GAJANAN JAKAPURE

• Company details – It is an EPC company setting up complete Distillery plants with Ethanol, Biogas, CPU (condensate polishing unit), DM Plant, Multi effect Evaporators Spray Dryers & Cogeneration plant
• Responsibilities:-
• Assisted Preparing Technical offers for Boiler, Turbine, BOP, Dryer, Hot Gas Generator, Conveyors, Bio Compressed Gas (CBG).
• Took part in Technical & Commercial Negotiations.
• Involved t in the design aspects, equipment sizing, vendor selection, project schedule, project planning.
• Worked closely with procurement tem for out sourcing major items & bought out.
• Finishing project in the given dead lines.
• Visited foreign countries Kenya & Tanzania for marketing & to take part in Exibitions.
• Interacted well with customers to build connections and nurture relationships.
• Negotiated price and service with customers and vendors to decrease expenses and increase profit.
• Managed budget implementations, employee evaluations, and contract details.

• Plant details – Capacity (54 MW), Boilers (160 tph, 60 tph, 60 tph, Trava grate type, bagasse fired, 60 (Trava grate, bagasse & Spent wash fired)), STG (1 x 35 (Condensing & Extraction), 1 x 16 mw, 1 x 5 mw (back pressure)
• Responsibilities:-
• Undertaken & carried out successfully modification works of Incineration boilers to increase the capacity from 52 to 60 tph (distillery boiler with pneumatic ash conveying and new ID/DA fan)
• Undertaken & carried out successfully modification works of two sugar co-gen
• Boilers to increase the capacity from 40 to 50 tph (2 boilers – with modifications in pressure parts, ID, FD & SA fans, ash handling system, feed pumps etc)
• Undertaken the work of capacity enhancement in existing 5 mw stg by replacing it with 8.8 mw stg to suite the extraction steam & power demand of distillery plant
• New STG & piping is ready for installation after crushing season
• Planning of Start-up & shut down of cogeneration plant as per demand
• Supplying steam & power to sugar process
• Supplying steam & power to distillery plant with optimum bagasse & Spent Wash ratio
• Exporting power to grid with desired norms & parameters (26 MWh)
• Give training to manpower in the objective of hassle-free operation in the demanding situation & as per SOP
• Carry out preventive maintenance of equipment
• Attend the break down efficiently with minimum stoppage time
• Monitor daily/ monthly MIS reports
• In off season, fulfil boiler statutory compliances & carry out repair works
• Supervise & manage manpower for efficient utilization
• Carryout off season maintenance work of turbines & BOP
• Budgeting, Scheduling & planning the maintenance/modification works
• Efficient energy management by adopting optimum loading of equipment & managing import side demand.

• Plant details – Capacity (41.3 MW), Boilers (120 tph, 90 tph, 30 tph, Trava grate type, bagasse fired, AFBC (coal & Spent wash fired)), STG (1 x 23.5, 1 x 5 mw back pr, 1x10 mw condensing/extraction, Make – Siemens / Triveni)
• Responsibilities:-
• Planning of Start-up& shut down of cogeneration plant as per demand
• Supplying steam & power to sugar process
• Supplying steam & power to distillery plant with optimum Coal & Spent Wash ratio
• Exporting power to grid with desired norms & parameters (26 MWh)
• Give training to manpower in the objective of hassle-free operation in the demanding situation & as per SOP
• Carry out preventive maintenance of equipment
• Attend the break down efficiently with minimum stoppage time
• Monitor daily/ monthly MIS reports
• In off season, fulfil boiler statutory compliances & carry out repair works
• Supervise & manage manpower for efficient utilization
• Carryout off season maintenance work of turbines & BOP
• Budgeting, Scheduling & planning the maintenance/modification works
• Efficient energy management by adopting optimum loading of equipment & managing import side demand

