Vijay Kumar
Torngallu
Summary
Dynamic manager with extensive experience at JSW Steel Limited, excelling in refractory maintenance and project execution. Proven track record in optimizing equipment performance and leading teams, utilizing SAP and MS Office for data analysis. Strong analytical skills complemented by effective communication, driving successful outcomes in high-pressure environments.
Overview
16
16
years of professional experience
Work History
Manager
JSW Steel Limited
Vijaynagar
04.2021 - Current
- Tracking the performance of Refractory equipment, evaluating vendor performance & technical rating.
- Root cause analysis of failures and premature down of refractory equipment used in primary and secondary steel making.
- Interacting with various refractory suppliers for technical issues & negotiations.
- Key role in the process of preparing BOQ by holding material discussion with clients, preparation of site facilities, manpower setup, handling inspection work, preparation and submission of required documents & reports and Execution of Project / shutdowns.
- Implementations of Plug functioning device to ensure purging failure.
- Led refractory gunning operations for critical equipment including Ladles, RH degasser units, and Basic Oxygen Furnace (BOF), ensuring timely repairs and extended lining life.
- Managed a 10–15 member team of refractory technicians and gunning machine operators across all shifts, ensuring safety, skill compliance, and productivity.
- Coordinated daily with steel plant production, mechanical, and refractory planning teams to schedule hot and cold repairs without affecting tapping cycles.
- Executed hot gunning during operational intervals to repair worn refractory areas (slag line, impact zone, barrel, and cone) in ladles and BOF vessels.
- Supervised RH snorkel gunning to extend snorkel campaign life and reduce RH unit downtime, ensuring precise material application in high-wear zones.
- Ensured proper selection, handling, and application of gunning materials (magnesia-carbon, dolomite, alumina-magnesia) based on wear patterns and campaign data.
- Maintained gunning machine health, spare inventory, and conducted regular performance checks to avoid unplanned breakdowns during shift operations.
- Implemented and enforced strict safety measures, including confined space entry protocols, hot work permits, and PPE compliance; conducted daily safety briefings.
- Prepared daily and monthly reports on refractory consumption, repair cycle time, lining life, and material efficiency for submission to plant management and refractory vendors.
- Participated in trials of new gunning materials and techniques to improve service life and reduce cost per ton of steel.
Ast. Manager/Dept. Manager
JSW Steel Limited
Vijaynagar
04.2015 - 03.2021
- Refractory Maintenance at Steel Making Shop (SMS#2).
- Installation and monitoring of refractory lining in HML, steel ladles, RH De-Gasser and converters.
- Condition based maintenance of Ladles, Snorkels and converters.
- Planning & timely readiness of Refractory lined equipments for smooth operation of shop.
Junior Manager
JSW Steel Limited
Vijaynagar
06.2011 - 03.2015
- Played a key role in the successful refractory commissioning of the Corex-2 capital expansion project, increasing capacity by 0.8MT within 82 days, encompassing mechanical, electrical, and pre-heating tasks, with technology supplied by Siemens.
- Monitoring erection of Carbon block and stave grouting in furnace.
- Erection of Refractory for 3 no's of HBS, HBM, bustle pipe, waste gas main and chimney, with technology supplied by Danieli Corus.
- Down comer, Bustle pipe, Hot blast stove and waste gas main gunning with Insulation and dense material.
- Played a key role in the successful refractory commissioning of the Corex-1 capital expansion project, increasing capacity by 0.8MT within 72 days, encompassing mechanical, electrical, and pre-heating tasks, with technology supplied by Siemens.
- Successfully completed the campaign repair of refractory work for a Lime Kiln Plant with a capacity of 600 tones per day, utilizing technology supplied by Cimprogetti Technologies, Italy.
- Oversaw the installation and commissioning of refractory systems in the furnace and heaters of a DRI Corex gas-based plant, employing Midrex technology, and achieved successful project completion.
- Gunning and Shot creating in Melter gasifier in corex #1&2 area.
Graduate Engineer Trainee
JSW STEEL LIMITED VIJAYNAGAR
·BF #4 Projects And Commissioning:
06.2010 - 06.2011
- Monitoring erection of Carbon block and stave grouting in furnace.
- Erection of Refractory for 3 no’s of HBS, HBM, bustle pipe, waste gas main and chimney, with technology supplied by Danieli Corus.
- Down comer, Bustle pipe, Hot blast stove and waste gas main gunning with Insulation and dense material.
Graduate Engineer Trainee
H&R Johnson Pvt. Ltd
Raigad
07.2009 - 04.2010
- Slip house – Inspecting parameters of slip such as viscosity, density and moisture content in powder.
- Pressing unit - Inspection of molds, maintaining of temperatures
in vertical heaters. - Glaze line – Inspection of viscosity of glaze and paint meanwhile
inspecting the prints on tile..
Education
B. Eng. Ceramic and Cement Technology -
V T U
01.2009
Skills
- MS Office
- SAP
- TQM-J1
Disclaimer
I, Vijay Kumar hereby declare that all the above statements are true & correct to the best of my knowledge.
Expertise Skills
- Refractory set up and installation for both lining and flow controls.
- Implementation of 5S methodology, SOPS and comprehensive safety measures.
- Project management
- Erection and commissioning
- Material management with optimization of inventory
- Vendor development
- Team building
Accomplishments
- Represent the refractory department in securing the 'DEEMING AWARD' for JSW Steel Ltd, Vijaynagar
- Successfully secured the silver award at the quality circle forum of India's CCQC demonstrating excellence in lean quality practices and team collaboration
- Represented JSW at IREFCON conference and refractory operating committee meeting.
- Part of the team in which refractory lining of 180-ton capacity BOF campaign repair done in only 51Hrs 45mins
- Highest DIDO 2953 MINUTES and Life 156 achieved in SMS#2 RH#2 and RH#1 respectively
- KR impeller refractory life acieved 303.
Languages
- English
- Hindi
- Kannada
Hobbies and Interests
- Horology
- Music
- Cooking
Personal Information
- Father's Name: Ramrao Kulkarni
- Date of Birth: 02/19/87
- Gender: Male
- Marital Status: Married
Timeline
Manager
JSW Steel Limited
04.2021 - Current
Ast. Manager/Dept. Manager
JSW Steel Limited
04.2015 - 03.2021
Junior Manager
JSW Steel Limited
06.2011 - 03.2015
Graduate Engineer Trainee
JSW STEEL LIMITED VIJAYNAGAR
06.2010 - 06.2011
Graduate Engineer Trainee
H&R Johnson Pvt. Ltd
07.2009 - 04.2010
B. Eng. Ceramic and Cement Technology -
V T U
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