Electrical Engineering Consultant - Challoch Energy Ltd - United Kingdom
(2024-03)
Challoch Energy is an energy consultancy company specialising in energy efficiency, renewable energy, combined heat and power (CHP), and grid flexibility solutions. The company has extensive experience in supporting domestic, commercial, and industrial applications while playing a key role in shaping UK and EU energy policies. Challoch provides expert technical services in solar photovoltaics (PV), wind energy, hydrogen, heat pumps, and energy storage systems.
Led several major projects focused on assessing renewable energy potential and designing integrated energy systems for communities and educational institutions.
- Led South Cornelly Village renewable energy project assessing ground-mounted and rooftop solar power generation, wind feasibility, and hydrogen plant sizing
- Analysed available land and geographical factors using Photovoltaic Geographical Information System (PVGIS) to model solar configurations and determine optimal energy generation setup
- Utilised historical wind data from different sites and employed Helioscope and AutoCAD software to analyse topographical data for ground-mounted panels
- Incorporated LIDAR data to assess potential constraints such as slopes and shading from buildings and trees for efficient solar farm layout design
- Ensured compliance with grid integration requirements by completing G99 forms and liaising with National Grid Electricity Distribution (NGED) to determine connection pricing
- Assessed roof areas, tilt angles, and solar potential for rooftop installations using PVGIS and Helioscope
- Conducted load analysis for homes and Tonypandy Primary School using smart meter electricity consumption data
- Estimated required battery storage capacity to manage excess energy and ensure reliable power supply during periods of low generation
- Developed energy model incorporating solar and wind system data, calculated Levelized Cost of Energy (LCOE) for solar farm, and modelled 1.75 MW wind turbine energy output
- Designed hydrogen generation and storage facility using electrolysis to store excess renewable energy
- Sized electrolyser and storage capacity based on projected excess energy from solar and wind systems
- Designed and optimised renewable energy system for Ysgol Nantgwyn to meet 24-hour electricity demand, reduce carbon emissions, and lower energy costs
- Modelled generation potential from solar and wind systems using PVGIS and historical data from nearby wind farms
- Integrated generation data into mathematical model to track energy generation and identified periods of production excess and shortfalls
- Calculated necessary battery storage capacity based on peak energy consumption and renewable generation forecasts
- Conducted Levelized Cost of Energy (LCOE) analysis to assess project financial viability
- Compared LCOE of renewable energy system with existing energy costs to highlight long-term savings potential
- Conducted thorough private wire route analysis for Ysgol Nantgwyn, identifying and mitigating potential obstacles
- Checked for conflicts with existing infrastructure including gas, water, sewer lines, and NGED power lines
- Reviewed land ownership data to confirm access rights and conducted detailed survey for potential obstacles
- Mapped private wire possible routes using AutoCAD, incorporating data on existing services, ownership, and utilities
- Created accurate CAD drawings illustrating optimal installation paths ensuring efficient and cost-effective installation
- Presented complex technical information in understandable way to both technical and non-technical stakeholders
- Presented technical proposals, progress reports, and energy system designs to clients, internal teams, and external partners
- Simplified complex calculations such as LCOE and energy storage requirements for client presentations
- Provided clear cost projections, performance forecasts, and implementation timelines
- Ensured all designs adhered to industry standards including BS 7671:2018+A2:2022
- Used Trimble ProDesign software to verify compliance with safety regulations
Assistant Project Manager - Whale Cloud Lanka (PVT) Ltd - Sri Lanka
(2021-09 - 2022-10)
Played a pivotal role in the design of a smart ticketing and seat reservation system for Sri Lanka Railways. This was a large-scale, multinational project requiring collaboration between technical teams from China, senior officials from Sri Lanka Railways, and project management consultants from EGIS. Led the data gathering and analysis phase, working closely with technical teams and senior stakeholders to define system requirements and project scope.
