid disturbances.

Established grid islanding and load management settings after extensive studies through RTDS( real time dgital simulation) in Central power research Institute.

Accomplished industrially Hiegiene in all areas of power plant by implementing HIRARC

Reviewed and updated the maintenance procedures as per the reliabiliy scores and FMEA data.

Achieved plant scheduled availability of 99.98 % two years consecutively .

Preparation of quality,environmental, health safety policies, procedures, work instructions as per ISO standard

Fair experience in Implementing ISO QMS, EMS, OSHAS.

Implemeted process efficiency programs like kaizen,pokayoke

Recognized as “Star performer” by Vedanta group

BALCO CAPTIVE POWER PLANT

HEAD OPERATION & MAINTENANCE

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.

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

Applied VED analysis to all O&M spares and Ensured the spares best availability through SAP MM functions

Headed the Electrcal maintenance department introduced the Hot line (live) maintenance on EHV switch yard and transmission lines and carried out tightening and replacement of clamps and insulators online

Carried out retrofitting and maintenance of Power transformers and rectiformers and onload tapchangers including Oil filteration

Introduced latest condition monitoring techniques on all power generation equipment and carried out predictive maintenance to reduce the potential failures

Carried out many Latest RLA tests on power generating electrical equipments and taken corrective measures to improve the life of the equipment

Organized OPGW cable laying on Tr. Lines and installed fast acting Tr. Line protection

Retrofitted all AVR’s to improve the generator availability during house load operation

Good experience in conducting OCC/SCC and Generator dynamic tests during capital overhaul of generators

Managed the Maintenance planning with proven SAP/CMMS software skills

Implemented 5S in three phases and reduced many occupional and safety hazards.

Implemented 6-Sigma in 2 phases and improved the generator and switchyard availability

Implemented GRID islanding & load management scheme to mitigate the power blackouts and improved the plant availability

Carried out HIRARC and Aspect impact studies and established indusrial hygine all over the plant.

Preparation of quality,environmental, health safety policies, procedures, work instructions as per ISO standard

Carried out O&M activity risk assessment and implemented the SAP PM-WCM module to ensure proper safety in all O&M activities

STERLITE INDUSTRIES LTD

HEAD MAINTENANCE-UTILITIES

Headed the Operaton and maintenance of Utilities of 250000 FKM plant

Best handled the 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

Headed the maintenance department and implemented Reliability centered Maintenance across power plant

Recognized as “star” performer of Sterile group through ACT-UP group to work

in BALCO after Sterlite acquired shares and management control

Erected, commissioned and tested all utility equipments of 2.5 LFKM expansion plant including 132 KV substation, 4400 KVA UPS system and associated batteries,VAM chillers,cooling towers, Chlorine scrubbing plant, acid plant, softwater and DM water plants,fire alarm, fire fighting,

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

M.R.F. Ltd–TYRE MANUFACTURING INDUSTRY-SADASIVPET, HYDERABAD

Sr. Engineer (Electrical-Maintenance) 1993-August 1999

Responsible for maintenance of Experience in AC/DC,Regenerative /Non-regenerative Drives of Siemens/ABB,PLC’s of Siemens/ABB,HT/LT switchgear,LT/HT Motors, DG sets,Wartsila-ABB make multiple 6 MVA HFO based sets

Core Competencies

O& M Planning /Management

Effective Maintenance planning techniques with reliability centered maintenance concepts and latest condition monitoring techniques

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

Applied VED analysis to all O&M spares and Ensured the spares best availability through SAP MM functions

Created best MRP planning in SAP MM function and automized the total procurement cycle of critical spares

Created the service master for all routine and overhauling services and established standard service rates for all plants.

Creation of router for production planning and creation of MRP to automize the procurement cycle for critical raw material

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.

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

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.

Conducted the workshops for equipment and system analysis using end to end Reliability Centered Maintenance RCM analysis methodology

developed system and equipment criticalities and efficiently schedule Reliability Reviews using RCM methodology for the operation assets.

Defined and scheduled review teams for RCM analysis sustainable through live program

Conduct detailed analysis to determine Failure Modes Root Causes and formulate solutions with the strategic think team

Coordinated with Operations, Maintenance,Inspection, Engineering and defect elimination to determine resources and cost requirements to strategy enhancement solutions

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.

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, maintenance task risks for all business functions of the organization.

Technical Expertise

Captive power plants ● PF fired Boiler ● Turbo generator,Brushless/brush type excitation systems, 220/11 KV Generator Transformer and offsite equipments ● Coal Handling Plant ● ESP’s & Ash handling ● DG sets ● cooling towers● HT/LT Motors,HT/LT switchgear,PCC’s & MCC’s.

Errection,commissioning testing of all power plant electrical equipments including Generator,GT,ST,UAT,brushless and Brush type excitation systems,boiler, turbine,BOP auxillaries.

HVAC and related auxilarries

Installation,testing,commissioning of static protection relays of Generator/GT/UAT/ST/Busbar/Transmission lines

patrolling &maintenance EHV transmission lines and associated auxilarries

maintenance of EHV switch yard(including GIS) and associated equipments like CV/CVT/LA/Sf6 CB/off load breakers and protection systems

AC/DC,Regenerative /Non-regenerative Drives of Siemens/ABB,PLC’s of Siemens/ABB,

Excellent maintenance planing with proven SAP PM,WCM,MM,EHS/CMMS software skills

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

Coal handling plant equipments like coal crushers, 1200 TPH coal conveyors, stacker reclaimer,wagon tippler, track hopper,dust collecton and dust extraction system,magnetic seperators, metal detectors, coal yard stacking and reclaiming, fire protection and fightinh systems.

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 protection systems,PAsystems

Compressors/Air driers: Kirlosker ●GEC ● Khosla make compressors

Diesel generator sets of Cumins, Detroit,caterpillar, Wartsila

AVR systems Grid synchronization ● SCADA system and load shedding system

KRAs and KPIs across the career span

Establishement of plant reliability with a goal of zero forced outage and 100 % plant availability

Establishment of best world class maintenance practices across the plant

Establishment of best safety & environmental practices with goal of zero accidents and zero LTI

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.

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.

Quarterly review of the the performance of the employees

Oversee 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.

Early Career

1991-’92 - Project Assistant - Western Regional Electricity Board-Mumbai- Study of SCADA System

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