1. RESUME
Name : SANJAY PRAKASH AGRAWAL
Age : 45 years (3rd
July, 1970)
Contact details : sanjaypagrawal@gmail.com , 09412601911(P) / 08392947803(O)
Passport Details : F 8755498, Issued from BAREILLY on 25.08.2006, valid up to 24.08.2016
Personal details : Married and blessed with 2 Sons (aged: 16+ years and 9+ years)
Educational Qualification : 1. [1991-1995] B.Tech in Mechanical Engineering from Aligarh Muslim University, Aligarh
with 72% marks.
2. Complete “Post Graduate Diploma in management” in 2004 from University of
Indianapolis, USA; through “B-School” which was arranged by the TCL at site.
Total Working Experience : 19 years (Working for M/s TATA Chemicals Limited, Fertilizer Business, Babrala, [UP], India
since Sep'1996.)
Current CTC : 23 L per annum (18 L + 5 L other facilities like furnished residence, medical, school
fee and other facilities in town ship)
Current responsibilities : Sr. Manager- Reliability & Planning; I am responsible for the functioning of
followings sections-
1. Reliability (Inspection cell),: 3 Engineers + 3 officers
Develop, review and adherence of Inspection plans (like ; Vibration schedule,
Piping Inspection, Steam trap inspection, Review of Risk Based Inspection plan,
& other NDT activities)
2. Maintenance Planning section: 5 Mechanical Engineers direct reporting +
Electrical & Instrumentation Planners indirect reporting
 Shut down planning (Anchor for S/D Planning at Unit Level)
 CAPEX & Revenue Budget preparation for Mechanical Function
 Detailed planning for Budgeted, CAPEX jobs for Mechanical.
 Detail planning ( Material, Gant Chart, QAP, Safety Analysis) for all Shut
down jobs of Mechanical + Co-ordinate for others
 Skill Evaluation & Training
 Maintenance contracts & Hiring of services for onetime jobs
 Long Term Asset management Plan
 Root Cause Analysis
3. Work shop, Mobile cranes & painting: 7 officers + 20 Contractor staff
 Operation & maintenance and mobile cranes,
 Machine Tools in work shop.
 Restoration painting across the Unit around 35000 M2/Per year.
Additional Responsibilities:

2. 1. Leading the team implement the Asset Integrity element requirement to Roll-
out Process Safety Management system at Babrala Unit.
2. Location Anchor for the Implementation of Job Safety Analysis requirement at
Babrala Unit in line with TATA group Safety Standard.
3. Development of Procurement Guide lines & Implementation at Unit level to
optimise Inventory level
Working Experience Summary:
Positioning summary:
Position Duration Working area
Sr. Manager 2013 onward
Reliability & Planning (Inspection & Condition monitoring cell, Maintenance
Planning & Mechanical Workshop)
Manager 2006-2013
Performance Improvement Program (Manthan), Morocco on deputation (2+
yr), Project procurement, Maintenance & Nigeria (NCIL) on deputation (1+ Yr)
Deputy Manager 2002-2006 Mechanical maintenance, Performance Improvement Program
Assistant Manager 1997-2001 Maintenance, Procurement
GET 1996-97 Mechanical maintenance
Functional exposure summary:
Function Area Period Location
Key activities/
Responsibilities
Remarks
Maintenance
Routine maintenance
Ammonia 2 years
TCL,
Babrala
India
• Maintenance of All type pumps used in
Ammonia, Urea, and O&U area
• Maintenance High Pressure exchangers &
Vessels in Ammonia, Urea & O&U
Urea 1 year
Offsite & Utilities 1 year
Product Packaging 1 year
Maintenance of Material handling system
Like ( Belt conveyor, portable conveyor, slat
conveyor, stitching machine, truck loader etc)
Work shop
1 year
• Operation and maintenance of cranes
• Operation and maintenance of machine tools
Fabrication Shop
Fabrication jobs in routine maintenance &
modifications
Central Planning &
PM cell
3 years
• RBI & LAMP
• Goal setting for Mechanical team
• Contract management
• Central spares management
• CAPEX and Revenue budget preparation and
tracking
Shut down
maintenance
Shut down planning &
Execution in Shut down
6 Ammonia
4 Urea
Specific jobs in
maintenance
1 year
Repairing of S-50
Ammonia converter
It was repaired 2 times at
site
6 Months
Replacement of 2.5 KM underground ring water
header
Materials Routine
Procurement
2 yrs
• Technical spec verification, RFQ preparation,
negotiation, ordering and follow-up for delivery
• Vendor grouping, NPA handling and item code

