Alok Kumar Gupta

Job purpose: - Plan, monitor and coordinate the Instrument Maintenance activities of Plant, so as to ensure optimum production and delivery within targeted cost and quality parameter.

Responsibilities: -

> Operation & Maintenance: Plan, monitor and coordinate the Instrument Maintenance activities of Plant, so as to ensure availability of instruments & control system for optimum production and delivery within targeted cost and quality parameter. Ensure planning of resources for implementation of preventive maintenance schedule, Planning & Ensure resources for annual maintenance shutdowns in line with production plan, MOC (Management of change) preparation & follow up for approval and execution, Root Cause Analysis, Report preparation (OEE, MTTR, MTBF).

> Ensure timely submission of statutory & customer audit documents.

> Review and propose improvements as per new technology development for continuous upgradation of the plant.

> Cost optimization: Plan, monitor & control cost (spare, inventory, repair & manpower) of instrumentation maintenance activities.

> Quality: Implementation of preventive & predictive maintenance to ensure maximum availability of all process instrumentation & Control systems in the respective section.

> Cost Control: Inventory management and budgetary control with ensuring of minimum stock level of critical spares to reduce the overall maintenance / inventory carrying cost.

> Execution of all identified schemes/Capex in desired time frame to achieve targeted results for the process requirements.

> Innovation: Identification of improvement projects to strengthen the overall functioning of the Instrumentation system.

> Productivity: Derive maximum productivity of the deployed manpower for providing prompt & effective services to process / internal customers.

> Team building, Development & Motivation: Identify development needs for self & team of technicians to build competent & multi skilled work force for providing prompt & quality service to process.

> Spare parts management: Finalization of specification, ensure availability of spares, Vendor development.

> SAP user: Track order & availability, QA clearance, make purchase requisition & Work order, Clarify notifications.

> Safety: Responsible for cultivate ownership concept & safe working culture to achieve unit goal of safety statistics. Implementation of identified safety rules and regulations to achieve Zero unsafe practices & accidents.

Job purpose: - Manage Project from concept, detail engineering, Procurement, Installation, commissioning, closing.

Responsibilities: -

Instrumentation & control system

• Prepare, Review, approve of DDL (Detailed Design and Engineering deliverables):- Instrumentation Design Basis, Instrument Index, Instrument I/O list/Schedule, System Architecture- DCS or PLC, DCS or PLC Specification, Specifications/Instrument Data Sheets based on ISA S20, Alarm and Trip Schedule, Control Room and Control Building Layouts, Instrument and JB Location Layouts, Instrument Cable Routing Layouts, Panel and Rack Layouts, Instrument Junction Box & Cable Schedule, Termination Schedule/Diagram, Instrument Hook-Up Diagrams (Electric, Pneumatic, hydraulic and/or Process), JB Wiring Diagram, Loop Diagrams, Instrumentation and bulk materials MTO (Material take off), BOQ, TBE (Technical bid Evaluation), Instrument Erection Tender.
• Review DDL (Detailed Design and Engineering deliverables): -

Process Design Basis, Process Flow Diagram Diagrams (UFDs), Process & Operational Control Description, Process Equipment List, Piping & Instrumentation Diagrams (P&ID’s), Cause & Effects Diagrams, Process Data Sheets for instrumentation (IPDS), Process Alarm & Trip Schedule, HAZOP Report, Interlock Description, Civil and Structural Design, Architectural Design, Piping Design: Process Area Plot Plans (Equipment Layout Plan), Piping Layout, Piping Material Specifications (PMS), Valve Material Specification (VMS),Piping General arrangement Drawings, Isometric drawings for 2" and above pipework above and below ground, Key Plans. MECHANICAL Design: Tank & Tower List, Mechanical Datasheet for Vessels & Tank Etc. (MDS). Electrical Design: Hazardous area classification drawings, Cable Tray Layout, Electrical Load List, Electric equipment list.

