Senior Panel Operator/Asst supervisor(operation/production)
EMIRATE STEEL INDUSTRIES
Total years of experience :21 years, 4 Months
Presently working in "EMIRATE STEEL INDUSTRIES" (ESI) . Abu Dhabi (UAE) . As a Senior Panel Operator/Asst supervisor (DR plant) in HYL-III Technology (Hytemp system with Steam Reformer, Process gas heater, Reactor & CO2 removal unit) . From May 2008 to till date.
Organization Profile:
EMIRATE STEEL INDUSTRIES is Division of Abu Dhabi Basic Industries (ADBIC). Under General Holding Corporation (GHC) .GHC is an Organization under Government of Abu Dhabi. ESI Integrated steel Complex project includes ESI Phase I & II. ESI Expansion project PHASE I was completed in 2009, project includes world 1st HYL III Hytemp plant (1.6 Million ton/annum), by this technology 600C Hot DRI charge to EAF by pneumatic transport system (PTS) .and also having Melt shop (1.4 MT/annum), Bar Rolling Mill (0.65 MT/annum), Wire Mill (0.55 MT/annum), ESI DR phase II Expansion project Hot commissioning & PGT completed on June 2011, includes HYL III DR Plant, Heavy section rolling mill, EAF, CCM, WTP, ASP etc. project planning and expansion for phase IIB & phase III is under progress.
Job Profile:
➢ During cold and Hot commissioning of phase I & II (HYL III Direct Reduction Plant)
Responsible for safe operation & process control with follows standard operating procedures, Coordinate with HYL experts.
➢ As Senior panel operator provide the guide line & technical support to shift supervisor and panel operator for start up & shut down of ZR direct reduction plant (Zero Reformer plant Al Nassir or GSPI which is now part of ESI Phase III)
➢ Works as a core member of commissioning & operation team of Direct Reduction plant.
➢ As Senior Panel operator, Responsible for plant start up and shut down, During normal operation maintaining process parameter (like FER, CER, TSR, TSC, RRV.PG CH4, PG CO2) to achieve the plant target production, responsible for DRI quality in terms of Metallization & carbon.
➢ Excellent operational knowledge of Steam Reformer, CO2 removal system, PGH, Reactor tower, Steam turbine solid flow and gas flow process of HYL technology with Siemens PCS7 operating system.
➢ Responsible for process safety and process optimization. During normal plant operation also involve in Data recording, collection & documentation (by SAP) and follows the HSE policy of ESI, maintain the work permit records, participating in Dept. budget planning, inventory control, new employee training program etc,
➢ Involve in Review and modification of P&ID, PFD, Safety matrix, process calculations, providing technical support & coordination to Automation and Electrical, mechanical dept etc.
➢ During shift responsible for complete plant operation, provide the instruction & gauide line to panel operator& field operators, coordinate with supporting department. Reporting to Shift supervisor, section head, DR plant manager.
➢ Emirates Steel Industries provides the 45 days valuable specialize training for smooth plant operation in MEXICO, Montterey (HYLSA, ternium) with ZERO REFORMER (ZR), VPSA & HYTEMP operation (in 4M & 3M5 plant) and in pabela (MEXICO CITY) with STEAM REFORMER (in 2P5 plant) and Chemical CO2 removal unit.
“QATAR STEEL COMPANY” (QASCO). Mesaieed, (QATAR). As a DR Senior Operator in MIDREX Technology (Natural gas CH4 based). From September 2006 to May 2008.
Organization Profile:
QATAR STEEL CO. is one of the largest integrated steel plant of the Gulf QASCO is having 400 series Midrex based DR module(1978), modifications which have been carried out in the Plant from time to time helped to increase production rate maximum to 105 tph. Commissioning of world 1st HBI/DRI combo plant (1.5Millon ton/annum) was completed at 2007 & plant is running with 210 ton/hr production rate.
Job Profile:
Works as a core member of commissioning team, for new DRI/HBI combo plant & working as senior operator in the field as well as control room, operating knowledge of Henywell DCS SYSTEM for MIDREX DR Plant. Good commissioning & operational knowledge of Koppern Briquetting machine for HBI production.
Responsibility In control room, observation, process parameter adjustment like BG CH4, RGCO2, RGCH4, H2/CO Ratio, PG CO2, PG H20, Reformer temp, Product corbon, metlization, HBI operation, etc. for smooth plant operation, Data recording, collection & documentation(by ERP).
Recording the operating data of the Briquetting machines, Seal gas compressor, Cooling gas compressor, Process gas compressor(centrifugal type), Main air blower, Auxiliary air blower, Ejector stack fan, Purge gas compressor, seal gas dryer and other equipments in the field.
Operation, Inspection and Data collection from the field (Seal gas system, Cooling gas system, Process gas system, Combustion system, Heat recovery system, MCW system, Process water system, Oxide material handling system, Product discharge(HBI/CDRI) system, HBI system, Dust collection system etc.)
