Head Engineering operations
South Seas Breweries & Distillery
Total years of experience :25 years, 5 Months
As Head Engineering Operations
responsible for Projects, total plant maintenance & coordinating production in operation of: Grain storage section, Malting, Brewing, Fermentation Reactores with auto dosing & steam distillation with PLC, DCS, Vacuum control system- Steam Ejectors, Evaporators, Condensors. Rotary Amonia Chillers, Krones India glass Bottling plant for Carbonated (Beer) & Non-Carbonated (Liquor) drinks aseptic Filling & packaging, 24 tons coal fired Boiler with 6 MW cogeneration plant with DCS, Power generation & distribution through out the plant includes PCC, Intelligent MCC. Milling plant, EPT & WTP, VAM & Rotary Ammonia chillers, C.T. CO2 plant, pumps & motors & all Utilies. Coordinating Corporate management in planning resources & Asset utilization. Analysis of production & maintenance KPI matrics to improve plant performance. Asset maintenance management with TPM with 5-S base. Assist production department in overcoming process & quality issues. Implementing GMP to improve process & product quality by eliminating non value adds, controlling of process variations & Utility wastages with lean six sigma. Planning & scheduling PM & PdM with OEM. Perform static/rotary asset condition monitoring, & CBM to reduce Reactive maintenance. Handling all Govt liaisoning for EHS, OHSA & other statutory compliances for projects & plant operations. Presenting CAPEX & OPEX of Engineering department phasewise to support finance strategy. Conducting periodic internal audits of ISO9001, EHS, OHSA & HACCP for safety hazards. Updating Corporate Management with MIS for Plant Asset Status, Resources & new improvement projects & benefits. Training of the staff to new implemented Technology & modifications. Preparation of technical data to implement CMMS is underprogress for 02 plants
Green field project (Engineering) for CCIL 250 TPD Soya oil seed preparatory & milling section, hexane Solvent extract plant, Refinery & 20 TPD Animal Feed plant - Administered engineering project planning with all resources procurements with preparation of BOM, BOQ, Cost estimation, Awarding of contracts, WBS & execution of all process & utilities machineries & equipments installation, commissioning & start up includes Plant structure & Buildings, Silo storage & feed conveying system, Seed Preparatory, Solvent extract plant & Refinery having DTDC, Vacuum evaporators, condensers, chillers. Implemented NFPA 496 & NFPA 36 standards for Hexane Solvent Extract plant. Successful completion of the plant before time estimated in one step without any changes as firm decisions taken during project scope planning strategies. Implemented Prince 2 project management model.
Responsible for Total plant Operation & Maintenance of existing 110 Klpd Alfa Laval milk plant & Prawns/fish IQF process plant includes- CIP, Pasteurizers, UHT, Homogenizer, Boilers & Steam vacuum system, Vacuum dryers, blenders, Centrifuges & Decanters, Evaporators, Condensors, VAM & Amminia rotary chillers +4℃-28℃, PHE, R.O. ETP, Filter press & all filling & packaging lines with PLC control. CM & CBM of all static & rotary machines.
Packaging section consisting of Sacmi SBF machine for PET bottles & Index-6 series rotary machine for PET bottles Hot & Normal filling for Soya oil & Milk, capping, labeling. Tetra Pak TBA8 & TBA19, Vertical form fill & seal machines (Bosch SVC4020) for milk powder. On line check machines, Robotic Cartoon former, Packaging & Palletizing lines.
Undertook designing, erection & commissioning of Substation 33kv/11Kv/0.415Kv AS Per NEPA Regs & CAT 03X1.7MW DG power plant, PCC & Distribution panels, Intelligent MCC panels with VFD’s & instrumentation to meet NFPA-70 & 70E - Installation & commissioning & Operating SOP. Cable & pipelines layout & structures to support the same. Utility machines installations. Prepared SOP’S for PPE, OHSA & EHS as per Local Govt authorities & ISO for property & personnel safety.
Overall Responsible for PM & PdM of Soya oil SEP & refinery, Milk plant & Prawns/Fish IQF Process. Opex for engineering department. Monitor asset utilization KPI, OEE & maintenance MTTR & MTBF to analyse overall plant performance. Condition Monitoring & CBM of all static & Rotary machines, Cold staorages machines.