• Handled instruments: E+H, Yokogawa, Emerson, ABB, Honeywell, Vega, Mettler Toledo, Fisher, Forbes Marshall, Dembla control valve, JDV, Swiss fluid, Rotex, Assco, Flowserve, Metso, Samson. DCS: Yokogawa Centum VP, Emerson Delta V, Siemens – PCS7. PLC: S7-200, S7-1200, S7-300 – Siemens. MicroLogix 1200, SLC 500 Allen Bradley.
• Experience for installation, commissioning, troubleshooting of Fully auto, Semiautomatic weighing machine 25 KG open mouth & valve type bag, 1000 KG jumbo bag, Make: Premier Tech, Solution pack, TMI, LLeal.

Electrical

• Prepare, Review, approve of DDL (Detailed Design and Engineering deliverable list): - EE design basis following by standard of IEC/NEC/NEMA, Statutory regulations, MEA requirements. Hazardous area classification. Single line diagram (SLD). Standby supply/Emergency power supply. Load evaluation/Load calculation. Voltage level & regulation. Specification/data sheet for MV switchgear/PCC/MCC/PMCC, protective devises, metering and control, distribution transformer, busduct, switchgear control supply, UPS system, Electric motors, power distribution boards, cable schedule/sizing, lighting, motors, VFD, Earthing & lightning equipment, CCTV, Fire alarm system, power and control cable. Motor list & BOM, tender documents.
• Facilities design requirements: Substation, Transformer yard, PCC and MCC building.
• Earthing system: Plant earthing, electrical system earthing, static bounding connections, instrument earthing, lightning protection.
• Plant lighting: Illumination level, plant light distribution & Schedule, cable schedule/sizing and selection, load calculation, emergency light load lighting and distribution.
• Layout drawings for electrical cable tray & conduit, LCS, Motor, control panels, plant lightning, LDB, PDB panels, grounding/earthing system, lightning system, fire alarm system, MCC/PCC/LDB/PDB panel arrangement drawing, cable schedule.
• Handled Electrical power system: - 24/22 KV high voltage substation and 2500 & 3000 KVA transformers. Low voltage 400V/4000A power distribution and motor control panels.
• Handled make of Electrical system: Schneider, Siemens, ABB. 24 KV switchgear: - Simoprime A4, Siemens. PIX24, ABB. High & Low voltage and control cables, TYPE: NYY, XLPE, PVC, THW, IEC10, CV. Plant lighting- Philips, Green yellow, Earthing/grounding system, Lightning arrester system, Fire alarm system, Make: Honeywell. CCTV, Make: Hikvision.

Project Management: -

• Lead Electrical & Instrumentation engineering function to ensure project execution/ completion as per schedule and within estimated budget adhering to Quality Systems, International Standards, Best Engineering Practices and Environmental Standards for highest degree of quality and safety in design.
• Provide input and support to the Project Lead during the development of project procedures (Project Execution Plan and Construction execution plan).
• Follow international codes & standards and Best Engineering Practices that apply to E&I.
• Coordinate with Local Project Team, Vendors, Contractor etc. to ensure successful project completion.
• Regular meeting with all stakeholders (End users, operations, project, contractors, vendors, etc.) to discuss project progress and issues that may arise during the project execution.
• Track, prepare and report progress weekly on project progress, risk, schedule, cost for discipline. Overseeing the project team’s work to ensure that they meet deadlines and milestones.
• Ensure all project scope is executed to safety standards and requirements. Review all job plans for high risk during construction in discipline related areas /scope.
• Review of project documents for compliance with company standards and procedures to ensure that they meet requirements and specifications.
• Identification and resolution of project issues and risks.
• Providing technical expertise and experience where needed to solve complex problems.
• Monitoring changes in legislation and industry trends to ensure that projects are up to date with best practices.
• Management Discipline Scope Change Process and documentation.
• Oversee disciplines installation Q&A assurance and Testing and Commissioning Activities.
• Coordinate and lead project closeout activities.
• Conducting project meetings and site visits.
• Managing Design & Construction vendors to ensure that they meet deadlines and deliver high-quality products or services according to specifications.
• Managing conflict among team members to ensure that all parties are collaborating well with each other towards the common goals/ objectives.
• Ensure successful delivery of seamless facility commissioning and turnover process that focuses on the end user (i.e. the Operations & Maintenance).
• Manage review and approve commissioning file for each systems & equipment’s which includes method statements, single line diagram, site instructions, deviation list, various tests, equipment datasheets & specification, relay setting calculations, etc.
• Manage Site acceptance testing (SAT) witness and certification process for all equipment and systems. Reviewing functional test data for evidencing compliance with performance specifications and other standards. Reporting on testing and inspection results and coordinating for Engineer/ consultant’s sign off /certification of the relevant systems/sub systems as applicable.
• Coordinate with the Construction manager, Engineers, Project Manager for Inspection of respective subsystems and documentations of functional testing record sheet for disciplines.
• Development of relationships with internal and external customers and organizations.
• Control the schedule and quality of discipline.
• Ensure the Installation & Commissioning is consistent with as-built model.
• Safety: observe the Health, Safety, Sustainability, Environment and Quality rules of the Company and the governing authorities of the host country. Responsible for adhering to all health and safety procedures, reporting hazards or incidents promptly, and actively participating in maintaining a safe workplace. Ensure mandatory safety training are completed for E&I team, Visitors, Contractor’s Team.

