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[QUOTE=Guest;177628]Sanjay P.Bagalkote 
[b]E –Mail [/b]: sanjay_bagalkote AT rediffmail.com 
 sanjay.bagalkote AT gmail.com 
Assignments in Production/ Project Management work with a technology driven organisation of repute.
SYNOPSIS
- A result oriented professional with over 15 years of experience in PPC, Quality Assurance, operations & maintenance & new project. Currently associated with Jubail Chemical Industries company, HASSAD Project, Kingdom of Saudi Arabia.
- Rich experience in equipment operations, all Engineering functions, resource utilization & manpower management. 
- Demonstrated abilities in working on initiatives, thereby bringing down equipment breakdown & achieving annual costs savings. Improved productivity by technology management. 
- An effective communicator with excellent relationship, management skills and strong analytical, problem solving and organizational abilities.
- Full fledged plant commissioning experience & process development through technical proposals. 
Since Mar’95 to Dec 07 working with Tata Chemicals Limited
From Jan 08 to till date working with Jubail Chemical Industries Company, HASSAD Petrochemicals Kingdom of Saudi Arabia 
 Career Path
- Trainee Engineer (Mar’95-Mar’97) in Tata Chemical Ltd.
- Senior Assistant Engineer (Mar’97-Dec’00) in Tata Chemical Ltd.
- Senior Engineer (Dec’00-May’04) in Tata Chemical Ltd.
- Asst. Manager (Since May’04 to Dec 07) in Tata Chemical Ltd.
- At present, as supervisor (Since Jan 08) in Jubail Chemical Industries company, HASSAD, Kingdom of Saudi Arabia 
 
