Plant Manager
Shuaiba Cement Co (A Adel Al Ghanim Co)
Total years of experience :30 years, 6 Months
I was responsible for the construction of a cement terminal of 1 million ton/annum with an operation which consists of cement unloading from ships, logistic & transportation with bulk cars, unloading to silos through compressors, loading of bulk cement in cars for local dispatch, packaging of cement in 50kg cement paper bags. I worked and helped the owner & shareholders to create a business with my experience, set up of organization with skills and engagement in staff selection.
Responsible for installation of packing plant & fertilizer bags loading on rail cars started with green field project, engineering and operation.
Kankinada, A.P.India
Deputy Head
Key Result Areas:
Installation & commission and Operation & maintenance of material handling system (EP, NN & ST belts, VFD feeders, traveling hoppers, magnetic separators & metal detctors, in house and specially designed lump breakers & reclaimers to loose the fertilizer lumps, trippers, plough divertors & flap divertors) and PLC controlled bulk packaging plant system supplied by “Premier tech-Chronos Richardson” with all auxiliaries
Installation of procurement system, store system, spares management & code generation, min-max list, sending en query to suppliers, freezing drawings, indenting through software, negotiation
Managing fertilizer operations (urea) consisting of neem oil tank farm and for each tank 20, 000 kl, screw compressors, sensors, gear pumps, pipelines for air and oil conveying, online spraying of neem oil through nozzles supplied by “spraying system” on belts
Leading a team of 80 technical staff & 350 labour workmen
Heading installation & commissioning of plant, operation & maintenance, procurement of plant machineries and spares, contentious development, manpower recruitment and team building, training, procedure making and making it one of the best projects in India
Management of approx.1sq kilometer work area with 12 long conveyors, 44 on line packagigng machines controlled by SCADA and overall mechanical 336 equipment s consist of big & small equipments in the plant.
Highlights:
Acted as an important member of Safety Committee and ISO Team for both Coal & Fertilizers terminals
Active safety auditor for both terminals
Achieved:
oAnnual turnover of 2 million tons for fertilizer and 10 million tons for coal
oPackaging & loading in 5 BCN or HL rakes (closed wagon) (approx.16000 /day) with electro-pneumatic-mechanized packaging system (bulk weigher, grvity feeder, bag closing machines & take away conveyors) supplied by “Premiertech-Chronos Richardson”in fertilizer port and 6 coal open wagon loading in a day
Successfully managed fertilizer importing & packaging plant with capacity of 0.3-million-ton fertilizer storage warehouse during reclaiming & packaging capacity 0.20 million ton/month of multi fertilizer product such as UREA, DAP, MOP, KPK and loading in 5 full wagons in a day
Achieved 2, 00, 000- 2, 50, 000 ton/month direct dispatch of packed material through rail car
• Actively participated as part of Loesche Technical & Marketing department and worked as proposal manager after assessment of customer requirement, selection of process plant and finalization of flow sheet, pre-engineering of plant, heat & mass balances for drying and grinding of raw material, plant and auxiliary equipment selection, proposal making, costing & techno-commercial meeting with client and evaluation.
• Conducted calculation of heat requirement for drying the moisture in raw material through Preheater Gas/Cooler Gas/WHR/HAG gas is a part of drying & grinding process and selected:
o Grinding in Vertical Roller Mill (VRM) based on Raw Material Clinker, Limestone, Coal, GGBF through latest software.
o Classification by highly effective classifier
o Heating by hot gas generators
o Transporting through ID fans, FD fans
• Visited client site to know the technical requirement (mechanical, E&I) and finding best system for them after round of meeting and discussion with technical team and vendor for bought out items.
• Highly specialized in automated machine and control systems repair.
• Instrumental in designing and engineering of Grinding Plant for cement plant, mineral processing, steel plant& power plant for grinding of raw material and final products as coal & cement grinding system for further processing or as final product.
• Successfully boosted new proposals by 20% by engineering and proposal making at Loesche India.
Jamnagar, Gujarat, India
Installed green field project consist of packaging plant & material handling system to cater 6000 MT TPD bulk unloading, transporting and 4000 MT TPD packaging products-Greenfield terminal project on Gujarat shore, India including Civil, M&EI.