Procurement Pre-order and Post order activities: -

• Preparing documents (RFQ/RFP, Technical comparison/Technical detail analysis (TDA) & recommendations), Vendor evaluation, technical question sheet (TQS), TBE (technical Bid Evaluation), Bird’s eye view of all projects maintains to help maintaining overall productivity and utilization of discipline, Review vendor documents and quotations for compliance with project requirements, Coordination & follow up with purchase team for material order and delivery at site within agreed time lines.

Communication: -

• Good Interpersonal skills, Presentation (Project progress dashboard, Gantt Chart, S-curve), Identify/report technical concerns and solutions in a clear and concise manner, attend project and team meetings, conduct technical training session for team, RACI (Responsible, Accountable, Consulted, and Informed) matrix, Work breakdown structure (WBS)

Achievement: -

• Completed milestones within the timeline of project schedule and under budget.
• Merged new DCS system with existing operational DCS system without impact exiting plant operation.
• Independently lead Electrical & Instrumentation team for project above projects.
• Implement solar power system 999 KW with a cost-saving of 2.06 MTHB/ Year and Total cost-saving of 44.7 MTHB with a 20-year PPA contract.
• Implement Solar power street light to save cable cost within plant area- Less traffic area.
• Upgrade controller of DCS system from FCS 10 to FCS 30 D, Yokogawa for operational plant within project budget.
• Upgrade the DCS system from Centum CS 3000 To Centum VP- Yokogawa for operational plant within project budget.

Job purpose: - Manage Project from concept, detail engineering, Procurement, Installation, commissioning, closing.

Job purpose:

• Plan, monitor and coordinate the Instrument Maintenance activities of Plant, so as to ensure optimum production and delivery within targeted cost and quality parameter.
• Identified areas for improvement within the department, implementing strategic initiatives to address gaps in performance or resources.
• Created and maintained a strong team culture that promoted high levels of collaboration, employee satisfaction, and overall performance.
• Review and propose improvements as per new technology development for continuous upgradation of the plant.
• Team building, Development & Motivation: Identify development needs for self & team of technicians to build competent & multi skilled work force for providing prompt & quality service to process.
• Spare parts management: Finalization of specification, ensure availability of spares, Vendor development.
• Responsible for cultivate ownership concept & safe working culture to achieve unit goal of safety statistics. Implementation of identified safety rules and regulations to achieve Zero unsafe practices & accidents.

Job purpose: - Plan, monitor and coordinate the Instrument Maintenance activities of Plant, so as to ensure optimum production and delivery within targeted cost and quality parameter.

Instrument overall plant Maintenance

Shift Incharge

Shift Incharge