U.S.K Brahmaji Rao
DGM(E&I)
Hyderabad,TG
Summary
Accomplished and dynamic professional with 29.5 years of total work experience in cement industry. Resourceful Deputy General Manager E&I driven to cut company cost and boost company revenue through innovative management techniques. Organized and diligent, with excellent written, oral, and interpersonal communication skills. Successful in building and motivating dynamic teams
Overview
29
29
years of professional experience
3
3
Languages
Work History
Dy, General Manager (Elect, Inst & Power Generation)
RAIN CEMENTS LIMITED
11.2021 - Current
- Project Leader – 12 MW solar plant, EPC by Tata Power
- Completed project within 7 months and to commercial operation along with 'Grid Synchronisation'
- Liaison with APTRANSCO, APSPDCL and APSLDC for Grid Synchronization
- Liaison with NREDCAP for Solar Plant Registration
- SAP exposure
- WHRS Experience – Reduced auxiliary consumption by
- Installed VFD for ACC Fans
- Installed VFD for ACW pump
- Installed VFD for CEP Pump
- BFP Pump overhauling
- Installed Fresh Air Damper in AQC boiler inlet Duct to dilute the excess Boiler Inlet Temperature
- To eliminate the problem of plant tripping by 132 KV under voltage/power dip – installed Vector surge relay and configured
- Avoided nuisance tripping of KC Blower VFD with undervoltage during power dip
- En MS 50001 certification documentation and audit
- Coordinator for CII GreenCo certification under the guidance of CII GreenCo wing
- Exposure in smart MCC
- Equipment’s handled: ABB DCS (server 6.0/3, PM 866 controllers), SIEMENS smart MCC for Line1 cement mill (Polycom), ABB VFD – ACS 800 & ACS 880, WEIGH FEEDERS & SFM – SCHENCK & TRANSWEIGH (FLS), HITACHI – MV DRIVE, XRF – Thermofisher, HT BREAKERS – ABB & SCHNEIDER, POWER TRANSFORMERS – AREVA & CGL, SIEMENS – MCC & PCC (DRAW OUT MODULES), WHRS - THERMAX
Assistant General Manager, Department: E&I
THE INDIA CEMENTS LIMITED
01.2009 - 11.2021
- Created and implemented new documents, procedures and check lists for regular activities that increased productivity across our department
- Designed and implemented training programs to enhance technical skills of our team
- Assessed prospective team members to ensure they have potential traits, characteristics and determination to be a candidate for accountability and objectives of management
- Implemented cost control measures and training initiatives increasing productivity and reducing costs
- Identified operational opportunities and implemented key standard operations thus increasing profit to meet goals
- Attended and led weekly and yearly manager meetings/seminars to build on management skills, teamwork, product knowledges
- Responsible for managing all E&I activities
- Overseeing cost efficient direction of contracts while ensuring qualitative work output of their labor and materials utilization
- My Achievements at The India Cement Limited: Project Experience in Raasi Plant (Vishunpuram), Line1 upgradation from 1300 TPD to 3200TPD with ABB DCS with Profibus connectivity of the panels, Project Experience in Yerraguntla Plant – Removing existing control desk operation to ABB DCS CCR Operation, Increased the operational efficiency of the process by implementing condition monitoring of the equipment’s and standards, Contributed substantially to a high level of loyalty through my interpersonal skills, length of service, personal presentation and my understanding of the personalities, preferences and expectations of management, Improved the effective PM activities by adopting TPM and 5S Techniques, Formed the Quality Circles to improvise the team activities for improving productivity, Focused on the KPI’s and formed the road map to meet these KPI’s, Imparting training and OJT’s to improvise the skills of the team, Part of the team in implementing management systems QMS, OHSMS, EMS, EnMS (Integrated Management System – ISO 2015 IMS) and API (Spec 10A), Documentation of PAT and implementing energy saving measures, Liaison with EB, PCB equipment’s maintenance and data uploading to State PCB and CPCB
- Liaison with PCB officials, In APFC panel, removed the relay control panel, which controls LT capacitor banks, and incorporated program in plant DCS, Siemens with respect to power factor of that MCC, In SFM, incorporated a circuit in hard wired and PID program in DCS to control dosing valve operation with respect to Belt load, In ABB DCS program incorporated: Slope tracking of PH drafts and bearing temperatures and alarm generation
Manager, Department: Instrumentation (HOD)
PRIYA CEMENT LIMITED
08.2007 - 01.2009
- Scheduled and planned green field project (Line2), coordinating the procurement of materials and labor and managing project
- Recruited Instrumentation team members for new project, delegating tasks associated with project execution jobs and maintenance
- Overseeing cost efficient direction of electrical contracts and sub-contractors while ensuring accurate accounting of their labour and materials pertaining to project execution jobs
- Lead the engineering team in equipment condition monitoring product line