• Sugar Plant – 4500 TCD, Co-generation Plant details – Capacity (21 MW), Boilers (70 tph, 40 tph, Trava grate type, bagasse fired), STG (1x12 mw back pr., 1x9 mw conden., Make – Triveni)
• Responsibilities -
• Start-up & shut down planning of cogeneration plant
• In season, Supplying steam & power to sugar process & distillery plant
• Exporting power to grid with desired norms & parameters
• Give training to manpower in the objective of hassle-free operation in the demanding situation & as per SOP
• Carry out preventive maintenance of equipment
• Attend the break down efficiently with minimum stoppage time
• Monitor daily/ monthly MIS
• In off season, fulfill boiler statutory compliances & carry out repair works
• Preservation of boilers, condensers etc
• Supervise & manage manpower for efficient utilization
• Carryout off season maintenance work of turbines & BOP
• Budgeting, Scheduling & planning the maintenance/modification works
• Efficient energy management by adopting optimum loading of equipment & managing import side demand

• Plant Details- (Capacity – 2 x 15 MW), (CFBC Boiler, Make – Wuxi (Chinese), Capacity – 2 X 75 TPH, Press. - 5.29 MPa, Temp - 4850C, STG Make – Nanjing Turbine, Capacity – 2 X 15 MW, condensing with bleed
• DG set Make – Baifa, Capacity – 3 X 2000 KVA, UF plant (2 X 53 M3/h), SWRO plant (2 X 20 M3/h), BWRO plant (2 x 12 M3/h) & DM plant (2 x 12 M3/h)
• Responsibilities -
• Since the plant was taken over from existing O & M Company, it required to study all the plant, efficient planning & scheduling for the safe start-up of Boiler, STG & BOP as the plant was not running when our company entered in to the contract
• And successfully started up both units after rectification & implementation of the following, Wood word governor configured for load mode
• Resolved governor actuator hunting problem
• Relay coordination & settings done in STG, Transformer & grid breakers
• Set priority of main transformer with STG to bring STG to home load after grid failed as LT & HT bus are common (New circuit in 20 KV bus was implemented)
• Replaced the auxiliary cooling water lines with new line as most of the pipes were corroded
• Safety valve floating of boilers done
• DCS automation implemented for hot well level, CEP auto start up, BFP auto start up, Deaerator level, WTP pre-treatment plant etc
• Start-up of auxiliaries taken on operating desk in control room from local for
• ACW pump, MCW pump, DM transfer pump, Drain tank pump etc with their run feedback indication
• Connected the condensate sealing water for extraction actuator & GSVC condensate back in drain tank & reduced DM make water consumption
• Fabricated the hand railings & gratings for safe approaches for operation & maintenance of equipment
• Coal handling plant sequence start up done by hard wiring in panel
• Encouraged colleagues & participated in Preparation & implementation of SOP for all equipment
• Conducted Technical & safety training for the Expats & Local employees
• Encouraged colleagues & participated in preparation of check list & scheduled
• Preventive Maintenance for all equipment
• Encouraged colleagues & participated in critical spare & running spare planning
• Actively interviewed local experts for vacant O & M positions
• Budgeted & administered the fund required for procurement of consumables, tools, safety PPE’s, travelling, vehicle, guest house, canteen, contract labour & other local expenses
• Well aware of Indonesian statutory compliances (KITAS, Insurance, VISA, BPJS JEMSOSTEK etc) & implemented the same at site
• Efficiently delivered & implicated the O & M contract on site
• Achieved the desired guaranteed performance parameters
• Prepared the annual leave schedules for Expats
• Learned the local language (Bahasa) to communicate with local colleagues & authorities

• Plant, Plant Details - (Capacity – 13.5 MW), (CFBC Boiler, Make – Thermax Ltd, Capacity – 1 x 85 TPH, Press 86 Kg/cm2, Temp 4350C, STG Make – Shin Nippon, Capacity – 1 x 13.5MW, Back Pressure with single bleed, DG set Make – Caterpillar, Capacity – 3 x 1400 KW, RO plant Make – Veolia, Capacity – 2000TPD, DM plant Make – Thermax Ltd, Capacity – 2 x 13 TPH, Oil Fired Boiler Make – Thermax, Capacity – 20 T/h, Press - 12 kg/cm2, Temp – 1500C)

