Mani Kumar

A result-oriented professional offering 15+ years of successful career distinguished by commendable performance in Electrical Maintenance, Reliability engineering. A competent and astute professional with 15+ years of experience in Electrical Reliability, maintenance, commissioning & testing. Exposure in equipment Reliability, all Engineering functions & in handling the complete maintenance entailing planning, resource utilization & manpower management.

Ability to take initiative, thereby bringing down equipment breakdown & achieving annual costs savings. Improved productivity by technology management. An effective communicator with excellent relationship, management skills and strong analytical, problem solving and organizational abilities.

Senior Manager, Electrical Reliability & Maintenance - Reliance Industries Ltd (RIL) - Dahej, Petrochemical complex, Gujarat, India

(2021-01)

Senior Manager, Electrical Reliability/Maintenance (REAM) in central Engineering Services (CES) at RIL-Dahej, Petrochemical complex, Gujarat, India.

• Improving reliability through continuous improvement techniques/upgradation/projects/implementation of advance diagnostic and online condition monitoring techniques
• Preparing, planning and effective execution of all types of electrical maintenance activities includes Preventive, predictive & corrective maintenance in Petrochemical industries.
• Modifying switchgear, schemes, designs as per reliability recommendations by creating MOC documents and implementation.
• Hazardous area equipment's inspection, maintenance and integrity checking as per international standards.
• Participating in EHAZOP studies, reliabilities meetings and corrective actions implementations.
• Participating in daily Rack up & pack up meetings with process departments to review all planned, unplanned jobs completion, plant electrical defects completion status, equipment's unavailability/MOC/RCA/EHS compliances/BSC checklists related discussions etc.
• Preparing purchase lists, purchase requisition of critical equipment, spares & services as a part of material & services management.
• Commissioning & testing experience on Fast bus transfer system (ABB SUE3000), Momentary parallelization of both HT and LT Switchgears, synchronization of sources.
• Managing plant maintenance cost budgeting and optimization of resources.
• Retrofit 6.6 KV Siemens make VCB from Voltas make SF6 breakers in HT switch board as obsolete
• Codifying new items in SAP using MMCS/Equipment BOM Creation/ updatation. Master data governance (MDG) request creation for new equipment/Functional location /Assets creation in SAP.
• Conducting stability testing, REF, SEF testing by Current/Voltage injection methods
• Transformer, HT motors differential protection scheme checking.
• Ensuring all HSEF compliances.
• Providing technical supports for new projects inside reliance like new petrochemical plants /Extensions/DBN projects pre-commissioning & commissioning activities.
• Compliance and documentation for ISO-9001-2000, ISO-14001 and OHSAS-18001 BSC/SSAC Checklist.
• Retrofit numerical relays- REF/REM (ABB make model no 615) with Electromechanical relays.
• Knowledge on Short circuit, motor starting, arc flash hazard studies, Relay testing/coordination
• Communicating with ARC/AMC vendors for services, materials procurement related discussions.
• Conducting & results analysis of Motors diagnostic testing like offline (LEAP/RLA) & online (MCSA).
• Conducting & results analysis of Breaker testing -CRM, HV, Timing test, Bus bar CRM, HV test, Cable HV/HI-POT test
• Conducting & results analysis of Transformer testing –Oil analysis, DGA, RLA, Furan analysis & Online PD. Health index calculation & fault diagnosis through Duval's pentagon.
• Conducting & results analysis of Lightning Arrestor Online LCM, offline testing's.
• Conducting & results analysis of HT Cables diagnostic testing: VLF testing/Online & offline PD, Tan delta, sheath testing etc.
• Conducting & results analysis of Testing of Numerical, electromechanical Relays.
• Conducting & results analysis of Battery banks capacity tests.
• Conducting & results analysis of OCC& SCC tests, stability tests of power transformers and differential protection/REF
• Testing, Commissioning & Maintenance of Hazardous and non-hazardous Type HT synchronous, induction motors & all type LT motors.
• Testing, Commissioning & Maintenance of Power & Distribution Transformers
• Testing, Commissioning & Maintenance of 220KV ,33 KV GIS & 400 KV AIS
• Testing, Commissioning & Maintenance of HV/LV Switchgears & Circuit breakers (SF6, VCB, ACB)
• Testing, Commissioning & Maintenance of HV/LV Cables (up to 220KV)
• Testing, Commissioning & Maintenance of All types of bus ducts (33KV SIBD,11KV IPBD,6.6KV SPBD, NSPBD)
• Testing, Commissioning & Maintenance of UPS, battery chargers, battery banks
• Testing, Commissioning & Maintenance of LV & MV VFD of ABB, Siemens, Hitachi, L&T Make

