Sontosh Bhattacharjee

Still work on same responsibility for research and development for all over the factory/company. Presently doing an special job for reducing downgrade production for all units into the factory. Some major activities on R & D department.
*On R&D department, I help to reduce 6 Hi mill strip breakage 164 per month to around 30 strip breakage per month.
*Help to use right greasing procedure in 6 Hi mill spindle system. Previous frequency was 90 times per month but present frequency is 2 time per month.
*Help to guide root cause of Mill drive motor oscillation on 20 Hi Mill 4. Previously it was assumed that journal bearing was the problem but later I submit the document that mention, problem is for motor alignment. Ground floor was settled unevenly due to huge CR coil stock.
*Help to understand all production units (both Cold rolling and Galvanizing/Galvalume), how coolant properties influence the both process and quality of product.
*Properly analyzed the root cause of pinion stand gear box failure in 6 Hi Mill. It was happen due to improper shearing pin use in 6 Hi mill motor and gear box coupling.


Duties/Responsibilities: 1.Conduct technical development and research initiative on all operational parameters to support operations team In bringing continuous improvements In scaling newer heights in operation al excellence. Some of the key parameters are as follows for instance: a) Process Improvement b) Checking INDENT raised by factory, inspect engineering spares and minimize repair &maintenance cost c) Electrical & Mechanical breakdown/ down-time Analysis d) Identify Delays affecting normal operations e) Process Machines & Support Equipment productivity Improvement f) Maintenance performance analysis g) Setting Standard Operating Procedures (SOP) where applicable

h) Cost efficiency in process & maintenance I) Follow up Engineering spares inventory level j) Others (direct/ indirect)as it comes as research Initiative 2. Examine historical data & trend analysis, consult & shear ideas with all stakeholders to find out new opportunities for improvement in each of the parameters, benchmark with best practices set new standard and suggest action plan for improvement in concerned areas, follow up implementation of action plan by concerned functions, evaluate performance and reports. 3. Any other job assigned by the Management.

Installation/ Erection (1.2 yrs), Operation & Maintenance (1.2 yrs), Project Management

Duties/Responsibilities: 6Hi Mill unit Mechanical Maintenance ( Six months)- # 6 Hi two stand tandem CVC Mill(SMS DEMAGE-GERMANY) # Rewinding Line ( DANIELI-ITALY) # Pickling Line (DANIELI-ITALY) # Water Treatment Plant # Roll Grinding Machine (CNC- WALD RICH SIEGEN GmbH, GERMANY) Key works: Here I introduced this mill to my company as traditional CVC mill not CVC plus mill. It was also found that this was the first twin stands cold rolling mill in world that is configured for rolling up 0.1 mm thickness flat steel. Initially we found one big problem that is called chattering. Inter stand tension was three times higher than ETR/DTR tension. Later problem was solved by reducing inter stand tension to one third. In rewinding line, at commissioning time, there was mandrel expansion and collapse problem and cutting problem. I successfully found the problem that mandrel was over heated due to rolled hot coil instantly put to start the trimming hence not getting enough cooling which is suitable for mandrel. On cutting, commissioning people set the cutter for higher thickness gauge instead of required lower thickness gauge. 6Hi Mill and CGL Mechanical Maintenance ( 6 Hi Mill with additional CGL 5 & 6 and CTL 10)(Six Months) # CGL 5 and CGL 6, supplied by Bronx, Australia. # Skin Pass Mill, one for each line, by Danieli. # CGL furnace, set up by Tenova, Italy. # Galvalum pot (induction furnace), supplied by Ajax Tocco-USA. # CGL 5 is able to run Galvanizing and Galvalume. # CGL 6 is able to run Galvanizing up 2mm CR/HR pickled coil.

