Senior Deputy Manager E & I
Novatex Limited, BOPET Unit
Total years of experience :15 years, 11 Months
• Working experience of installation, commissioning, operation and maintenance of Diesel (Caterpillar) and gas (Jenbacher) generators. Participated from the beginning, in designing activities of complete power plant having installed capacity of 14 MW.
Preparation of maintenance for power plant electrical equipment, including motor control centers, generator ACB’s, synchronizing, metering, generator excitation systems, station batteries, battery chargers, etc.
• Design and supervised complete cable routing and laying of whole power plant, including Generators, LV panels, Control panels and Auxiliaries.
• Up gradation and modifications of old 3516 Cat diesel generators which include installation of new AVRs, PLC system and load sharing systems.
• Preparation and maintenance of Grounding system.
• Actively participated during installation of Absorption chillers, Hot water Chillers, Electric chillers, AHU’s and Fresh Air Fans.
• Performed routine maintenance of all Chillers Process, burners, Motor, Control Panel, PLC's, VFD's, and Air Handling units in the facility according to the scheduled PM program.
• Worked with foreign engineers and machine suppliers during the installation and commissioning of BOPET film manufacturing plant by "Dornier", major sections include
a. Drying & crystallization
b. Extruders
c. Stretching Machines
d. Winding and Slitting Machines
e. Metalizer
Analyzed Project contracts as per site requirements
Reviewed PIDs, BOQs & Prepare technical evaluation and comparative statements Negotiated with local and foreign suppliers
Planning and optimizing capacity and resources (manpower and assets)
Monitoring/Reporting on progress in line with schedule
Ability to work under pressure and to realistic deadlines
Arranged teams of contactors and subordinate
Manage & Supervise project installation, testing and commissioning
Coordinated with other departments and prepare project reports
Ensure Preventive Maintenance schedules into Asset Management Software (CMMS) as per supplier / manufacturer recommendations so that maintenance is done as required for maximum plant efficiency.
Prepare maintenance schedules well in advance for the Operations & Maintenance to plan the operations so that Machine Breakdown minimize.
Supporting and promoting all continuous improvement activities on site
Reviewed daily automation and instrumentation Maintenance work orders and classify them into corrective or preventive maintenance categories.
Prepared daily management reports based upon analysis of previous day’s activities.
Proposal development of annual Budget of Imported items, ensuring it should neither overestimate the funds required nor underestimate budgetary needs.
Assisting subordinates with any safety issues which may arise
Ensured proper spare parts management.
Installation, commissioning and faults finding of AC drives of Micro master 440, Micro master 430, Sinamics S120 (Siemens), Yaskawa and ABB.
Installation of Sinamics Drive, including Torque motors, Double Motor Modules & Encoder commissioning.
Installation, commissioning and faults finding of DC drives of Simoreg DC-Master (Siemens).
General maintenance of main incoming and distribution Panels, transformers, PFI panels and capacitor banks.
Maintenance of general lighting system and over head lights
• Installation and commissioning of ASI network.
• Hands on Experience of Installation, testing, commissioning and Troubleshooting of following PLC systems
Siemens PLC (S7-200, S7-300 & S7-400)
Simotion-D Controller
Schneider PLC
General Electric (GE Fanuc)
Working experience on various HMI including PC based WinCC and touch panels of Siemens.
Redesigning and conversion of Relay based logic to PLC systems.
Installation and commissioning of ASI network.
Knowledge of Profibus and industrial Ethernet.
Experience in SCADA systems design and development of Siemens WinCC.
1. PLC, Pneumatic and Hydraulic System :
• Hands on Experience for the Troubleshooting of Siemens PLC (S7-200, S7-300 & S7-400), and General Electric PLC
• General Maintenance of PLC & HMI based Hydraulic and Pneumatic control systems of various Industrial applications.
• Supervised Commissioning and Parameter Fixing of HMI based pump control
2. Maintenance of E & I system of :
• Operation & process control of Reheating Furnace
• Maintenance of continuous rolling mill and roller table system
• Fault finding on field devices such as proximity, thermocouple, temperature transmitter, pressure switches, flow switches, pyrometer, oxygen analyzer, differential pressure transmitter, shut-off valves, solenoid valves and flow control valves etc.
• Maintenance of Analog and Digital instruments of Furnace, Motor Lubrication, Motor Protection Devices, and Limit switches, Electronic PCB Cards, etc.
• Preparation of automation and instrument drawings, datasheets, I/O wiring diagrams, P&IDs, specifications, calculations, chart and graphs.
• Review daily automation and instrumentation Maintenance work orders and classify them into corrective or preventive maintenance categories.
3. AC/ DC Drives and Low Voltage Distribution
• Installation, commissioning and faults finding of AC drives of Micromaster 440 (Siemens), Yaskawa and ABB.
• Installation, commissioning and faults finding of DC drives of Simoreg DC-Master (Siemens).
• General maintenance of main incoming and distribution Panels, transformers, PFI panels and capacitor banks
• Operation and maintenance of different ratings of Diesel generators
• Maintenance of general lighting system and over head lights
4. Cranes
• Over Head Bridge Cranes having different load carrying capacities.
• Hand on experience of installing AC drives on all three dimensions of cranes (i.e. long travel, cross travel, Hoist).
• Maintenance of Induction motors, slip-ring motors of cranes.
5. Furnaces
• Operation & process control of Reheating Furnace
• Fault finding and maintenance of furnace instruments such as thermocouple, temperature transmitter, pyrometer, oxygen analyzer, differential pressure transmitter, shut-off valves, solenoid valves and flow control valves, etc.
• Maintenance of cooling system of water skids.
6. Rolling Mill
• Good understanding and experience of basic roll and guide pass and mill rolling schedule design and implementation.
• Basic knowledge and experience of the operational and maintenance requirements of Section Mills hot rolling processes and automation - inc. management and control of consumables.
• Thorough knowledge of sections mill quality control and defect elimination.
• Good understanding and basic knowledge of Quenching Process.
• Experience of speed controlling systems for tension free rolling and dimensional accuracy, of Continuous Rolling Mill Stands.
Complete internship in Telecom department of Engineering Services, where study the installation BTS tower.
Complete internship in Switching Network Region, department of Pakistan Telecommunication Company Limited, where study switching and transmission of land lines phones.
Complete internship in an E & I department of Peoples Steel Mills, where study PLC control system of walking beam furnace and Reheating furnace.
Completed M.Engg in "Industrial Control & Automation" from Pakistan.
Awarded by Scholar Ships, seven times on Best Performance by “Sir Syed University of Engineering & Technology.
