Lead-Utility Maintenance & Instrumentation (Assistant Manager) - TATA Power Solar Ltd. - Plot No. A104-A109, SIPCOT, Industrial Gangaikondan, Tirunelveli, Tamil Nadu, 627352
(2025-01)
Overall plant running and maintenance with focus on utility systems automation and instrumentation.
- Completed automation work for the ETP RO system. The auto control system was not functioning properly, so I analyzed the internal PLC program and identified errors in the control logic. After modifying and correcting the program, the system is now operating normally. Previously, it was operated manually, resulting in inefficient output.
- The water plant flow meters were continuously fluctuating. After analysis, the issue was identified and rectified. The problem was related to inlet and outlet distance and cabling. The readings are now stable and normal.
- The ammonia stripper ammonia rejection system was not functioning properly. After analyzing the system, modifications were made, and the rectification work is currently in progress.
- The HT compressor was frequently tripping. After analysis and corrective feedback, the system is now operating normally. This issue had persisted from the time of erection for the past two years.
- Responsible for Overall Plant Running.
- Cell plant and module plant Utility maintenance.
- Coordinated project handover activities by reviewing and receiving all engineering documents such as P&ID, Hook-Up drawings, Single Line Diagrams, Cable Tray diagrams, As-built drawings, and SOPs.
- Water: UPW, WTP, ETP, ZLD, STP All process running and improvisation.
- HVAC: MAU, AHU, RSU, CSU All instruments and actuators and operation maintenance.
- Problem identification and root cause analyzing work.
- Process improvement and modification work.
- Chillers and Compressor: Chillers and Compressor, Dryer All instrument operation and maintenance.
- PEX (Process Exhaust system) All cluster instrument and operation maintenance.
- Hot water system All instrument and operation maintenance.
- Plant UPS system maintenance.
- Plant DG & HSD maintenance.
- Annual instrument maintenance budget (5 Crore) prepares and maintenance.
- Annual calibration 5000 instruments maintenance.
- Analyzer: Ammonia analyzer and its maintenance and control.
- TOC (Total Organic Carbon) analyzer it's maintenance and control.
- Silica analyzer and its maintenance and control.
- Gas: The gases are uses and controlling- NH3 SiH4 TMA(Trimethylamine) BCl3 CH4 N2O H2 PH3.
- Chemical: The chemicals are uses and controlling -Hydrogen peroxide(H2O2) Hydrogen chloride (HCL) Hydrogen fluoride (HF) Potassium hydroxide (KOH).
- 5S daily meeting and maintenance.
- ISO, IEC, OSHA, GMP, EHS and statutory regulation
- Over all plant PH, flow meters, pressure and temperature transmitter working responsibility
- Responsibility of all control valves in the plant
- Materials and spare details maintaining in overall plant
- Materials handling in SAP
- PLC & DCS program checking and SCADA Installing work
- New improvisation system erection and commissioning work did for running plant
- Compressor operation responsibility and maintenance of spares
- Calibration of Pressure and Temperature gauges and Transmitters.
- Modification of instruments for better operation & maintenance.
- Calibration of Electric and Pneumatic Control valves, Dampers etc.
- Wiring and termination of instrumentation cables and loop checking, Tagging.
- Document Maintaining.
Instrumentation Incharge HOD - Amaravathi power associates - MRK Sugar Mill, Sethiyathope, Tamil Nadu, India
(2023-01 - 2025-12)
Instrumentation management for sugar mill operations including boiler, turbine, and water treatment systems.
- The DCS system was experiencing continuous analog and digital card channel problems for a long time. After analyzing the issue, I rectified it and permanently resolved the problem
- The process steam line temperature control system was not maintaining properly and was previously struggling. After I arranged additional controls and implemented an automatic sequence control, it is now running normally.
- Responsible for plant maintenance.
- Responsible for Boiler all interlocks and running
- WTP, ETP, STP All process running and improvisation
- Over all plant PH, flow meters, pressure and temperature transmitter working responsibility
- Responsibility of all control valves in the plant
- Materials and spare details maintaining in overall plant
- Materials handling in SAP
- PLC & DCS program checking and SCADA Installing work
- New improvisation system erection and commissioning work did for running plant
- Compressor operation responsibility and maintenance of spares
- Calibration of Pressure and Temperature gauges and Transmitters.
