RAMAN BAJPAI

• Led comprehensive Electrical and Instrumentation operations for an 477.5 MW captive power plant with 05 nos. Turbo-Generator units. Directed capital projects, maintenance activities, and system upgrades while managing technical teams across multiple locations.
• Instrumental in leading the Power Plant towards 100% Reliability and thus ensuring Zero Tripping.
• Speraheaded various Reliability Projects and Maintenance Practices which resulted in achieving 100% reliability of the VFD System, DCS, CILMS, Protection Relaying System and High Voltage System.
• Achieved zero motor failures due to electrical faults in FY'23 through implementation of advanced protection schemes
• Directed protection system coordination and testing for diverse equipment (ABB, GE, SIEMENS, Easun Reyrolle)
• Oversaw erection and commissioning of 400/220 kV switchyard infrastructure, Inter Connecting transformers, and Protection System and integration to CILMS system.
• Managed transition from legacy protection systems to state-of-art numerical protection platforms
• Trained personnel in equipment maintenance and enforced participation in exercises focused on developing key skills.
• Monitored financial performance, set budgets and controlled expenses to provide financial stability and long-term organizational growth.
• Increased overall company efficiency by streamlining operations and implementing innovative managerial strategies.
• Implemented effective cost-saving measures to reduce overhead expenses without compromising quality or service.

Effectively managed Total Electrical and Instrumentation Renovation and Modernization of Turbo Generator Unit #1 and Unit #2 with approximately 120 crore capital expenditure.

Competently directed Total Electrical and Instrumentation Renovation and Modernization of Turbo Generator Unit #5, adhering to Cap-Ex of 56 Crore.

Coordinated procurement, assembly, and commissioning of electrical and instrumentation system for 7.5 KM aerial ropeway and belt pipe conveyor system with CapEx of 20 crore for coal transportation through mines.

Pivotal role in rectifying extensive winding failure in 100 MVA generator in record timeframe of 21 days, allowing generation with reduced outage, preserving Rs. 260 Cr

Protection relays testing, coordination, and protection planning of the captive power plant (829.5 MW, 10 units) of Hindalco Industries Ltd. Of various makes (ABB, GE, SIEMENS, Easun Reyrolle, etc.), intra-plant communication, and maintenance of the Automatic Voltage Regulator (AVR) of Siemens, ABB, and GE.

Facilitated erection and commissioning of 132 kV switch yard, transformers, CT, PT, PLCC, VFD drives, PLC, and 132 kV bus bar differential system involving 32 buses

Installation and commissioning of PLC panels (SIEMENS S5-S7), programming, and VFDs (SIEMENS, SIEI, YASKAWA) rated at 1000 kW capacity.

Oversee maintenance of 132 kV substation power transformers and associated accessories, including circuit breakers (SF6, VCBs).

Established Disturbance Fault Recorder (DFR) for assessment and planning of relay settings aimed at avoiding blackout at Hindalco Industries Limited

Commissioned numerous UPS units of Emerson with associated battery banks, Commissioned 48 battery banks with rating ranges from 65 Ah to 1,820 Ah.

Commissioned Solar panels and micro hydro generators for renewable energy.

Reduction of the auxiliary consumption of the plant by using Variable Frequency Drives (VFDs) wherever necessary at Hindalco Industries Limited.

• Implemented and developed operational standards, policies and procedures.
• Provided strong leadership to enhance team productivity and morale.
• Led cross-functional teams to achieve project milestones and deliver high-quality results.
• Collaborated closely with peers from other departments to drive organizational success jointly as one cohesive unit.

- Commissioned Disturbance Fault Recorder of Easun Reyrolle make in record 10 days for analysing the effects during the faults occurring in the power system which starts from Renusagar which is providing electricity (829.5 MW) to Hindalco Renukoot over a distance of 35 kM.After studying the reports generated by DFR, settings of various Protection relays were changed due to which Blackout was prevented.

Reduction of the auxiliary consumption of plant by using Variable Frequency drives (VFD’s) wherever necessary at Hindalco Industries Limited

- Pivotal in the installation and commissioning of DG sets, various sub-stations, transmission towers and lines, cables etc.

- Installed Complete PLC System for Coal Handling Plant#4 and minimising the outage time of Plant.

- Studied the effects of jerk, and then planned to reduce it at the turbo generator at Hindalco Industries Ltd., thus preventing the machine from tripping.