Responsibilities

• Managed operations, maintenance & commissioning of Boiler, Turbine, DG & BOP (Refractory dry out, steam blowing, safety valve floating, Turbine on barring gear
• Turbine rolling & first sync with DG)
• The frequent problems of tube leaking & bursting in boiler were rectified by, Conducting tube endoscopes & X ray test to identify tube internal rusting & chocking
• Acid cleaning of boiler pressure parts internally followed by nitrogen capping
• Supplied power to Sugar Refinery as per demand
• Supplied exhaust steam to Sugar Refinery for process with makeup from oil fired boiler as & when required
• Developed daily & monthly performance report of Boilers & Turbines
• Created monthly Chemical Consumption Report of WT Plant
• Prepared bill of material for annual overhauling & repair work of boilers
• Prepared Budget for the forthcoming year
• Prepared equipment changeover schedule
• Planned spare for all equipment
• Efficiently drafted preventive maintenance schedule.

Contracted companies during the tenure –

A) USDPCL at Datta Sugar Co-op Ltd at Shirol, Dist Kolhapur

• Plant Capcity - (Co- generation Plant, Capacity – 36 MW) (Travelling Grate Boiler, Coal & Bagasse Fired, Make – IJT, 1 x 180 TPH, Press -109 kg/cm2, Temp.-5400C, STG Make - Siemens, Capacity-1 x 36MW, Condensing with 3 extractions).
• In Sugar plant season (Generation-33.4MW, Grid Export -22MW, Sugar plant Export – 7MW)
• In Sugar plant off season (Generation-33.5MW & Grid Export-29MW)
• Responsibilities -
• Run boiler with milled Bagasse with 50% moisture in season of sugar plant & with imported coal in sugar plant off season
• Supplied steam with controlled extraction & PRDS for sugar process use
• Achieved the desired guaranteed performance parameters successfully
• Administered interviews for recruitment on site
• Planned & carried out Annual over hauling of BTG & BOP
• Planned critical spare & running spare & avoided plant stoppages due to want of spares
• Managed statutory compliance of Boiler for annual inspection
• Delivered the O & M contract on site as a head of the site

B) JK Cement Ltd, Muddapur, Karnatak

• Responsibilities -
• Carried out commissioning of Boilers, Turbines & BOP
• Run boiler with Indian coal, Petro coke (lime as sulphur catcher) & blending of both
• Exported power to Grid (as per grid code) & Cement plant as per demand (Dumping of steam in ACC as per requirement)
• Maintained DGR, Monthly production report etc
• Planned & carried out Annual over hauling of BTG & BOP
• Managed statutory compliance of Boiler for annual inspection
• Followed the pollution control board norms for emission
• Delivered the O & M contract on site as a head of the site
• Got opportunity to work as reliever for Station Manager for 20 days in a CPP at
• Philippines (Bataan)

C) JK White Cement Ltd, Gotan, Rajasthan

• Plant Capacity - (CPP, Capacity – 7.5 MW), (AFBC Boiler, Make – Thermax Ltd., 40 TPH, STG Make – HTC, Capacity – 1 x 7.5 MW, Condensing with Bleed)
• Responsibilities -
• Carried out commissioning of Boilers, Turbines & BOP
• Run boiler with Indian coal, Lignite & blending of both
• Used charcoal for start up
• Exported power to Grid (as per grid code) & Cement plant as per demand (Dumping of steam in ACC as per requirement)
• Maintained DGR, Monthly production report etc
• Received Platinum Card for the outstanding performance for site execution