After one year, we successfully started the Galvalume production by placing scraper blade into required angel with required shape which is myself. On starting time both Galvalume/Galvanizing lines had so many breakdowns. Now both line running smoothly with limited breakdowns. Here I worked on furnace hearth roll, water rotary union, accumulator tower, Ajax induction pot furnace cooling system, skin pass mill, chromic passivation system, replacing several UC-209 bearing by UK-210 bearing etc. 20Hi Mill Mechanical Maintenance ( Three months) # Mill 1, Mill 2, Mill 3 & Mill 4(SENDZIMIR-USA) # Pickling line # Boiler # Water Treatment Plant # Acid Regeneration Plant-ANDRITZ Technologies Private Ltd. # Rewinding Line with TLL(REDEX-FRANCE

CGL 5&6, CTL-10, Hydrogen and Nitrogen plant, CCL and Roll Forming Line Mechanical Maintenance ( Present..) Colour Coating Line, ( Fata Hunter-USA and Bronx-Australia) # Roll Forming On color coating line also had so many breakdowns. Now I reduced these breakdowns by solving the hydraulic pump trip problem that for relief valve, repairing hydraulic pump from abandon pump, replacing one deflector roll by two deflector rolls with roller bearing which helps the rolls by distributing load and reducing wrapping angel as existing single roll neck and ball bearing always broken on every two days. Surface Cleaning Machine was also successfully run by adjusting back up rolls though these rolls were out of equal diameter. On roll forming lines I successfully find out the way of cassette roller gap setting and also introduce to our people some technical term such as twisting, spring back, flare, bow, camber etc. hence reduce the adjusting time. CTL -10(Cut to length) I successfully found out the cutting problem, as adjusting wedge and holder channel were grinded mistakenly for gap adjustment. LPG station We unloaded LPG from container vessel by pump and four way compressor. By pump we unloaded LPG liquid portion and by compressor we unloaded gaseous portion of LPG. When pump got failed I myself transferred both liquid and gaseous portion of LPG by four way compressor.

Duties/Responsibilities: Department: Mechanical Duties/Responsibilities: PROJECT NAME: First Track Project (Brown Field Project) : Design, Engineering, Procurement, Supply, Installation, Commissioning & Testing of Two (2) Nos. Glycol Dehydration Type Gas Process Plant (75 MMSCFD capacity each) at two different locations including Four (4) separate 6 inch Nominal dia. Gas Gathering Pipelines (approximate length of one no. 2500 meter, one no.1000 meter and two nos. 500 meter each) and associated facilities on Turn-Key Basis at Titas Gas Field, Brahmanbaria, Bangladesh by Pietro Fiorentini SpA, Italy Responsibility : civil design/engineering & civil construction of generator buildings, piling works, equipment/ tower/skids/tank foundations, road, walkways, pavement, fencing, surface drainage system; construction of 4 (four) pipelines from wellheads to two process plants including roads & khal crossing and all other associated works; erection/installation of skids/vessels & equipment; field interconnecting piping works; tank construction; NDT of all field welding works; electrical/instrumentation works; testing & commissioning assistance and construction/installation of other functionally required auxiliaries viz, power generating facilities, yard lighting facilities, fire fighting & hydrant system, fire detection system etc. Test run of both plants successfully completed. PROJECT NAME: Titas 17 & 18 Project(Green Field Project) : Design, Engineering, Procurement, Supply, Installation, Testing & Commissioning of 1x75 MMSCFD capacity Glycol Dehydration Type Gas Process Plant and Gas Gathering Pipe Lines with Associated Facilities on Turnkey Basis at Titas Gas Field, Brahmanbaria, Bangladesh under Bangladesh Gas Fields Company Ltd (BGFCL) by Pietro Fiorentini SpA, Italy Responsibility : civil design/engineering & civil construction of operation, workshop & generator buildings, piling works, equipment/tower/skids/tank foundations, road, walkways, pavement, fencing, surface drainage system; construction of 2x3500 meter high pressure cross country gas pipelines i/c river crossing by HDD method & all other associated works; erection/installation of skids/vessels & equipment; field interconnecting piping works; tank construction; NDT of all field welding works; electrical/instrumentation works; testing & commissioning assistance and construction/ installation of other functionally required auxiliaries viz, power generating facilities, yard lighting facilities, fire fighting & hydrant systems, fire detection system etc. Present Condition: Successfully completed all works with test run of the plant and handed over to BGFCL. PAC issued and one year warranty of the plant was completed on 11 October 2014.