Green field project (Engineering) for Alfa Laval 500 TPD Palm Oil Refinery Plant & Soap plant with PLC & DCS control- Responsible for engineering project planning, material procurement, installation, commissioning of the Palm oil Refinery with fractionation & the 100MTPD Soap plant with Glycerol recovery plant. - Estimated BOM & BOQ, budget, licensing vendors & contractors, Man power utilization, Work planning & Work progress reports to related stakeholders. Engineering equipment/machineries of Palm oil refinery & the Soap Plant-Thermax Boilers, Distillation column vacuum system steam ejectors, condensers, evaporators, Filter Press, Centrifuge & Decanters, C. T., ETP, Water DM, air Compressors, Thermic Fluid Heater, VAM & Ammonia rotary chillers, Vacuum dryers. Crude oil, refined oil & Soap Tank farm, Soap Saponification & Glycerol recovery plant, Soap & Detergent production & packaging plant. Packaging Section Palm Oil- JagMohan Extrusion Blow molding machines for jerry cans & drums, Injection molding Ferromatik Milacron 200T & 400T PET preforms & Cap closers. Sidel stretch blow form machines for PET bottles, Edible oil filling, capping, labelling & packaging lines. Successful Commissioning with zero abnormalities & accidents. Supprting production & QC to start the production with Total maintenance. Implemented all Iso standards for PPE, OHSA & EHS. Prepaerd all machine data’s & implemented CMMS Maximo software for Palm oil & Soap plant. Perform PM with 5S & GMP with effect analysis with solutions to have production & Quality.
• Successful commissioning of 3000 beverages can/min. manufacturing plant Having Printing machine with 8 ink stations. Entire Plant is controlled with supervision of Allen Bradley’s control Logix 5000 with Device Net. 3x2.2 MW GE Genbatcher GG & 2x2 MW CAT DG power station with Exhaust HRSG for VAM chiller & All Utilities. Total plant Operation & Maintenance with PM & PdM planning & scheduling. CM & CBM of rotary machines, palletizing & packaging lines. Strict adherence to ISO GMP for HACCP, PPE & OHSA on production floor due to high speed machines operation through out the plant.
• During Expansion of the plant: Review the Design made by consultant to the correct ratings for the extension of sub-station, HT transformer sizing, LT panels, sectional distribution panels with PLC, cable ratings with load flow, Cummins DG plant sizing & all utilities as per expansion of plant load & finalizing contractors & vendors. Execution & Controls.
• Acknowledged for commissioning, operation & PM of DRT & stolley USA hydraulic press machines used for metal beverages cans/can ends with Allen Bradley’s Automation with HMI, rotary compound lining machine with 8 applying stations, Auto conveying system, Hydraulic & pneumatic auto-controls. AMC Heavy load (12000 PBS) hydraulic uncoilers, Palletizing/Wrapping machines, Scrap handling system maintenance, trouble shooting. Monitoring of machines to know root causes & find out implement solutions. PM of all machines through out the plant.
• Attended major shut down for glass plant at Riyadh- high temperature furnace with regeneration updating instrumentation & control system with Saint Gobain engineers. Planning & Overhauling all electrical, rotating & static machines, Continuous Batch plant, R.O, ETP, Printing & labeling machines, Anealing lehres, Packaging & Palletizing etc.
• Responsible for smooth operation & maintenance of the plant process & all utilities electrical, instrumentation, mechanical machines & equipments. High temperature furnace with regeneration, batch plant, Cooling towers, Blowers, Dust Control Equipments, Heavy load crushers & Mixtures, R O plant. CM & performing CBM with RCA of rotary & static assets. Coordinate production staff & quality department for productivity with quality to profit. Member of ISO 9001, EHS, OHSA, HACCP for internal audits. Monitoring Maintenance KPI & RCA for frequent stoppages with solutions to reduce Reactive maint.
ON COMPLETION OF 15 YRS. IN INDIAN NAVY WITH THEORY & PRACTICALS ( WORK ON HANDS) IN ELECTRICAL & CONTROL ON BOARD SHIPS, SUBMARINES & Naval Dockyard received this qualification. There after 19 yrs in continuous process industries for engineering projects & Total plant maintenance