Operation of the equipment in the field & physical observation & inspection of Reformer, seal gas coolers, compressors, blowers, top gas scrubber, cooling gas scrubber, mist eliminators, shaft furnace, belt conveyors, clarifier, settling pond, sump, dust collections etc.
Trouble shouting of the field equipments & control room.
Ensuring Safety working Condition & Maintaining the good house keeping.
Shutdown planning for the equipments changeover.
Checking & monitoring the Raw Material & finish product quality.
Field operation during plant shutdown & start up.
Physical condition monitoring of running equipments.
"SAL STEEL LTD." Gandhidham, (Gujarat) . As a Production Engineer / Shift In charge (DR Operation) in Sponge Iron Division (SL/RN process) . From January 2005 to August 2006.
Organization Profile:
S.A.L. STEEL LTD. is the Group of SHAH ALLOYS LTD. which is India's Second Largest Manufacturer of Stainless Steel. S.A.L. Steel involves in production of Sponge Iron (DRI) by SL/RN process, Ferro Alloys and Wire Rods with generation of 80 MW Power Unit.
Job Profile:
➢ During Project, Responsibilities that erection & fabrication of complete Sponge Iron (DRI) Division including 100 TPD Kiln & 500 TPD Kiln, Cooler, E.S.P., Raw Material Handling System etc. Good Knowledge of Refractory work of Kiln & D.S.C. & A.B.C.
➢ In the time of production maintaining the C/Fe ratio through out the campaign.
➢ Maintain the process parameter through PLC (ABB, MODICON) & DCS Control system.
➢ Maintaining the air/ton of Sponge Iron (DRI) through out the campaign.
➢ Taking the corrective action for obstruct the Accrecsion formation.
➢ Maintain the oil consumption and process parameters during light up.
➢ Co-ordination with all the departments to maintain the product quality and to avoid loss of production.
➢ Promptly response corrective action during any irregularities in the process parameters.
➢ Kiln hold should be taken carefully during any equipment breakdown to avoid loss of production.
➢ Maintaining the equipments in safe & healthy condition being in touch with maintenance department.
➢ Laboratory for immediate action to avoid for loss of productivity.
➢ Detecting the alarm situation of equipments to avoid breakdown of the same.
➢ Co-ordination with field operator for smooth operation of the plant.
➢ Co-ordination with quality control department for analysis report & taking corrective action for maintaining the product quality.
➢ Recording of Important parameters reading.
➢ Inspection & Trouble shouting of the equipments during shutdown.
NALWA SPONGE IRON LTD. Raigarh, (C.G.) As a Graduate Engineer Trainee (DR operation) in Sponge Iron Division (JINDAL process) From January 2003 to December 2003. & Working as a Asst.Engineer (DR operation) from January 2004 to December 2004
Organization Profile:
NALWA SPONGE IRON is the member of JINDAL GROUP OF INDUSTRIES. Manufacturer of Sponge Iron (DRI), Mild Steel, Wire Rod, T.M.T. with Generation of Power. NSIL involves in production of Sponge Iron (DRI) by JINDAL process.
Job Profile:
➢ Operation of the equipment in the field.
➢ Maintain the process parameter through YOKOGAWA DCS Control system
➢ Recording the operating data of the equipments in the field.
➢ Trouble shouting of the field equipments.
➢ Ensuring Safety working Condition & Maintaining the good house keeping.
➢ Shutdown planning for the equipments changeover.
➢ Checking & monitoring the Raw Material & finish product quality.
➢ Field operation during plant shutdown & light up.
➢ Physical condition monitoring of running equipments.
➢ Clarities underflow flushing & monitoring for smooth of operation.
Industrial training:
➢ 45 days training for the smooth plant operation in MEXICO, Montterey (HYLSA, ternium) with ZERO REFORMER, VPSA & HYTEMP operation (in 4M & 3M5 plant) and pabela (MEXICO CITY) with STEAM REFORMER (in 2P5 plant) and Chemical CO2 removal unit.
➢ 90 days training by HYL Technology in Emirates steel industries (ESI), Abu Dhabi (UAE)
➢ 60 days training by MIDREX Technology in Qatar Steel Company (QASCO), Qatar.
➢ 30 days industrial training in Bhilai Steel Plant (BSP), Bhilai, CG, INDIA.
➢ 15 days SAP operation training in Emirates steel industries (ESI), Abu Dhabi (UAE)
➢ 10 days ERP operation training in Qatar Steel Company (QASCO), Qatar
➢ HSE orientation, work permit, fire fighting, Emergency response, Environmental safety, training by Emirates steel industries (ESI), Abu Dhabi (UAE)
Computer Knowledge
➢ Qualifying the "DB2" Specialist Exam, Conducted by IBM (U.S.A.)
➢ MS Office, C, C++ Language, Internet.
➢ SAP Operation.
➢ ERP Operation.
M.B.A. (Operation) School of Management I.G.N.O.U. 60% 2011
B.E. (Industrial & Production) Institute of Technology Guru Ghasidas University Bilaspur (C.G.) 62% 2002