OVERALL RESPONSIBILITY-
Project planning, execution, project ordering. Plant maintenance (predictive & preventive), spares procurement, breakdown analysis & planning. Operation planning & production .Maintenance of Store’s min-max spares and its planning, inquiry, supplier’s identification, price negotiation techno commercial evaluation, purchases order generation, material receipt note generation, and payment. Identification of bag supplier PP/HDP and inspection of quality and process of manufacturing at their factory for bags being used for company’s own fertilizer brand bagging at own plant. Plant E & I package, automation & operation with the help of power, pneumatic, hydraulic drive. Generation of Zero base budge and analysis of actual/budgeted. Contractor’s bill inspection & payments release, reconciliation, EHS auditing & training. Extended Consulting services for developments and optimization of company’s own business unit such as flour mill, fertilizer unit and installation of edible oil refinery at different locations worldwide. Exposed to worldwide accepted standards and work culture.
Committed to deliver and achieved (unload bulk 10, 000MT/day at port, feeding to ware house -4000MT/day & feeding to bagging plant 6000MT/day).
Kodinar, Junagadh, Gujarat, India
As Project Planning & Development Engineer.
Constructed & successfully commissioned cement plants and its ports and developments of existing system.
Reporting to: VP-Projects/Sr. Manager-Projects
Involvements:
1. Commissioned one Million ton cement plant (Gaj line-II, Kodinar, Gujarat) : Raw mill, Coal Mill, Crusher, ESP, Bag House, Long raw material conveyor, material handling system, storage silos, all necessary auxiliary equipments required for cement plant process.
2. Commissioned import & export port (Muldwarka, Kodinar, Gujarat), material handling system to and fro from port, Stacker & reclaimed at port for coal unloading system, Oil tank farm & loading, unloading system, pumping, piping’s, pipe rake, anti corrosive paint or rubber coating on entire structure and pipeline & pig passing for cleaning of sludge, bulk cement & clinker loading on ships, also bag cement loading on ships.
3. Modified feeding and venting of cement grinding section: Polycom (Roller press) & Cement mills.
4. Installation of AHP at State thermal power station “Sikka” Gujarat for getting ash as additive for cement mill.
Deputed as resident engineer at-Shaktinagar & Bilaspur, India.
Well known special welding alloy manufacturing company.Based at Bangalore, Karnatka, India.
As Sales & Service Engineer (After Sales Service Engineer for cement & thermal power plant)
Worked as Sr. Sales & Service Engineer to introduce products in cement plants with complete technical solutions.
Reporting to: GM-North Zone Head
Involvements: Repairing & Super conditioning of cement plant critical machinery with selection of proper alloy for base metals, making quotations, taking job orders, taking inventory, order of running and special welding electrodes, selection of welders for specific job orders, handover and commissioning, guarantee, payment collection, emergency plant breakdown attainment, attending plant meeting for maintenance optimization, projecting market demands and improving sales, conducting training to customer etc.
Satna, M.P, India
Maintenance engineer in well known cement producer in central region
As Jr. Trainee Engineer (Plant Maintenance/Shift In charge/Plant Maintenance & Workshop Repair)
Reporting to: Manager Maintenance/GM Mines
Involvements: Active Involved In Plant maintenance of : Cement mill/Coal & Raw mills/Packing plant/Bag house/Esp/Fans & Blowers/Pre heter/Cooler/Gyratory/Jaw crusher/ hammer crusher/ impact crusher(6000MTlimestone)/belt conveyor/various material handling system/hydraulics/centrifugal pumps/compressors, dryer, receiver tank, pumps & piping’s/screen /apron feeder/rope way/central Work Shop-machining shop-12 lathes, drill machine, grinding, milling, honing Shaping & planner, management of production lathe /assembly shop/special coating & welding shop/Plant Shutdown, Predictive & Preventive maintenance.
I earned B-tech (Mechanical) with distance education 3 years program and recognized by Government of India. This degree earned along with my regular work got based on "Diploma in mechanical".
This diploma earned through distance education and industrial training along with my regular jobs.
The primary and basic education "Diploma in mechanical" 3 years regular course after 12th in Science.This was the basic education to enter into industry.