- Modification of instruments for better operation & maintenance.
- Calibration of Electric and Pneumatic Control valves, Dampers etc.
- Wiring and termination of instrumentation cables and loop checking, Tagging.
- Document Maintaining.
Senior Instrumentation Engineer - GSH Utility Service Private Limited - JK Tyrese and Industries Ltd, Chennai, Tamil Nadu, India
(2019-02-20 - 2023-07-31)
Instrumentation engineering for boilers, compressors, chillers, HVAC systems, and cooling towers. Managed DCS and PLC systems using PCS 7, ABB 800XA, and Siemens S7 400.
- HVAC machine cooling system modification work has been completed. A control valve has been installed near each machine to regulate the cooling water temperature, resulting in reduced TR consumption and improved efficiency.
- Nitrogen control system modification work has been completed. Previously, a mechanical PCV was installed, which occasionally caused pressure drops. We replaced it with a pneumatic control valve, and the system is now operating smoothly.
- The boiler deaerator system requires steam for proper efficiency and deaeration. Previously, steam was supplied separately. We have now installed a thermo compressor to utilize low-pressure condensate steam. The small quantities of steam are collected, compressed, and reused successfully.
- A groundwater level sensing system has been implemented in the borewells. Water for the WTP plant is taken from the borewell with the highest water level and low TDS.
- Document Maintaining for Auditing
- Responsible for Boiler all interlocks and running
- WTP, ETP, STP All process running and improvisation
- Over all plant PH, flow meters, pressure and temperature transmitter working responsibility
- Responsibility of all control valves in the plant
- Materials and spare details maintaining in overall plant
- Materials handling in SAP
- PLC & DCS program checking and SCADA Installing work
- New improvisation system erection and commissioning work did for running plant
- Cooling tower and HVAC parameters maintaining
- Compressor and Chiller operation responsibility and maintenance of spares
- Calibration of Pressure and Temperature gauges and Transmitters.
- Modification of instruments for better operation & maintenance.
- Calibration of Electric and Pneumatic Control valves, Dampers etc,
- Wiring and termination of instrumentation cables and loop checking, Tagging.
Instrumentation Engineer - M/S ENMAS O&M SERVICES PVT LTD - Cauvery Iron & Steel (India) Ltd, Kajapur Village, Medak-Tq, Telangana, India
(2016-02-13 - 2019-02-12)
Instrumentation engineer for 15 MW CPP (AFBC Boiler) and turbine operations. Managed DCS systems including ABB Industrial IT 800xA and Siemens S7 400. Handled SCADA with max VUE.
- Work planning for Preventive and breakdown Maintenance and job allotment
- Calibration of low pressure and high-pressure transmitters such as PT, LT, FT, DPT (YOKOGOWA, ABB, SIEMENS-PDS Tx's.) using master instruments of HART communicator
- Calibration of Temperature and Pressure gauges using master instruments of NAGMAN calibrator
- Operation and maintenance of field equipment such as Temperature, pressure, level, flow, speed sensors, electrical MOV's and switches
- Logics & interlock checking in PLC & DCS
- P&I diagram checking
- Good Knowledge and troubleshooting of field devices like control valves, smart transmitters for pressure, flow and temperatures, O2 analyzers and pollution control analyzers, proximity sensors and switches
- Hands-on experience in Commissioning and testing of RTD and thermocouples, pH, Conductivity meters, Pneumatic and Electrical control valves.
Graduate Apprentice Trainee - Thiruarooran sugars pvt ltd - Thirmandangudi, Tamil Nadu, India
(2015-01-02 - 2016-01-31)
Graduate apprentice trainee involved in preventive maintenance of field instruments and calibration work for boiler and turbine systems.
- Preventive maintenance of all field instruments in area wise (Boiler, Turbine, Shout Level controller, Sugar Bin, Air Compressor)
- Calibration of field instruments in defective area (Pressure Gauge, Temperature Element, Transmitter, Flow Meter etc.).
- Servicing of Control Valves, I/P, Positioner and On-Off Valves.
- Calibration and Servicing of Indicators Temperature and Pressure Indicators.
- Servicing of Pressure Switches, Temperature Switches, Limit Switches, Level Switches.
- Calibration of all type Control Valves (globe valve, ball valve, butterfly, ON-OFF valves).
