Irfan Shaikh

Oversight of Plant Utilities: Manage the operation and maintenance of plant utilities, including Boilers (10 TPH & 25 TPH), Chillers (100 TR x 2), Cooling Towers, Water Treatment Plant (25 M³/Hr), Screw Compressors (520 CFM x 5), and various pumps. Co-Generation Plant Management: Oversee the operation and maintenance of a 2.5 MW co- generation plant to ensure optimal performance. Thermic Fluid Heater Operations: Ensure efficient operation and maintenance of a thermic fluid heater with a capacity of 150,000 Kcal. Budget Preparation and Cost Management: Develop and track the annual budget, driving initiatives for cost-saving projects. Preventive Maintenance Implementation: Establish preventive maintenance protocols to minimize breakdown occurrences and enhance operational reliability. Utility Maintenance Oversight: Maintain various storage and reactor systems, including 4KL, 32KL, 10KL GLR, and SS reactors (40 KL, 25 KL). Root Cause Analysis (RCA): Conduct thorough RCA of breakdown incidents to prevent future occurrences. Equipment Breakdown Analysis: Perform breakdown analysis, including WHY-WHY analysis, Mean Time to Repair (MTTR), and Mean Time Between Failures (MTBF). Reporting and Documentation: Prepare daily Management Information System (MIS) reports and monthly Operational Risk Management (ORM) reports; develop Job Safety Analysis (JSA) prior to initiating tasks. HAZOP Studies: Conduct Hazard and Operability (HAZOP) studies for utility operations to safeguard personnel, machinery, and processes. Leadership in Process Safety Management (PSM): Serve as team leader in the PSM initiative for Process Hazard Analysis (PHA) elements. Hazard Identification and Risk Assessment (HIRA): Execute HIRA for the entire facility across individual departments. Shutdown and Inspection Planning: Plan and implement annual shutdowns and inspections of boilers in compliance with IBR regulations. Inventory and Contract Management: Monitor and manage inventory for engineering goods, including indenting and maintenance contracts utilizing SAP. ISO System Implementation: Develop and execute ISO standards within the power plant and utility operations (ISO-9001, ISO-14001, OHSAS-18001). PSM Element Implementation: Facilitate the integration of 14 Process Safety Management elements across various departments to enhance safety and compliance.

AFBC Boiler Management: Oversee the operation of a 50 TPH AFBC boiler with specifications of 67 kg/cm² pressure, 480°C temperature, manufactured by Cethar. The system features DCS control, coal firing, an Electrostatic Precipitator (ESP), and a Dense Phase Pneumatic Ash Handling System, complemented by a 7.5 MW Triveni condensing turbine. Additional Boiler Operations: Manage a 22 TPH AFBC boiler with a pressure of 10.5 kg/cm² and a temperature of 180°C from Cheema Make, as well as a 14.5 TPH AFBC boiler operating at 24.6 kg/cm² and 360°C from IBL Make. Also, oversee a Demineralization (DM) plant with a capacity of 17.5 M³/hr, utilizing Ion Exchange technology. Breakdown Analysis: Conduct comprehensive equipment breakdown analysis, including WHY-WHY analysis, Mean Time to Repair (MTTR), and Mean Time Between Failures (MTBF) to enhance operational reliability. Reporting and Documentation: Prepare daily Management Information System (MIS) reports and monthly Operational Risk Management (ORM) reports to monitor performance and safety metrics. Inventory and Contract Management: Efficiently monitor and manage inventory for engineering goods, including indenting and reviewing maintenance contracts using SAP. Shutdown and Inspection Planning: Strategically plan and execute annual shutdowns and inspections of boilers in compliance with IBR formalities, ensuring adherence to safety and regulatory standards. This role emphasizes my dedication to maintaining operational excellence and regulatory compliance within boiler operations.