- Led data gathering and analysis phase, working closely with technical teams and senior stakeholders from Sri Lanka Railways
- Translated technical documentation between Chinese engineers and Sri Lanka Railways, ensuring clear understanding of project specifications
- Facilitated effective cross-cultural communication between engineering team and client, bridging language barrier
- Acted as translator and liaison for Chinese engineering team with limited English proficiency, ensuring accurate conveyance of project goals and technical details
- Wrote all technical points in English first, then provided precise documents in Chinese for accurate translation
- Participated in and facilitated high-level meetings with key stakeholders including representatives from Sri Lanka Railways and EGIS
- Maintained open communication, aligned project goals, and resolved issues arising during development
- Conducted site surveys across various Sri Lankan railway stations to assess infrastructure requirements
- Determined optimal locations for installation of new system equipment
- Verified and finalised technical documentation ensuring all reports and drawings met engineering standards
- Developed and closely monitored project milestones, tracking tasks, deadlines, and deliverables
- Used robust tracking methods to keep project on schedule and within scope
- Tracked 93 documents with required submissions, submission deadlines, revision histories, and document statuses
- Established and maintained risk register to identify potential risks and develop mitigation strategies
- Signed agreement with Softlogic imposing daily penalty fees for delayed survey submissions to ensure accountability
- Created responsibility matrix clearly defining who was responsible for each phase of the project
- Ensured accountability for equipment damage or vandalism post-installation
- Managed total project budget of $22 million across three delivery phases
Project Engineer - Anesll Lanka Pvt. Ltd. - Biyagama, Sri Lanka
(2019-11 - 2021-08)
Worked as a Project Engineer at Ansell Lanka Pvt Limited, a global leader in manufacturing industrial and medical gloves. Part of the Global Engineering and Manufacturing Technology (GE&MT) department undertaking various projects and research initiatives related to glove manufacturing machinery, process optimisation, and new machine developments. Conducted process improvement projects, capacity expansion, control system upgrades, and machinery commissioning to enhance production efficiency and reliability.
- Led capacity expansion and process improvement projects to enhance production efficiency and system reliability
- Identified bottlenecks in existing processes and implemented technological advancements to optimise performance and safety
- Focused on industrial automation, researching new technologies, PLC programming, and control system integration
- Managed team of 15-25 individuals including 23 supervisors for L10 glove dipping machine installation and commissioning
- Coordinated work of diverse team of engineers, contractors, and technicians from multiple disciplines
- Resolved design discrepancies on-site where original machine drawings did not align with operational realities
- Modified safety features such as repositioning sensor brackets and guarding systems to ensure functionality and compliance
- Took proactive approach in re-engineering installation elements not covered by initial designs
- Modified safety rail placements and adjusted sensor bracket locations based on real-time factory floor conditions
- Facilitated smooth communication between mechanical, electrical, and safety teams during unforeseen challenges
- Identified gaps in communication between mechanical and electrical teams regarding cable tray layouts
- Facilitated cross-disciplinary meetings to align schedules and define task dependencies
- Ensured electrical installations did not obstruct mechanical setups and vice versa
- Adjusted guarding systems to ensure safe and efficient operation while implementing more robust safety mechanisms
- Documented design changes for use as new standard for future machine installations at Ansell
- Implemented automated glove installation system, replacing manual processes with advanced robotic mechanism
- Introduced automated maintenance programme and installed new safety sirens
- Managed upgrade of L9 dipping mechanism, implementing new dipping process more efficient and reliable than original
- Used AutoCAD to view, edit, and prepare printable versions of drawings for supervisors
- Added dimensions and notes to help supervisors understand component installation procedures
- Managed total budget of approximately $300,000 including installation costs
- Commissioned machine with remote support from Chinese engineering team despite communication difficulties and lack of proper documentation
- Managed installation despite challenges such as time zone differences and unexpected technical issues
- Achieved cost-effective Sri Lankan commissioning compared to Chinese team
- Provided technical training and support to maintenance department
- Developed training documents and conducted hands-on workshops for maintenance team
- Empowered team with better diagnostic skills and structured troubleshooting procedures
- Reduced equipment-related downtime and improved machine utilisation
- Introduced preventative maintenance strategies enabling early detection of potential failures
- Led introduction of Rapid Curing technology, a breakthrough innovation in glove manufacturing
- Researched and implemented alternative curing method to replace traditional 40-minute curing process
- Identified induction heating as most suitable technology for significantly reducing curing time
- Designed system tailored to production process and managed contractors for specialised tasks
- Used SolidWorks to design customised induction coils for glove curing
- Created detailed drawings for technicians to manufacture coils according to specifications
- Managed all aspects from selecting equipment to hiring contractors for coil design, wiring, and conveyor system
- Made cost-effective decisions and carefully monitored expenses throughout project
- Oversaw necessary upgrades and repairs to improve system reliability before full-scale implementation
- Reduced curing time by 92.5%, from 40 minutes to 3 minutes per glove in pilot project
- Maintained high quality standards verified by QA department for abrasion and cutting levels
- Secured funding for full-scale implementation following successful pilot
- Applied technology to new manufacturing line
- Contributed to major cost savings, reduced energy consumption, and increased overall production capacity
- Provided regular progress reports to senior management ensuring transparency and continuous system improvements