On this plant I personally solved one major problem. As this is green field project, plant getting shutdown when there was any lighting with thunder storm. Though we installed all lightening protection system that design and supplied by Italy, we were unable to continuous running on time of rain with lightning and thunder storm. I personally installed earthling system at four different point with 40 mm dia and 60 feet length(deep) GI pipe on different place and connected with grounding grid. One point is near to Flare and other three points are on process plant area. After that plant never stopped for any raining time with or without lightning and thunder storm. Additional Activities on SUNNEX : Participating on Government Tender process on several power plant projects(Combine Cycle and coal base power plants)

Duties/Responsibilities: Take care of all Engineering Departmental work

Cold rolling steel mill complex 6 HI cold rolling mills (HAGC controlled) FLAT PRODUCT
made, Pickling line, HR slitter, CR slitters, E.O.T. cranes, Boilers, Pump House,
Compressor, ETP and DM water plant also.
• Responsible for Preventive, Breakdown and Autonomous Maintenance
• Responsible for the Maintenance of Hydraulics and pneumatics operated parts e.g.
Cylinders, D.C. valves, Pressure relief valves, Pressure reducing valves, Flow control
valves, Check valves, Heat Exchangers, Servo valves, Hydraulic pumps, Compressors,
and Centrifugal pumps etc.
Awareness with the different types of hydraulic circuits used. Example: Unloading valve
circuit, Sequencing circuit, Regenerative circuits etc.
Awareness with the Quality Management systems.

Some of my achievements in this factory were
• I saved TK 250000 per month of gas bill by adjusting air- gas ratio in boiler.
• I saved TK 200000 per month by arresting Hydraulic leakage through Mandrels.
• I saved TK 100000 per month by proper greasing Schedule.
*I reduced Production loss time two hours per day for Rewinding Line by adjusting
Hydraulic circulating pump.
• I made two Hot Air Dryer for CGL line by re-generating Steam. For which company
does not have to pay any regular cost. Equivalent of two burner cost 3 core Tk and
monthly gas bill almost 2.5 Lakh Taka.
*I serviced one mandrel for usable condition. A new mandrel cost TK 3 core.
• I reduced compressor spare parts consumption from TK one lakh to 10000 per
month.
• I made several air dryer systems.
• I solved some critical machine problems.

Installation, Operation, Maintenance, Testing & Commissioning (with PNMS)of
Microwave Radio Equipments of NEC (1000 Links) under Banglalink Projects all over
Bangladesh.
: Software download of 11GHz NEC MW link on all over the Bangladesh on
Grameenphone Project.
: Installation, operation and Testing & Commissioning of Microwave Radio
Equipments of Marconi under Ericsson of Warid Project.
: Supervising for fabrication and installation of Side Strut, Side Arm, different
types of Pole etc on Banglalink and Grameenphone Project.
:Tender Preparation for participation on Grameenphone solar power Project
: Involved the Projects Management works, Supervision & Implementation the
projects under Time Schedule. Prepare the all necessary documents to submit the
customers. Working for Automatic Car Parking System and BTS grounding system
(newly design).

Erection of Water line, Steam line, Hydraulic and Pneumatic line, Pump
House, 35 Tons, 25 Tons and 5 Tons EOT crane in Appollo Ispat Complex Ltd. Dhaka on
6-
Hi cold Rolling Steel Mill Project.
I was the local authority of 6 Hi Reversible Cold Rolling Steel mill On Appollo
Ispat Complex Mill Ltd for completing Mill erection, commission and production time
maintenance.
Erection and commissioning experience in 6-Hi Cold Rolling steel mill,
Continuous pickling line, Boiler, Chiller (Central Air Conditioning system), Compressor,
DM Water Plant and ETP.
I personally solved one Major problem of Acid Regeneration Plant Furnace (Origin-Flat
Product, India)
Problem- Furnace highly vibrates after 2/3 days of ignition (Production Time) and also
damage furnace base.
Solution- Changing Furnace Base from high temperature sustainable concrete to High
temperature sustainable Brick work.

Job started on commissioning of German made 6 Hi CVC (Continuous Variable Crown)
cold rolling steel Mill with German and Indian expert at Chittagong as Assistant
Engineer for maintenance of 6-Hi CVC Cold Rolling steel Mill, Pickling line, Rewinding
line, sophisticated Hydraulic and Pneumatic lines, Boiler, Pump house, EOT cranes, DM
Water plant, Effluent Treatment Plant and Roll Grinding Machine.