Water Tube Boiler Management: Oversee the operation of a 30 TPH water tube boiler operating at 65 kg/cm², equipped with a Distributed Control System (DCS) and utilizing bagasse and biogas as fuel sources. Preventive Maintenance Planning: Develop and execute a comprehensive Preventive Maintenance (PM) planner for utilities, including screw compressors, reciprocating air compressors, centrifugal pumps, reciprocating pumps, screw pumps, and cooling towers. Plant Equipment Maintenance: Manage the maintenance of critical plant equipment such as columns, heat exchangers, re-boilers, and plate heat exchangers (PHE) to ensure optimal performance and reliability. Material Management and Inventory Control: Implement effective material management and inventory control processes utilizing SAP to streamline operations and reduce costs. PM Annual Planning and Budgeting: Conduct annual planning for preventive maintenance activities, including budgeting and expense control, while ensuring effective utilization of available manpower. Permit System Implementation: Utilize a robust permit system to safeguard personnel and equipment, striving for zero accidents in the workplace. Collaboration and Team Leadership: Foster a collaborative work environment by leading cross- functional teams, ensuring alignment on maintenance goals and operational efficiencies. Continuous Improvement Initiatives: Drive continuous improvement initiatives by analyzing maintenance processes and implementing best practices to enhance productivity and reduce

Boiler Operation and Maintenance: Manage the operation and maintenance of multiple boilers, including a 40 TPH Sitson boiler operating at 45 kg/cm² and 450°C, a 40 TPH Thomson boiler at 21 kg/cm² and 350°C, a 20 TPH Thomson boiler at 21 kg/cm² and 350°C, and a 15 TPH Texmaco boiler at 21 kg/cm² and 350°C, all utilizing bagasse as fuel with a dumping grate system. Steam Turbine Oversight: Oversee the performance and maintenance of steam turbines, including a 3 MW Triveni, a 2.5 MW Bellis, and a 1.5 MW Borsig back-pressure turbine, ensuring efficient energy conversion and reliability. Comprehensive Plant Maintenance: Supervise the maintenance of essential plant equipment, including centrifugal pumps, reciprocating pumps, screw pumps, gear pumps, and reciprocating air compressors, to maintain operational efficiency and reliability. Safety and Compliance Management: Ensure adherence to safety protocols and regulatory compliance during operations and maintenance activities, fostering a culture of safety within the team. Process Optimization Initiatives: Implement process optimization initiatives aimed at enhancing equipment performance and minimizing downtime, contributing to overall operational efficiency. Data-Driven Decision Making: Utilize data analytics to inform maintenance strategies, predict equipment failures, and implement proactive measures that enhance reliability and performance. Team Development and Training: Mentor and train team members on best practices in equipment operation and maintenance, promoting a knowledgeable and skilled workforce committed to excellence. Collaboration with Engineering Teams: Work closely with engineering teams to design and implement upgrades and modifications to existing systems, ensuring alignment with operational goals and safety standards. Performance Monitoring and Reporting: Develop and maintain performance monitoring systems to track key performance indicators (KPIs), facilitating informed decision-making and continuous improvement efforts.

Inspection Coordination: Organize and oversee the receiving, in-process, and final inspection of raw materials, purchased components, and finished products, ensuring adherence to quality standards and specifications. Material Identification and Traceability: Implement robust systems for material identification and traceability throughout the production process to enhance accountability and compliance. Control of Measuring and Testing Equipment: Manage and maintain measuring, inspection, and test equipment to ensure accuracy and reliability in quality assessments. Non-Conformance Review: Conduct comprehensive reviews of non-conforming products, providing critical input to management to facilitate informed decision-making and corrective actions. Prevention of Non-Conformities: Develop and implement strategies to proactively prevent non- conformities within the department, fostering a culture of continuous improvement and quality excellence. Training and Development: Provide training to staff on quality assurance practices and standards, ensuring a thorough understanding of processes and responsibilities. Collaboration with Cross-Functional Teams: Work collaboratively with cross-functional teams to address quality issues, enhance processes, and promote a shared commitment to quality across the organization. Implementation of Quality Management Systems: Lead the implementation and maintenance of Quality Management Systems (QMS) in alignment with industry standards to ensure compliance and continuous improvement. Data Analysis and Reporting: Analyze quality data to identify trends and areas for improvement, generating reports that inform management decisions and strategic planning. Supplier Quality Assurance: Engage with suppliers to ensure that incoming materials meet quality standards, conducting audits and assessments as necessary to uphold supplier performance.