Senior Manager Electrical & Instrumentation, Reliability Centered Maintenance at (Cement and Power)
MAPLE LEAF CEMENT FACTORY AND POWER PLANT
Total years of experience :12 years, 2 Months
Responsibilities:
ELECTRICAL:
Trouble shooting, Inspection and Condition based monitoring of:
1.) Transformers, motor Control Centers MCCs, switch gears, Grid and distribution substations by frequency based tests including thermography, online High Voltage Partial Discharge survey, Dissolved Gas Analysis (DGA) (ASTM D3612) (outsource), Transformer oil analysis (IEC 60422) (outsource), Break Down Voltage (BDV), vacuum integrity test, CT and protection relay testing using Flier T250, PDS Air HVPD, Megger OTS 80PB (IEC-60156), VIDAR and SEVERKER 900.
2.) MV/LV (Medium/Lower Voltage) motors and generators by frequency based tests of winding resistance, IR, Surge tests curve analysis, starting current analysis and carbon brush wear rate using Schleich MTC 2 and PICOSCOPE tools as per IEEE 43-2000 standard.
3.) Power system analysis using ETAP 12.6 for load flow analysis, star relay coordination study and short circuit analysis.
INSTRUMENTATION AND CONTROL:
Trouble shooting, Inspection, calibration and preventive maintenance of cement line and power plant instrumentations including but not limited to Pfister rotary, apron, belt weigh feeders, ABB Gas Analyzer, Bernard/Auma Actuator, Jorgensen/TMAX/local Temperature, e+h/Danfoss/Atlas Copco Pressure, VEGA/Siemens/e+h ultrasonic level, sensors/switches/transmitters and controllers.
Maple Leaf Power generation plant 98 MW consists of:
1. Sinoma Energy Conservation Ltd (China) Coal fire power plant of 40 MW, condensing turbine type, with tube type boiler and 03 nos of coal mills make: BPEG type: ZGM65.
2. 04 NIIGATA 18V32CLX, TOYODANKI generator of 6 MW each and 01 WARTSILA 18V50DF, ABB generator of 16.6 MW capacity.
3. NANJING 12 stages steam turbine, QFWL-18-2 generator of 18 MW with five KAVASAKI, Heat Recovery Steam Generator (HRSG) tube type heat exchangers.
4. 50 MVA & 20 MVA grid with AEG and Siemens NX PLUS C 6.3 kV switch gears.
~ To ensure Power generation plant reliability, my responsibility includes but not limited to, planning and preparation of maintenance schedule, conducting electrical tests, wear measurements, 4s inspections, preparation/modification of inspection/parameter checklist, daily parameter analysis, and inspection of assets before & after maintenance and issuance of job completion certificates.
~ Incorporate plant assets and maintenance activities in eAM oracle base, ensured compliance of manual/planned work orders and maintained job quality by generating job completion certificates and implementation of LOTOTO and safety work permit.
~ Incorporate plant assets and maintenance activities in eAM oracle base, ensured compliance of manual/planned work orders and maintained job quality by generating job completion certificates and implementation of LOTOTO and safety work permit.
~ Trained and evaluated my team capabilities and promote them accordingly.
Achievements:
+ Analyzed short circuit and took preventive remedial action of 2500kVA Siemens transformer after condition 4 Electrical Arching diagnosed in DGA test 5500 ppm of above the LEL (lower explosive limits) accompanied by red spots observation by thermography report and Break Down Voltage (BDV) test of 15kV.
+ Analyzed and prevented short circuit of 2000kW Siemens motor after measuring abnormal wear rate of carbon brushes, carbon spots on slip rings/rocker arm and pitting on short circuit contactor of liquid stator.
+ Diagnosed multiple times faults on MV AEG/Siemens switch gears, slip ring/liquid stator of MV motors, MV cables and Motor Control Centers (MCCs) using online High Voltage Partial Discharge test and thermography test.
+ Developed and lead inspection, maintenance work instructions on experience based and OEM instruction manuals.