Reduction to Zero Boiler tripping due to Tripping of VFD’s of ID, PA, and FD Fan

Due to efficient Maintenance Practices saved approximately 21 Crores by reducing Unit Tripping due to VFD’s,UPS,Relay coordination etc

- Taking adequate measures to monitor and analyze the performance of transporters pertaining to cost, quality and delivery norms.

Carrying out Isolation, decontamination, re commissioning, preventive maintenance schedules of equipments and instruments to increase their reliability.

Proactively identifying areas of obstruction/breakdowns and taking steps to rectify the machines through application of trouble shooting tools.

• Accomplished multiple tasks within established timeframes.
• Maximized performance by monitoring daily activities and mentoring team members.
• Cross-trained existing employees to maximize team agility and performance.
• Carried out testing of the station battery, battery charger, UPS, etc.
• Maintenance of VFDs of various makes, like Siemens, L&T, and SIEI, of various capacities for PA, ID, and FD fans.
• Executed programming and maintenance of Siemens, Rockwell Automation PLCs, and ABB PLCCs.
• Calibration of multiple types of meters, transducers, etc. executed preventive maintenance on power transformers (132/33kV, 48MVA, 11/33kV, 33/3.3kV, 3.3/.415kV)

• Improved team efficiency by streamlining processes and implementing innovative management strategies.
• Identified areas for improvement within the department, implementing strategic initiatives to address gaps in performance or resources.
• Completed extensive testing of protection relays across multiple functions during Turbo-Generator shutdown. Tested generator protection, distance protection, feeder protection, and bus-bar differential protection. Carried out various interlock tests to validate operational integrity.
• Executed extensive inspection of AVRs from diverse manufacturers.
• Executed comprehensive testing on GE 76 MW, SIEMENS 88 MW, ABB 80 MW, and Kraftwerk Union 80 MW generators during scheduled shutdown. Completed multiple interlock tests to verify system integrity and functionality.

• Promoted teamwork within the workplace by encouraging collaboration among staff members on various project tasks.
• Collaborated with the management team to develop strategic plans for business growth and improvement.
• Commissioned numerous UPS of Emerson make of 2 x 135kVA, 6 x 120 kVA, 4 x40 kVA with associated battery banks.
• Spearheaded commissioning of 48 Battery Banks across rating ranges of 65 Ah to 1820 Ah.
• Executed installation of solar panels alongside micro hydro generator to optimize renewable energy generation.
• Conducted VFD deployment for Ash Plant Compressors aimed at optimizing energy savings.
• Commissioned Energy Management System for Renukoot Plant, enhancing operational efficiency. Implemented Fast Bus Changeover System to ensure uninterrupted power supply. Established 132 kV Bus-Bar Differential System for improved fault detection and reliability.
• Identifying potential performance bottlenecks and executing corrective actions to eliminate risks

• Provided specialized technical support for power distribution and control systems at Bangalore International Airport during critical pre-launch phase.
• Enhanced customer satisfaction by streamlining communication channels and improving response times.
• Developed innovative solutions to complex problems, resulting in improved organizational performance.
• Mentored junior staff members for accelerated career growth, developing future leaders within the organization.
• Optimized operational efficiency by redesigning processes, systems, and workspaces for increased productivity.
• Managed cross-functional teams for successful project completion within budgetary constraints and deadlines.

• Managed maintenance operations for 132 kV sub-station infrastructure, power transformers, circuit breakers, and industrial equipment including EOT cranes and CNC machines.
• Responsible for maintaining the Reid Hammer, Graphite Anode Plant Maintenance and its reliability.
• Improved Maintenance practices resulted in increasing the Plant reliability by 25% and reduction in Unplanned outages by 12%.
• Achieved successful project outcomes by maintaining accurate documentation and meeting strict deadlines.
• Provided input to team lead regarding areas for process and procedural improvement.
• Wrote, reviewed and edited technical document in accordance with template requirements.
• Enhanced plant performance by conducting thorough failure analysis and recommending improvements.

• Conducted Erection, Installation and Commissioning of power distribution systems including DG sets, substations, and transmission infrastructure.
• Delivered high-quality field services, ensuring all projects were completed on time and within budget constraints.
• Provided review of design modifications and requests for clarification.
• Prepared documentation that would be used in requests for proposal.
• Collaborated with multidisciplinary teams to develop innovative solutions for challenging field problems.