• Managed operations of Boilers (AFBC & Travelling Grate, Coal & Husk fired)
• Managed operations of Steam Turbines (Condensing with extraction type, back pressure type)
• Got promoted for Coordinating new project of power house extension and headed team of 24 members
• Supervised layout marking, excavation, erection & commissioning of new Project consisting AFBC boiler, Turbine, ESP, AHP, CHP & RO plant with respective OEM team (AFBC Boiler - Thermax Ltd, Capacity - 30 TPH, Pr - 45 kg/cm2, Temp –, STG – Aeg Kanis, back pr type, Capacity - 3.2 MW, Pr
• 45 kg/cm2, RO
• Plant - Ion Exchange, Capacity - 10 TPH, ESP - Himachal Eniviro)
• Being new system of PLC SCADA, learned & adopted operation of AFBC Boiler & trained existing team to adapt with new operation system
• Managed and expertise charcoal startup of AFBC boiler
• Capacity – (Cogeneration Plant, 1 x 3 MW, 1 x 2.5 MW, 1 x 1.5 mw).

• Sugar – 5000 TCD, Cogen - 1 x 3, 1 x 2, 1 x 1.5 MW
• As a Shift in charge in season- Supervised operations of
• Boiler - Steam & water parameters, its capacity utilization, steam export to process, steam flow to steam turbines for power generation, boiler auxiliaries’ daily checks, fuel management, manpower management
• Steam Turbines - Live steam, Turbine & Power parameters, captive power generation & utilization, turbine bearing cooling water management, exhaust steam export to process
• Monitoring & controlling of Raw water, DM water, Spray Pond, Injection pumps Compressors etc (BOP)
• In off season -Planning, controlling and supervision of off-season maintenance of
• Boilers - Carrying out statutory compliance under guidance of Boiler Inspector (open inspection, repair works of pressure parts, hydraulic test etc.), maintenance of fans, pumps, valves, compressors, blowers etc
• Steam Turbines - Maintenance of turbines under inspection of OEM engineers (opening casing, decoupling, taking out rotor assembly and fixed diaphragms, cleaning and checking blades, cleaning & checking bearing clearance, assembling turbine, checking coupling alignment & trial test etc.

• As a Shift in charge in season- Supervised operations of
• Boiler - Steam & water parameters, its capacity utilization, steam export to process, steam flow to steam turbines for power generation, boiler auxiliaries’ daily checks, fuel management, manpower management
• Steam Turbines - Live steam, Turbine & Power parameters, captive power generation & utilization, turbine bearing cooling water management, exhaust steam export to process
• Monitoring & controlling of Raw water, DM water, Spray Pond, Injection pumps Compressors etc (BOP)
• In off season -Planning, controlling and supervision of off-season maintenance of
• Boilers - Carrying out statutory compliance under guidance of Boiler Inspector (open inspection, repair works of pressure parts, hydraulic test etc.), maintenance of fans, pumps, valves, compressors, blowers etc
• Steam Turbines - Maintenance of turbines under inspection of OEM engineers (opening casing, decoupling, taking out rotor assembly and fixed diaphragms, cleaning and checking blades, cleaning & checking bearing clearance, assembling turbine, checking coupling alignment & trial test etc.

• As a Shift in charge in season- Supervised operations of
• Boiler - Steam & water parameters, its capacity utilization, steam export to process, steam flow to steam turbines for power generation, boiler auxiliaries’ daily checks, fuel management, manpower management
• Steam Turbines - Live steam, Turbine & Power parameters, captive power generation & utilization, turbine bearing cooling water management, exhaust steam export to process
• Monitoring & controlling of Raw water, DM water, Spray Pond, Injection pumps Compressors etc (BOP)
• In off season -Planning, controlling and supervision of off-season maintenance of
• Boilers - Carrying out statutory compliance under guidance of Boiler Inspector (open inspection, repair works of pressure parts, hydraulic test etc.), maintenance of fans, pumps, valves, compressors, blowers etc
• Steam Turbines - Maintenance of turbines under inspection of OEM engineers (opening casing, decoupling, taking out rotor assembly and fixed diaphragms, cleaning and checking blades, cleaning & checking bearing clearance, assembling turbine, checking coupling alignment & trial test etc.