+ Developed and lead inspection, maintenance work instructions on experience based and OEM instruction manuals.
PROJECTS:
1.) Waste Heat Recovery Power Plant (Up Gradation) MAPLE LEAF CEMENT FACTORY AND POWER PLANT. ISKANDERABAD, PAK. (Nov 2020 - Sep 2021)
Role:
+ Testing of Switch gears, CTs, PTs and generator.
+ Planning and design review of E&I.
+ Coordination with OEM.
+ Testing and calibration of different field instruments (Control valves, MOVs, Field Transmitters, Sensors, Actuators etc).
2.) Up Gradation Of 132 KV Grid Station
Up Gradation Of 132 KV Grid Station
MAPLE LEAF CEMENT FACTORY AND POWER PLANT. ISKANDERABAD, PAK. (Nov 2015 - Jun 2016)
+ Installation/erection/testing and commissioning of MV panels (scheider Electric).
+ Supervising technically and managerially all site activities.
+ Solve site execution issues and check the entire work as according to approved drawings.
ENGINEERING AND COMPUTER SKILLS
++ PRACTICAL POWER SYSTEM SCHEME DESIGN AND SIMULATION using ETAP 12.6 for load flow analysis, star relay coordination study (50, 50N, 51, 51G, 64G, 87, 27, 81, 32, 52), ARC flash analysis, grounding grid, optimal capacitor placement, static and dynamic motor analysis and renewable/DG integration and analysis.
++ Switch gear vacuum integrity test, contact resistance (tool outsource), timing test (tool outsource), CT ratio/knee point and Protection relay including (ANSI 50, 50N, 51, 51G, 32) testing using VIDAR and SEVERKER 900.
++ Capable of analysis for Transformer health monitoring such as dissolved gas analysis (tool outsource) and oil analysis (tool outsource).
++ Apprehend P&ID, control/protection schemes, read its drawings and trouble shoot protection equipment problems.
++ Capable to solve diverse problems through Root Cause Analysis (RCA) and Apollo diagram of equipment failure and suggest/implementation avoiding reoccurrence.
Responsibilities:
Time honored operation, routine/periodic inspection, maintenance, trouble shooting, bench testing, calibration and optimum store management of 6.3kV substations and area instrumentation, Main system include.
1.) MV/LV Motors up-to 5100kW, MV/LV Switch gears up-to 1250/3000A, Protection relays and control circuits. Make: VEM, AEG and Siemens.
2.) Electrostatic Precipitators (EPs) & Power Factor Improvement panels.
3.) Hasler belt & Pfister rotary, apron, belt weigh feeders, ABB Gas Analyzer, Bernard/Auma Actuator, Jorgensen/TMAX/local Temperature, e+h/Danfoss/Atlas Copco Pressure, VEGA/Siemens/e+h ultrasonic level, transmitters and controllers.
Established loop testing and interconnection interlocks of area instrumentation, MCCs, Siemens and Schneider Electric PLCs.
Achieved optimum store management by forecasting spares, consumables, tools, services of right quantity, quality and on time availability within the predefined budget. Provided technical data, comparative statements and submit purchase recommendations.
Achieved optimum store management by forecasting spares, consumables, tools, services of right quantity, quality and on time availability within the predefined budget. Provided technical data, comparative statements and submit purchase recommendations.
Achievements:
+ Achieved 7 million white cement plant store budget reduction and identified the least number of consumable and safety limits of run to failure electrical/instrumentation equipments. Redefined and reconstructed spare identification codes, store spare locators and spare description.
+ Troubleshooted and eliminated 37 times/day EP tripping by Pfister rotor weigh scale balancing.
+Installed and commissioned weigh feeder electrical and control panel with bin balancing of 300 ton load cells.
Integration of sustainable energy systems in conventional energy systems. Major Subjects: Renewable Energy sources. Advance Thermodynamics. Steam and gas turbines. Electrical System study.
Electronics engineering, major Electrical Power system analysis.