Assistant Manager Utilities
Engro Eximp Pakistan
Total years of experience :15 years, 8 months
Oct.2013-to date Assistant Manager Utilities at Engro Eximp Pakistan
Utilities plant consists of: • Husk fired Solid fuel water tube boiler Cap. 35 ton/hour working pressure 65 Barg,
• Oil fired, fire tube boiler Cap. 10 Ton/hour working pressure 10 bar.
• Steam turbine condensing and extraction type Power 4.0 MW/hour.
• 2 Diesel Engine allied power 1.2 MW each.
• Cooling tower Induced type 8 cells.
• Air compressors 3 model ZR-500 pressure 9 bar each.
• Demineralization plant capacity 40m3/hour.
• RO plant Capacity 50 m3/hour.
• Deep well turbines 2 capacity 300m3/hour each.
• Effluent treatment plant.
Responsibilities: - Training
- Environment
- Document Control
-OH &S implementation
Follow DuPont
I am responsible for managing all the repair and maintenance activities across all the plant areas to ensure that the same remain in perfect working order all the time and the plant remains in compliance with AIBI and PWF standards.
I am also responsible for the Managing of operation and maintenance of all utilities (High pressure boilers, steam turbines, ETP, C/T, water treatment, Diesel engines, compressors), and direction of engineers involved in the monitoring, controlling and operation of the equipment associated with power, cooling towers, water treatment, waste water treatment, chilling system, ice water system, compressed air and Steam generating units. Core duties involve overseeing of efficient and reliable power generation, steam generation & water treatment providing technical guidance in diagnosing and troubleshooting plant problems, field inspections to ensure compliance to company's safety regulations, and also provides leadership in first-line containment response during emergency situation
•Set all KPI targets within the OPEX budget allocations
• Safety and fire prevention
• Manage and maintain plant performance/efficiency
• Lead to recommendation process improvements that lead to lower costs, greater profitability, better productivity, and higher throughput
• Follow all company approved rules, standards, procedures, governmental requirements, company policies, and follow consistently and completely and cascading to engineers.
• Manage and maintain the latest state of the art technology and equipment
•Aggressively manage and maintains a safe working environment with all applicable environmental, health and safety policies
• Manage troubleshooting, diagnostics, and repairs to correct the cause of any operational and maintenance abnormality or problem
• Manage and cascading corrective action to maintain chemical analysis and chemical control on steam, cooling, and condensate systems
• Leads to emergency operations during unit trips and abnormal operating conditions to place plant equipment in a safe operating condition
• Manage plan shutdown and startup procedures during outages
• Manage all plant equipment/systems
• Manage to position and configure plant equipment for proper operation
• Report all abnormal plant conditions to the Manager factory
• Manage and asked to engineers "writes and updates plant operating procedures"
• Manage plant drawings and cascading updated P&ID's and others documentation as needed
• Communicate effectively with all plant subordinates
• Manage to maintain area of responsibility as per legal, regulatory and AIBI/PWF Standards (Quality and HSE) to keep state of readiness for all the audits.
• Manage that all plant equipment's and machinery are maintained in perfect working condition all the time and perform safe, smooth and trouble-free operation when needed.
• Manage efficient allocation and utilization of resources to meet maintenance targets while executing Preventive, Predictive as well as Breakdown maintenances.
• Manage effective utilization of Inventory Management Software for engineering stock management/monitoring of consumable materials/spare parts inventory and their consumption for maintaining all the equipment in working condition.
•To lead Recon agenda at Plant to meet all resource conservation targets.
• Manage to maintain all Utilities equipment at the plant in perfect working order and deliver the required utilities to the production operations as and when needed.
•Manage R&M and utilities (Electricity, Gas, Fuel and Water) related expenses within budget and plan.
• Manage to timely annual maintenance of the boilers at the plant with minimum disruption to production operations while also complying with all regulatory requirements.
•Manage to provide support in planning as well as execution of capital projects at the plant.
•Manage to Implement standard requirements & take all necessary actions in area of responsibility to Sustain ISO 14001 & OHSAS 18001 certification
HSE - Actions: • Developing an HSE culture
• Assessing compliance
• Learning from experience and its implementation.
• Providing support to new entities
• Broadening environmental and safety certification
Aug.2011 - Oct.2013 Team leader, Nestle Pakistan Kabirwala Factory
Fully support to subordinates and Supervised, coordinated, provided leadership to and reviewed the work of assigned staff.
I was responsible to lead in Steam & Power generation unit (Utilities) . and shift-based supervision and direction of operation involved in the monitoring, controlling and safe operation of the whole utilities associated with steam generation and power generation. Worked for safe and stable operation of plant (utilities) and control various parameters and handled different emergencies at plant which includes:- Power Failure. Steam Failure.DCS Failure.
Aug 2006 - Aug 2011 "Boiler Engineer" FFC (Fauji Fertilizer Company) Goth Machhi from Aug 2006 to Aug 2011.
My foremost job responsibilities included;
✓ Waste heat Steam Generators (Power Generation System (combined cycle)
Operation on DCS (Yokogawa centum CS 3000) Power generation: This section has two "gas turbines rated capacity 18 MW each, Waste heat + composite steam generators rated capacity 57T/HR, WP 40kg/cm2 Tem.390c with forced water circulation system" These waste heat recovery boilers are mounted at turbines exhaust,
✓ Auxiliary Boiler Steam Generator.
Operation on DCS (Yokogawa centum CS 3000), A high-pressure water tube auxiliary boiler with forced draft, water cold furnace, Capacity 77 ton/hr Superheated steam temp. 510c & working pressure 110kg/cm2 with natural water circulation system.
Steam turbine rated capacity 22 MW.
Steam Letdown stations ( steam letdown from 110kg/cm2 to 40kg/cm2 and also letdown 40kg/cm2 to 3.8kg/cm2 for the requirement of plant)
✓ Pretreatment system of water
Ground water and surface water used for plant requirement. Ground water taken from wells and surface water from canal. To remove temporary hardness and turbidity we use clarifier. Turbidity removed by dosing alum and poly electrolyte solution for the removal of temporary hardness lime solution fed in the clarifier. Also gravel filters are use to remove suspension turbidity.
✓ Demineralization System
Demineralization takes place with 04 Cations and anions exchangers with capacity 660m 3/hr totally. 04 mix beds with capacity 805m3/hr totally.
✓ Cooling tower
This section consist of 09 cells cooling tower with 32000-m3/hr circulation rate circulated through 05 centrifugal pumps driven by 6.3 kv motors and with a steam turbine. Rated capacity 2.2 MW
✓ Nitrogen plant
3 adsorption type nitrogen plants each capacity 6000NM3/Hr.
✓ Chilling system
3 chillers absorption type each capacity 300T/Hr.
Oct 98 - Jan Aug 06 "Erection and operation engineer" FBL Group Company
During the period of services one year as App. engineer (Oct 1998-Oct 1999) and (Oct 1999- Aug.2006) as Errection Engineer and Operation engineer,
Errection, Commissioning and operation of water tube boilers (gas fired, oil fired), Fire tube boilers, Waste heat recovery boilers, RO. Plants, DM. Plants, Sodium zeolite softening plants, Cooling Towers,
RESEARCH WORK
• MSC Research on Occupational Health and Safety.
Msc applied Environmental Sciences
Power Generation, Steam Generation
1994 - 1996 B.Sc. (Double Math, Physics) Islamia University Bahawalpur