Team Leader Instrumentation
dubal
Total years of experience :24 years, 9 Months
Highlights
• Smart Instrument Configuration, Maint, Calibration, Measurement system analysis.
• PLC Programming & Upgradation.(Allen Bradley, Siemens)
• RS Logix 5000 functional design and configuration, Scada, HMI design & Configuration using Factory talk.
• Argon gas vessel filling control and chlorine gas distribution systems.
• Commissioning of CNC Machines( From Panel design to commissioning testing).
• Ethernet, Controlnet, Devicenet using RS Networx, DH+, Fieldbus, Powerflex drives - Configuration and Maintenance.
• PID Controlled applications (Optimizing Proportional, Integral, Differential).
• Natural gas combustion principles, Stochiometric ratio, Oxygen analysers, Nox.
• Gas detection and safety devices.
• SAP & ORACLE Maintenance module, MS Office (Advanced Excel, word, Power point, Access).
• Weigher Configuration Calibration, Loadcell selection and troubleshooting.
• ABB Industrial Robotics - programming and troubleshooting.
• Chemical dosing systems, PH, ORP, Conductivity
• Volume and surface Ultrasonic testing of Aluminium billets (Backwall, Crack, Intrusions).
• Compliance to ISO 9001 & ISO 14001, Developing Maintenance system and Procedure, 5S activities.
• Data analysis using SCADA.
• VMware workstation installation, configuration, network settings and working knowledge.
Reliability, Planning, Technical support, Safety, Cost management Skills
• Reliability techniques like RCA, RCM, HAZARD identification and management to ensure EHS.
• Computerised maintenance using SAP ORACLE, Energy Audit and conservation.
• Reliability growth, Recurrence analysis using JMP (SAS)software, SAP (Critical BD data, MTR, MTTR)
• Implement manage preventive and predictive Shut down maintenance.
• Develop, implement, monitor, review and revise the maintenance and inspection strategy for Instrument equipment and systems to achieve the safety and reliability .
• SIS like safe cast abort and emergency water system in DC, HDC machines, Risk Analysis, SIL, HAZOP.
• Set, monitor& control dept budgets to ensure costs are in line with budgets.
• Providing Technical support and coordination for commissioning of new projects.
• Predictive maint - Condition monitoring (vibration, temperature) of critical Motors, Recirculation blowers.
• Deals with technical queries of warehouse, purchasing and suppliers., knowledge of MAXIMO.
• Conducting Safety meeting, Tool Box talks and Training UAE nationals.
Accomplishments
(From Aug 2006 to till date in Dubai Aluminium Company)
• Implemented several Energy saving measures throughout the plant including a Natural Gas saving in Launder Pre heater suggestion with recurring saving of 2.2 million AED per annum (audited).Won Best International idea award 2013 at DIB GERMANY, Best Idea of the year and Overall idea of the year at IDEAS AMERICA.
Published in ALUMINIUM TIMES a flagship international aluminium industry Magazine recognizing the value of the idea.
• Implemented an innovative idea of Mechanical amplification in Sensor detection system in HDC machine which increased the availability of equipment from 75% to 99%.(won an annual gold award ).Nominated for Ideas UK in innovation and Technology category.
• Developed a mini robot 3 axes PLC controlled Marking system - won Silver award in Best idea category in Dubal 2014.
• Modified / Developed PLC programs in Allen Bradley PLC throughout the plant to increase the efficiency, safety, Productivity.
• Upgraded Allen Bradely PLC 5 to Control logix with RS logix 5 to RS logix500 program conversion.
• Upgraded Uncompensated(temperature pressure)Turbine gas flow meters with Mass flow Gas meters to monitor the Furnace gas consumption accurately .
• Developing Asset management system.
ACHIVEMENTS:
1. Implemented Energy saving techniques in Cooling towers with temperature control instead of continuous running, Controlling unwanted running of machineries.
2. Upgraded On Off controllers with PID controllers to increase the process efficiency.
3. Increased the productivity by 25% in Crane intense activity area - Replacing Rotor Resistance Induction motors with Drive controlled Induction motors.
4. In house development of Core making plant with PLC control (Rs 25 lakhs saving).
5. Modified the Kanthal heating element mounting system in Heat Treatment furnaces and minimised the BD.(Annual saving of 5 lakh rupees).
PROJECT, COMMISSIONING, E&I MAINTENANCE, ISO SKILLS
1. IMF Italy Mixer Moulding machines(PLC Telemechanique),
Thermax sand Processing plant..
2. PLCs - Siemens (Simatic S5, S7 200/300), Fanuc Telemecanique,
3. CNC Machines(Fanuc, Heidenhain).
4. Configuration and Maintenance of Instruments Like
PID controllers(Toshniwal & Yokogawa), Differential Pressure Transmitters (Rosemount), Valve positioners, Temperature controllers & Recorders, Pyrometers, Safety & Control equipments for Oil burners, Level controllers (Capacitance type switching), Ultrasonic Thickness gauge meters.
AC/DC Drives -(Siemens, AB, Indramat, Telemec, )
5. ISO 9001 :
Work Instructions, Calibration Procedures, Approval of equipments. Maintaining quality records, History cards.
Preparing & Carrying out PREVENTIVE MAINTENANCE.
6. ORACLE ERP SYSTEM Maintenance module.
7. ISO 14001 activities.(internal auditor)
8. Pneumatic & Hydraulic controlled equipments
9. Medium frequency Induction furnaces (1250 KW)
with Rectifier/Inverter Firing, Thyristors, Capacitor banks1000 kvar, Induction furnaces
10. Thyristor controlled Heat treatment furnaces with PID controllers, zero angle fired thyristor control boards, 400 kw heating elements, Thyristors.
11. 11 KV Transformers, 11 KV OCBs