T. Papaiah

"Passionate Mechanical Engineer Graduate and MBA | 18+ Years of Expertise in Rotating Equipment Reliability & Condition Monitoring | CAT-III Certified (Mobius) | SSGB| Driving Operational Excellence"

• Established strong relationships with clients and stakeholders, ensuring long-term partnerships and repeat business.
• Implemented and developed operational standards, policies and procedures.
• Reduced costs, optimized resource allocation, and improved efficiency in managing projects.
• Improved team performance by providing comprehensive training and fostering a collaborative work environment.
• Managed budgets effectively, achieving financial objectives while maintaining strict control over expenditures.
• Reviewed and analyzed reports, records and directives to obtain data required for planning department activities.
• Demonstrated exceptional adaptability in navigating complex situations or rapidly changing environments with ease.
• Achieved operational excellence by streamlining processes and implementing best practices.
• Conducted performance evaluations, compensations and hiring to maintain appropriate staffing requirements.
• Evaluated vendor offerings critically to select the most appropriate partners for delivering desired results at optimal costs.
• Developed and executed successful training program for junior managers, equipping them with essential leadership skills.
• Evaluated employee performance and conveyed constructive feedback to improve skills.
• Established performance goals for employees and provided feedback on methods for reaching those milestones.
• Key Projects and Strategic KRAs at Greenko
  1. Condition-Based Monitoring (CBM) for WTG Drive Train – Achieved >95% True Positive rate and 2. CMMS Tool Implementation – Successfully piloted CMMS for Poly and Jed sites to streamline preventive maintenance, asset tracking, and fault reporting, enhancing visibility and maintenance planning.
  3. Main Shaft Bearing Vendor Development – Established alternate vendors (e.g., ELECON, N-Power, Speed Team) to reduce dependency on OEMs, cut lead time, and improve cost and service flexibility.
  4. Rescue Grease Implementation – Applied Klübersynth BEM 48-1501 to damaged main shaft bearings, extending bearing life, avoiding crane deployment, and reducing O&M cost by ₹6–10 lakhs per turbine.
  5. CBM Team Development – Built and deployed a 4-member CAT II certified CBM team monitoring 800+ WTGs with ecoCMS; standardized processes and regional leads appointed to support diagnostic accuracy and predictive response.
  6. Site-Level CBM & Vibration Analysis Training – Conducted extensive training on fault identification and data interpretation for Stud Failure and other Greenko Wind locations, enhancing field team capability.
  7. Hydraulic System Workshop – Delivered 4 highly engaging training sessions across Karnataka and AP, WTG hydraulics, improving fault resolution efficiency and reducing external dependencies.
  8. CBM Team Certification & RCA Execution – Enabled CAT II certification for 2 CBM engineers; initiated standardized RCA procedures post major component replacements for improving diagnostic practices and reducing recurring faults.
  Centre of Excellence (CoE) Responsibilities
  • Conducting detailed wind turbine audits across Greenko wind farms to ensure alignment with predictive maintenance standards.
  • Carrying out quality inspections of refurbished drivetrain components and newly procured mechanical parts.
  • Reviewing and approving reliability standards during procurement to ensure compatibility and lifecycle alignment.
  • Leading availability-focused task forces to address underperforming turbines and improve site-wide machine uptime.

• 🔹 Led condition monitoring initiatives across multi-brand wind fleets by analyzing vibration signals, temperature trends, and lubrication data. Accurately identified early-stage faults such as bearing cracks, gearbox misalignments, and rotor imbalance—enabling proactive maintenance planning and avoiding unplanned downtime.
• 🔹 Collaborated with cross-functional site teams and OEM partners to validate CBM alerts through field inspections, driving operational decisions with data-backed insights. Contributed to reliability improvement workshops and RCA discussions that strengthened component lifecycle management.
• 🔹 Mentored junior engineers on FFT spectrum interpretation, CBM software tools, and report writing. Played a key role in building Greenko’s in-house CBM capabilities, standardizing diagnostic processes, and supporting over 850 wind turbines under predictive monitoring.
• Mentored junior team members, fostering professional growth and skill development.
• Collaborated with cross-functional teams to achieve project goals within deadlines.
• Contributed to a positive work environment by promoting teamwork, collaboration, and shared accountability for results.
• Managed daily operations, ensuring smooth workflows and timely task completion.

