General Manager Capital Projects

Sanjay Terdal

Pune, India +91-702-***-**** ********@*****.***

IRON & STEEL COPPER FLAT & LONG PRODUCTS CAPITAL PROJECTS MAINTENANCE

ELECTRICAL & AUTOMATION INDUSTRY 4.0-DIGITAL TRANSFORMATION-GREEN STEEL INITIATIVE PROFESSIONAL EXPERIENCE

General Manager, Electrical and Automation) Hulas Group (Nepal) Sept 2021 – Present

● Successfully commissioned 2 ERW pipe mills, 2 SS tube mills, 4 wire drawings, and 1 wire galvanizing line with 0.05MTPA production capacity, ensuring safety compliance and quality standards.

● Spearheaded the expansion project of structure galvanizing and narrow strip galvanizing by commissioning SIEMENS and ABB PLC/HMI including mechanical, civil,and structural functions- more output productmix

● Conducting Greenfield project feasibility study for 1.5MTPA capacity Green steel initiative that uses Arc furnace route

(DRI and scrap) with caster, narrow hot strip mill, and section mill as backward integration. Associate Head, Automation and Electrics Sunflag Iron and Steel (India) Feb 2019 – Jun 2020

● Upgraded Upstream Mini Blast Furnace with Bell-less Top (BLT), Rockwell automation system (PLC), and Relining activity within 40 days of planned capital shutdown resulting in increased output production by 10%

● Modernized Continuous Billet and Bloom Caster with electrical servo Mould oscillation system, Slag detection system, and camera-based Billet cutting system for improved surface quality

● Upgraded bar and section mill with 12 Nos ABB Digital drives for Roughing and Intermediate stands Proactively implemented SAP-CMMS for Induction, Electric arc furnace, Caster, Rolling with ISO system

● Achieving <1.5% near-zero breakdowns through TPM Metrics usage (5S, CAPA) for predictive analysis.

● Commissioned Integrated Plant Monitoring system to integrate all manufacturing & operational data of Steel Melt shop and Rolling mills using ABB Ability Digital Data analytics platform with IOT . This ensured real time plant operations on modern dashboard as a part of wider Digital Transformation Initiative. Chief, Electrical PT Surabaya Steel Investama (Indonesia) Jul 2014 – Jan 2019

● Successfully executed Downstream Greenfield project of Cold-Rolling Mill Complex with detailed Engineering and Erection of 6 Hi Mill (Tenova I2S), push-pull pickling, annealing, slitting, and rewinding (SMS Esmech, ABB PLC and Drives) for sister company consumption of CRFH and CRCA products

● Conducted a Techno economic viability study for relocating and refurbishing 2nd hand 1.5MTPA Hot-Strip Mill (HSM) from BlueScope Steel, Australia and 0.12 MTPA Section Mill from Hansun Wire, South Korea to Indonesia with a capital Investment of $150 million including contract management and procurement planning, ensuring seamless turnkey Project Supply with Sino Steel and TMEIC/ABB as backward integration Deputy General Manager, Electrical and Automation JSW Steel (India) Jun 2006 – Jun 2014

● Successfully executed a Downstream Greenfield project including conceptual bid specification, design, detailed Engineering, Commissioning, and start up of 0.8 MTPA Cold Rolling Mill Complex–I, comprising CPL, ARP, Twin stand Reversing CCM (SMS Siemag and ABB - PLC, MV, LV Drives), ECL, BELL annealing, Skin pass, RCL, APL, followed with maintenance for production of commercial grade steel

● Delivered a $700 million Greenfield project of 2.3 MTPA Cold Mill Complex-II for automotive grade steel with state-of-the-art PLTCM (SMS Siemag), CAL1and2 (0.9MTPA each),and 0.4MTPA Dual Pot Continuous Galvanizing/Galvannealing (Steelplantech, Japan), integrating TMEIC USA/Japan L1 & L2 automation (OT), and upward IT integration (MES/ERP) achieving timely completion (28 months) without cost overrun with automated production and processing real time plant operation data for analysis and decision making.

● Boosted operational efficiency by more than 40% by engineering a complete Roll Shop Management System (Waldrich Siegen) with automatic roll tracking and retrieval using RFID, Siemens Level2, and communication with mills and process lines. This was part of IIOT initiatives (Industry 4.0) and data in real time.

● Designed and implemented a near patented Coil Yard Management System (PESMEL, Finland) with L1 & L2 Siemens PLC/HMI, integrating automated cranes, transfer cars, WIP tracking and Finished Goods - Automated Storage and Retrieval System (ASRS) to enhance efficiency in WIP material and real time location

● Underwent safety training with DuPont consultants and effectively implemented Safety practices

● Increased Overall Equipment Efficiency (OEE) by monitoring daily plant activities for production stabilization and ensuring equipment availability with real time monitoring

● Collaborated with Pesmel (Finland) for the simulation of complete Coil Yard Management system, ArcelorMittal (Spain), ThyssenKrupp (Germany), and SMS Siemag (Germany) for technical and operational study of CRM equipments, and TMEIC (USA) for System Integration Test of PLTCM automation system. Chief Engineer, Electrical & Automation Mabati Rolling Mills - SAFAL Group (Kenya) Sept 2000 – May 2006

● Successfully executed a $30 Million Brownfield project with complete Engineering, Erection, and Commissioning of Dual Pot Continuous GI/GL production Line 0.14~0.8mm 1250mm wide (Kawasaki-Japan, Centum DCS-Yokogawa, Automation-Rockwell). This is a first-of-its-kind project in Africa in the year 2000.