The Key Result Areas 
Production Planning & Control
- Minimizing performance bottlenecks for achieving high productivity by maximization of material & machine.
- Handling operations for improvement in existing products based on market trends & requirements.
- Preparing SOPs, manuals & work instructions for production operations for the unit and maintaining monthly reports for facilitating decision making by the management.
- Reviewing of precomissioning, commissioning procedures, work instruction etc
- Regular study & analyze product/process issues & help to troubleshoot them, also analyzing important parameters of plant
- Directing maintenance technicians; monitoring expenses with optimum utilization of resources.
- Daily active monitoring of performance of assigned equipments, recommend & implement actions for troubleshooting operational issues.
- Monitor the trend of KPI (Key performance indicator) & take necessary action for keeping the specific consumption within the limit.
- Actively involved in many plant commissioning activities, shut down activities.
- P & ID, PFD, drawings study & review.
- Monitoring & procuring the raw material & catalyst stocks. 
- Generating Monthly reports of plant performance.
- 
Operations & Maintenance
- Overall Equipment effectiveness (OEE), Mean time to repair (MTTR), Mean time between failure (MTBF) of important equipment calculated.
- Proactively identify areas of obstruction / breakdowns and take steps to rectify the equipments through application of trouble shooting tools. 
- Regular communication with internal customers to meet production oriented requirements.
- New catalyst charging in oxidation reactors/hydrolysis reactor
Quality Control & safety
- Developing of standard maintenance and operation procedures w.r.t ISO certification.
- Ensuring adherence to ISO 9001 QS and ISO 18001 system. Undertook new initiatives like 5 “S” & SEDAC projects.
- Hazop study & RCA
- Participation in incident & accident investigation team, preparation of investigation reports
- Conducting prestart up safety review
Process Enhancement/ Cost Control
- Identifying scope for implementation & monitoring of technological changes to enhance productivity.
- Controlling of wastes, scraps, and inventories.
- Preparing the required process data for different instruments in plant for smooth & efficient running of plants.
- Optimizing the process with different modifications by determining scope of modification & initial approximate cost.
- Executing cost saving techniques / measures and modifications to achieve substantial reduction in O&M 
- Controlling expenditures and work within the budget.
Man Management
- Directing and leading the technical personnel. Imparting continuous on job training to the workforce for accomplishing greater operational effectiveness / efficiency. 
- Working on talent pool and succession planning of the management cadre and workforce, appraising their KRA (Key Result areas) based performance and providing feedback on the same. Resolving interpersonal issues and working towards a harmonious work environment.
o Training the graduate engineers for smooth plant operations.
The Attainments in Jubail Chemicals Industries Co., Kingdom of Saudi Arabia
- Working as a supervisor from Jan 08.
- The main product is Epichlorohydrin.
- Precommissioning activities like dry out, flush out of system 
- Commissioned Utilities like 
PLC based Chilled water system with NH3 refrigeration system for supplying AT 500 m3/hr for supplying chilled water to main plant at AT 50C.
PLC based Chilled Brine system with NH3 refrigeration system for supplying AT 500 m3/hr for supplying chilled brine to main plant at AT -200C.
Cooling tower system for cooling the cooling water to supply to plant at AT 360C. The cooling water flow to the plant is 12000m3/hr. This plant consists of mainly cooling tower including 3 pumps with 6000m3/hr capacity, cooling tower with 4 compartments & fans, 9 heat exchangers & cooling water sump with 3 pumps of 6000 m3/hr capacity. 
Nitrogen handling system with N2 compressor for supplying N2 to the plant at 25 bar.
- Commissioned OSBL sections like 
HCL incinerator for burning wastes like heavy ends, light ends, waste organics & exhaust gases produced in main plant. This plant consists of incinerator, waste heat boiler, quencher, absorber, scrubber & stack.
Milk of lime solution preparation plant for ECH plant consisting of silo, conveyor, solution preparation tank & storage tank with agitators, 
Flare unit for burning all emergency & flamable gases
Tank farm for storage of all organic products with N2 blanketing & vent scrubber system.
- Commissioned 100 TPD Ally alcohol plant. This plant handling hazardous & flammable materials like propylene, acetic acid, Allyl acetate. The major equipments involved in this plant are Propylene vaporizer, oxidation reactors, hydrolysis reactors, CO2 removal section. AAL purification section by distillation columns for removing the light ends & heavy ends etc.
- Commissioned 94TPD Epichlorohydrin plant. This plant consists of chlorination reactors, HCL stripper, DCH & ECH purification section by distillation columns Light end towers, heavy end towers & saponification reactor.
- P & ID, PFD, drawings study & review for above plant
- Making plant completion status report, preparing punch list & making walk through for plant areas.
- Making Pre start up safety review of the utilities.
- Preparation of Standard operating procedures.
- Performance test preparation after plant commissioning
The Attainments in Tata Chemicals
As Assistant Manager
- Co-ordinated all activities of boiler feed water unit. 
- Done RCAs of diff. failures & issues in castic, Bromine & WTP plant
- Also I was responsible for reduction in Raw Material consumption (Through statistical process Control for diff parameters of CCG)
- Achieved reduction in Overtime through cross-functional training of workers. 
- Guiding Process Engineer in performing process engineering activities for plant development & troubleshooting& reviewing the documents prepared by process engineer 
- Commissioned 
- 100TPD Caustic Plant with Membrane cell technology with Tata Honeywell DCS system 200TPD Brine Evaporation Plant for the production of Pure Salt with Double effect
- Evaporators & 32% NaOH Evaporation Plant with single effect Evaporator
- Conducted 
- Risk Assessment & Hazard Identification of CCG
- SPC (statistical process Control) for diff parameters of CCGHandled installation of new equipments & provided the cost effective changes/suggestions in plant as per customer requirements by developing primary stage process flow diagram.
- Undergone Process Hazard Analysis training conductthed by DuPont which includes HAZOP study, FMEA, What If analysis & enhance safety by using these tools . Also completed the Hazop study of HCL plant & Bromine plant.
As Senior Engineer
- Handled Liquid Bromine plant through cold process plant, plant capacity increased from 3 TPD to 7 TPD. Alos done Safety enhancement by changing wooden boxes to plastic crates. Commissioned 3rd glass tower for bromine production
- Involved in Boiler feed water treatment plant (65 MW), including water pretreatment plant, DM water unit, DA water unit, MB water unit. In this plant Drinking water unit for town supply & inside works supply was also included.
- Undertook safety initiative like Job safety analysis & hazop study done. Root Cause analysis as & when required, Parato analysis of Cold process plant doneHandling production of Caustic, Liquid chlorine, HCL, Bromine & flammable gases like H2/NH3 & Hazardous fluids like Liquid & gaseous Cl2, H2SO4 (98%), NaOH, Liquid Br2 with safe practices.
- Developed check list of plants, standard operating procedures of plants
As Senior Asst. Engineer
- Handled 100TPD Caustic Plant with Membrane cell technology with Tata Honeywell DCS (TDC 3000). 
- Handled H2 blowing & cooling plant which is used for producing Hydrochloric acid
- The plant was involved handling of most flammable gas like H2 & hazardous fluid like liquid Cl2, H2So4, and NaOH.
- Co-ordinated material balances for calculating raw material consumption quantity with flowrate for Caustic production. 
- The plant had 3 biproducts-180 TPD 32%HCL Plant, 90TPD Liquid Chlorine & Sodium hypochloride plant. 
- Handled Utility plant with Ammonia Refrigeration system for chilled water production.
- Done the theoretical mass balance of all plants
 
TRAININGS ATTENDED
[b]Attended [/b]: 
- Hazard Identification & risk Assessment - 5 “S” Workshops
- SEDAC Workshops - Total Productive Maintenance 
- Autonomous Maintenance Workshop - Safety Awareness Workshop/ First Aid 
-Process Hazard Analysis by Dupont
 [b]IT SKILLS [/b]: Microsoft Office—word, Excel, Power point & Internet application
[b]ACADEMIA [/b]: B.E. Chemical from Shivaji University in 1994
Completed PGDM (Management) from B School[/QUOTE]

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