Maintenance Manager electrical - Reliance Industries Ltd (RIL) - Dahej, Petrochemical complex, Gujarat

(2015-10 - 2020-12)

Maintenance Manager electrical at Gas cracker Unit (GCU), Purified Terephthalic Acid (PTA), EOEG, HDPE etc. Plants inside Reliance petrochemical complex, Dahej, Gujarat.

• Site Electrical Equipment's reliability improvement planning and execution by implementing the standard work packs for preventive, corrective and predictive maintenance.
• Identifying the bad actors, single point of failures that affecting the equipment reliability and preparing improvement plan to improve site electrical reliability.
• Developed and implemented Asset Management Activities, facilitated preventive and breakdown maintenance on production and support equipment to reduce down time and increase throughput.
• Tracking breakdowns & Failure analysis through FMEA, RCA, 5-Why Analysis, Weibull analysis & Fault Tree analysis (FTA) and implements counter measures to increase mean time between failures (MTBF) and reduce mean time to repair (MTTR) & to ensure reliable operation avoiding repetitive failures.
• Responsibility of planning & reviewing Turnaround (TA)/Shutdown (SD) activities based on site conditions, manage the resources and materials, mitigate job clashes between multidisciplines and ensure timely completion of planned activities.
• Safe execution of jobs in order to get zero safety incidents by following standard site safety procedures, permit to work system, preparing and execution of all type of risk assessment analysis.
• Creating standard maintenance practices, task lists, best maintenance practices (BMP) for all electrical equipment's and revise existing SMP/SOP based on RCA, FMEA analysis or if any revision in international standards.

Sr. Engineer-Electrical - PowerMech Projects Ltd (PMPL) - Thamminapatnam, Nellore, Andhra Pradesh

(2013-08 - 2015-09)

• Installation and Commissioning of 6.6 KV H.T Switchboard panel (ABB make).
• Operation & Maintenance of dis-connectors, earth switches, Wave traps and Lighting arrestors (AIS 400KV)
• Testing and troubleshooting VFD drives (ABB, SIEMENS).
• Maintenance of H.T/L.T Motors, 2MVA Distribution & up to 100 MVA Power Transformers.
• Maintenance of H.T board & switchgears, SF6/Vacuum breakers, MLDBs, MCCs, PCCs, LRS, H.T & L.T capacitors, reactors, APFC panels, battery bank charger, earth, Lightning systems.
• Planning and effecting preventive maintenance schedules of various machineries to increase machine up time and equipment reliability.
• Preparing SOPs, SMPs, JCC & SWPs for maintenance and calibration operation for the plant.
• Coordinating material / spare parts planning related activities encompassing identification of vendors, requirement of specification and offer evaluation.

Electrical Shift Engineer - AST Power O&M - Nanded, Maharashtra, India

(2011-04 - 2013-07)

• Responded to electrical faults & breakdowns, carried out troubleshooting, and restored equipment with minimum downtime.
• Conducted routine inspections, IR/PI/WR tests, breaker functional checks, relay testing equipment health verification through LLF rounds.
• Prepared shift reports, logged electrical parameters, monitored load variations and ensured smooth power supply to plant systems.
• Ensured adherence to electrical safety procedures, PTW & LOTO practices.

Electrical Engineer Trainee - ENMAS O&M Service Ltd: Gallants Metals - Samakiyali, Kutch, Gujarat

(2010-05 - 2011-03)

• Assisted in operation and maintenance of HT/LT motors, transformers, switchgear and electrical auxiliary systems in plant.
• Supported troubleshooting activities during electrical faults & assisted in safe restoration of equipment.

B Tech - Electrical and electronics engineering - JNTU –Kakinada university (2010)

12th - board of intermediate AP (2006)

10th - board of secondary education –AP (2004)