● Recommissioned inter-plant relocation project of 2nd hand Cut-to-length (CTL) with Control Techniques Drives, while optimizing process flow and cost.

● Identified and implemented best operational practices(Gemba Kaizen),achieved near-zero breakdowns and enhanced productivity.

● Practised preventive and breakdown maintenance of 4HI Cold Rolling Mill (Hitachi PLC and Drives), Bell annealing, Dual Pot CGL with NOF, colour coating, cut-to-length line, 132kv substation to ensure equipment availability.

● Explored procurement and inventory management using the Plan-For-Every-Part (PFEP) model and vendor analysis Manager (Electrical) SWIL LTD, India Dec 1994 - Jul 2000

#Strip and wire unit manufacturing Integrated non –ferrous (copper and its Alloys)

● Erected &commissioned New 20hi mill & Semi Concast (WERTLI Sweden) Melting Channel/ and Holding Coreless Induction furnace

● Managed In-house erection & commissioning of 2nd hand Imported-20Hi Sendzimir mill, 2hi BD mill, slitting line achieved reduced project cost and increased Plant capacity

● Guided Implementation of TPM /5S/ Autonomous Maintenance techniques by Creating BD MILL as Equipment Role Model and improved OEE by 8%

● Worked on Business process ReEngineering & optimised process material flow and reduced cost by effectiveness in operation

● Undergone Professional Training-Total Productive Asset Management (TPAM) & accomplished improvement in asset availability and reliability with optimised maintenance cost Senior Engineer Nippon Denro Ispat Ltd (now JSW Steel Coated Products Ltd) India Apr 1989 – Dec 1995

● Managed the commissioning and maintenance of a 6 HI cold rolling mill, the first of its kind in India, supplied by Hitachi Japan

● Led a special assignment to Thessaloniki, Greece, for the supervision of dismantling a 4 HI cold rolling mill and spearheaded its relocation, erection, and commissioning in India.

● Coordinated with production and process teams ensuring commissioning to stabilize operations Shift Engineer Ravindra Steels Ltd, India Dec 1987 – Mar 1989

● Handled preventive and breakdown maintenance of electric arc furnace (GEC MAKE) and semi – continuous Casting machine (Billets), EOT. Cranes & utilities to maximize Equipment Availability & Resolved Electrical breakdowns EDUCATION

Bachelor Of Engineering (Power Electronics), Nagpur University 1987 EnergyX :Sustainable Energy: Design for Sustainable Future,DelftX: Delft University of Technology 2025 SKILLS & EXPERTISE

● Capital Projects: Greenfield Projects, Brownfield Projects, Modernization/Upgradation, and Relocation Projects

● Upstream: DRI, Sinter, Blast furnace, EAF, LRF, AOD/VD, Caster (Bloom/Billet/Slab), Hot Rolling Mill (Long, Flat)

● Downstream Flat: Cold rolling (PLTCM, Twin stand CCM), Continuous Annealing, Continuous Galvalume//Galvannealing, Color coating

● Downstream Long: ERW pipe, Tube mill, SS tube mill, Low carbon wire drawing, flattening mill, wire galvanizing, Struct Galvanizing, PEB

● Non-ferrous: Copper and Copper alloys (PB, NiS, Brass) integrated plant for Strip and wire production using Melting, holding furnace, Rolling mill, Annealing

● Proficiency in Electrical Systems, Electric Drives, Industrial Automation, Instrumentation, and Power Systems

● Substation 132KV, 33KV, 6.6KV, LV power distribution 0.4KV, Captive power, DG sets, Utilities

● Green steel: H2 generator Electrolyser (Norsk Hydro) for NOX furnace

● Automation Equipment: Siemens PLCS7, TIA PORTAL, HMI, SCADA ABB PEC, AC500, Process Automation, MV and LV drives Hitachi HSeries, HISEC04 TMEIC NV series, Process Automation, MVand LV drives, L1 & L2

● Auxiliary Automation: Coil Yard Management System (YMS), Auto storage and Retrieval system (ASRS), Material flow L1 and L2 automation

● Computer Skills: Microsoft Office Suite, Microsoft Project, Advanced Microsoft Excel

● Business Process Re-engineering, Total Productive Maintenance, Asset Management

● Process Improvements Cost Reduction Energy Management

● Quality Standards: ISO system 9001/14001/45001

● Competencies: Problem Solving Analytical skills Innovative Collaborative Resilient

● Leadership: Project Engineering Project Coordination Erection Commissioning Strategy

● Maintenance: SAP-CMMS, Planned, Preventive Maintenance, Condition Based maintenance Predictive Analytics

● Digitalization: Integrated plant monitoring system, Data collection, Data analytics, IOT

● Supply Chain Management: Inventory Management PFEP model, Vendor Analysis, Procurement

● Additional Functional Skills: Mechanical, hydraulics, civil and structural construction functions PROFESSIONAL CERTIFICATIONS

● EnergyX:Sustainable Energy: Design for Sustainable Future,DelftX: Delft University of Technology 2025

● Automax PLC, SIGMA HMI & System Drives (Reliance Electric, Japan)

● CENTUM CS 1000 (DCS) Fundamentals and Engineering (Yokogawa Electric Corp, Japan)

● Operation of HICON/H2 Bell Annealer (EBNER Industries GMBH, Austria)

● Safety Practices (Dupont Consultants, India)

● Total Productive Asset Management (TPAM) (Hofincons Consultants, India)

● Business Process Re-engineering (SWIL, India)

● Course Work: Operational Management and Financial Management HONOURS AND AWARDS

Winner of Best Energy Management Award - Innovation Category - Industry Association of Kenya (2005)

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