• Reliability Engineer – Technical Expert (SKF India Ltd.)
• Led Condition‑Based Monitoring (CBM) programs for Maruti Suzuki – Gurgaon, monitoring 150+ critical rotating assets including spindles, blowers, pumps, and motors, enabling early fault detection and planned maintenance.
• Performed advanced vibration analysis and asset health diagnostics, resulting in:
• 30–40% reduction in unplanned breakdowns through timely correction of misalignment and rotor unbalance.
• Dynamic balancing of 25+ rotors (blowers, fans), reducing vibration levels from >8 mm/s to
• Executed predictive bearing and spindle replacements on high‑speed machinery, improving MTBF by ~20–25% and preventing secondary damage to gearboxes and motors.
• Implemented pulley alignment and blower impeller cleaning programs, leading to 15–20% reduction in energy losses and improved airflow efficiency.
• Diagnosed and eliminated structural and resonance issues by improving base rigidity of rotating blowers, resulting in sustained vibration stability and extended bearing life.
• Conducted CBM diagnostics at ITC Paper Mill (PSPD) for 200+ rotating assets including paper mill rollers, dryers, pumps, and high‑rated motors:
• Identified roller condition degradation and bearing defects, reducing roller‑related failures by ~25%.
• Detected pump cavitation and impeller erosion, enabling corrective actions that reduced pump failures by 30%.
• Delivered technical RCA reports and corrective action plans to plant maintenance teams, contributing to higher equipment availability and measurable reduction in maintenance costs.
• Improved customer satisfaction by addressing and resolving complaints promptly.
• Offered hands-on assistance to customers, assessing needs, and maintaining current knowledge of consumer preferences.
• Coordinated with vendors to ensure timely delivery of products and resolve any supply chain issues.
• Facilitated clear communication between employees and upper management through regular meetings and updates.
• Ensured compliance with all safety regulations by conducting regular inspections of equipment/operations within the store.
• Streamlined and monitored quality programs to alleviate overdue compliance activities.

As Assistant Manager – Reliable Maintenance, I was responsible for executing predictive maintenance strategies across critical rotating equipment in industrial environments. I led the collection and evaluation of offline vibration data from motors, fans, pumps, and gearboxes, interpreting the results using advanced CBM-FFT techniques to identify misalignment, unbalance, and bearing degradation. My role involved implementing corrective actions such as precision shaft alignment, rotor balancing, and foundation strengthening to stabilize machine dynamics and extend asset life. I also coordinated closely with plant maintenance teams to ensure data-driven decisions, while mentoring junior engineers in condition monitoring practices and promoting a reliability-focused maintenance culture.

Senior Engineer – Condition Monitoring
• Conducted offline vibration data collection from a wide range of industrial rotating machinery including motors, pumps, fans, and gearboxes across cement, steel, and power plants.
• Performed FFT-based signal analysis to detect common failure modes such as unbalance, misalignment, bearing faults, and structural looseness.
• Generated detailed diagnostic CBM reports with actionable recommendations, directly supporting plant maintenance and reliability teams in predictive maintenance decision-making.
• Led corrective actions including shaft alignment correction, rotor balancing, and machine base improvements, ensuring stable dynamic performance and prolonged equipment life.
• Played a pivotal role in identifying resonance-related issues and implementing mechanical changes to eliminate root causes of excessive vibration and recurring failures.
• Acted as senior CBM engineer on site, collaborating closely with plant teams, and training junior engineers in vibration measurement techniques and SPM data interpretation tools.