- Plan and execute the concept phase for new techniques
- Managed instrumentation department with Instrumentation engineers and technicians
- Lead implementation of engineering standards, processes and procedures in instrumentation systems
- Planned and executed equipment condition monitoring that has improved machinery reliability
- My Achievements at Priya Cement Limited: Independently managed the instrumentation installation in the green field project, Organized Instrumentation preventative maintenance activities, Worked closely with electrical and mechanical engineers to meet operational efficiency of the plant, Improved project management for better cost control and delivery schedules, Optimized work efficiency, structured discipline, and met on-time delivery requirements achieving uniform production control and consistent product quality, Developed team member skills by training, identifying skill sets, and team building through discipline and reward, inspiring higher moral and ethical standards, Extract daily KPI numbers, merging with an excel spreadsheet to brief upper management; allows total quality management in areas of concern
Deputy Manager, Department: Instrumentation
THE INDIA CEMENTS LIMITED
06.1998 - 08.2007
- Scheduled and planned green field project, coordinating the procurement of materials and labor and managing projects through their completion
- Implementation of modifications in field instruments, PLC Programming and equipment safety
- Imparting training on SOPs of the equipment’s and calibration procedures
- Providing material to the technicians to implement their ideas for plant operation benefits and encouraging them to meet the organization goals
- My Achievements at ICL: Implemented cement bag counting system with existing internal resources and then designed management system for bag counting with shift wise and day wise counting in our plant PLC
- Received management recognition award for this, Modified the PH inlet Analyzer probe safety system
- This has given power saving and saving of cost to the company of Rs 2 Lakh pa
Assistant Engineer, Department: Instrumentation
GOLD STAR STEEL AND ALLOYS LIMITED
01.1996 - 06.1998
- Preparation of Instrument Index, I/O list, Datasheets of all field instruments
- Preparation of Instrument installation diagrams (Hookup)
- Preparation of JB wiring diagram, Logic diagrams, tag assigning, development of graphics page
- Engineering, procurement, erection, testing & commissioning and maintenance of all field instruments
- Maintenance & calibration of transmitters FT, PT, LT, TT, DPT
- Maintenance and calibration of control valves
- Raising Department Purchase Order & Technical evaluation
- Planning and implementing additional control loops as per site requirements
- Lead a team of E & I Technicians
- Assist in preparation of final As Built Drawings
- Erection of Field JB and Local Panels
- Interfacing of Signal with the existing control system
- Ensures that all the subordinates and contractors are aware of safe working practices and take necessary precaution in hazardous work environment, while carrying out activities
- To provide technical advice to my subordinates / contractor staff and ensure the proper use of tools and test equipment
- Awards Received: Attended Kaizen competition in New Delhi conducted by CII, received 3rd Prize in Kaizen competition
Education
Bachelors of Engineering - Electronics and Communication Engineering
JNTU Kakinada
Post Graduate Diploma - Computer Science
Central University
Diploma - Electronics and communication Engineering
State Board of Technical Education & Training
Skills
Maintenance management
Trainingprogramsattended
- Leadership skills (21 day programme in Chennai). Received award from beloved MD Srinivasan sir.
- ABB DCS 800 XA Training programme in Bangalore (5 days).
- Tata Honeywell PLC and SCADA in PUNE (1 week).
- Effective Communication in Chennai (5 days).
- Allen Bradeley PLC and Siemens PLC Programming (3 days).
- Time Management and Leadership qualities.
- Training the trainers.
- Facilitation Skills for Technical Trainers.
- TPM & 5S training by CII in Bangalore.
- Training on basic financing.
Awards
Attended Kaizen competition in New Delhi conducted by CII, received 3rd Prize in Kaizen competition.
Personal Information
- Passport Number: M 2394693
- Number of Children: 2
- Gender: Male
- Marital Status: Married
Timeline
Dy, General Manager (Elect, Inst & Power Generation)
RAIN CEMENTS LIMITED
11.2021 - Current
Assistant General Manager, Department: E&I
THE INDIA CEMENTS LIMITED
01.2009 - 11.2021
Manager, Department: Instrumentation (HOD)
PRIYA CEMENT LIMITED
08.2007 - 01.2009
Deputy Manager, Department: Instrumentation
THE INDIA CEMENTS LIMITED
06.1998 - 08.2007
Assistant Engineer, Department: Instrumentation
GOLD STAR STEEL AND ALLOYS LIMITED
01.1996 - 06.1998
Bachelors of Engineering - Electronics and Communication Engineering
JNTU Kakinada
Post Graduate Diploma - Computer Science
Central University
Diploma - Electronics and communication Engineering
State Board of Technical Education & Training
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