3. standardization as special projects
Project
procurement
6 months
Negotiation, ordering and transportation of
material for Customized Fertilizer project
Performance
improvement
program
(Manthan)
Reduction of NPA
& Stores Inventory
6 months
Identify the NPA items in revenue inventory and
installed assets in facilities
Reduction in
Specific energy
consumption
Study the Process flow diagrams and identify the
energy saving scheme to reduce variable cost/ per
ton of Urea production
International
exposure (3+
yrs)
Technical
controller
2 yrs
IMACID,
Morocco
• Technical controller on behalf of India partners
• Implement the Good Engineering practice in
maintenance
• Develop RBI & Long Term Asset management
plan
• Establish Root cause analysis in maintenence
Technical Adviser
14
months
NCIL,
Nigeria
• Gap analysis in Maintenance practices
• Develop maintenance & Inspection systems
• Performance tracking system
• Use of quality tools in maintenance (RCA &
FMEA)
Additional
Professional
Exposures
Process Safety
Management
Additional
along with
functional
working
TCL,
Babrala,
India
• Safety Culture enabler team
• Lead Asset Integrity team to develop and
implement the maintenance & inspection
philosophy in line of PSM guide lines(across
the maintenance).
Tata Business
Excellence Model
• Part of internal assessment team in 2007
• Member for external assessment team
ISO Qualified for Internal audit in 2005
Legal Compliance Compliance of legal requirement
Six Sigma (Green
Belt)
One project to” reduction of unplanned jobs in
Maintenance” in year 2005-06
FMEA Critical equipments & Maintenance Processes (ISO)
Risk Assessment
Leader of Risk assessment carried out for the all
routine activities in maintenance
BBS Leading member to introduce BBS at location
Details of Working Experience:
International Assignments (3.5 Years)
NCIL, Nigeria (14 months: June’11 to July’12):
Tata chemicals has signed “Technical service agreement” with M/s Notore Chemicals & Industries limited, Nigeria
( only fertilizer Comp in Sub Sahara region) to provide technical support and develop operation & Maintenance system
for smooth operation. Key activities of the agreements are as follows;
• Gap analysis & develop the system for performance tracing
• Suggest corrective action for existing problems and long term action
• Develop systems for sustained production
• Sharing of Technical knowledge and system for in-house technical skill development
• Lead maintenance jobs for better maintenance practice
• Training & use of quality tools in maintenance
IMACID, MOROCCO (2+ years: August 2007 to October 2009):

4. Tata chemicals Limited have many international projects (Owned or Joint Venture) and I was selected for international
projects as Indian representatives for INDO MAROC PHOSPHORE S.A. (IMACID), Morocco from August 2007 to
October 2009.
It is a joint Venture of OCP group (Morocco), Tata Chemicals Limited & CFCL (India) to produce Sulphuric acid ( 3800
TPD) and Phosphoric Acid (1400 TPD).
I have been there for more than 02 years to look after the maintenance function as the representative of both the
Indian companies.
I was responsible for the followings:
1. Technical controller for all maintenance (Mechanical, Electrical, Instruments & Civil) functions, and involved in
the procurement, critical maintenance activities, shut down planning, and development of the required
improvements in the maint. Procedures
2. Detailed Planning for all critical jobs in Mechanical Maintenance.
3. Analyze future risk & plant reliability, and prepare LAMP (long term asset management plan). I was also
responsible for the implementation of inspection and replacement plan as per the LAMP.
4. Responsible for the routine and shut down inspections planning and carryout required inspection.
5. Failure analysis along with Production and Maintenance dept.
Specific Tasks handled:
• Preparation of Risk based inspection plan for Sulphuric Acid and Phosphoric Acid plant.
• Review of all inspection plan and record preparations.
• Inspection and maintenance of Waste heat boiler in SAP to avoid frequent leakage problem.
• Leading member of team for the repairing of super heater.
India Operation (15+ Years):
MECHANICAL MAINTENANCE (11 years+ 1 year GET ):
Special Tasks/ Projects Handled in maintenance (1 year) :
I have spent around 1 year for handling various specific maintenance jobs, as mentioned below;
1. Replacement of underground service water header 2.5 km, in green belt area.
2. I have lead S-50 (2nd
ammonia converter) repairing team along with L&T engineer in 2010; Bottom potion of
this converter was having multiple ir-repairable cracks at different locations. So shortening of converter was
done at site (1st
time in India), and it took around 5 months against the planned schedule of 6.5 months. It is 3
layered, 3 mtr. OD & 25 mtr. long equipment and its weight is 270MT.
3. I was a leading member of the team for AMMNOIA CONVERTOR 3rd Seam repairing job in 2004. This
ammonia Converter is made by 48.5 mm thick 3 layers of P22 material (Total wall thickness is 145.5 mm).
Approximate 700x2500 mm piece was replaced at site as multi cracks were found at various locations in the
wall.
4. Both Urea Stripper (weight=75 MT) reversals in Urea Plant as tube ends were damaged at solution inlet side.
5. Additional 5 Trays were provided in the bottom portion of both Urea Reactors in Urea Plant to increase the
efficiency.
Central planning and Spares Management (3 years ):
I have established central spares management cell (after getting experience in Materials Management) in
maintenance to avoid duplicate procurement and focused approach for better inventory control.
1. Procurement of major equipments and jobs under CAPEX.
2. Contract management.
3. Preparation of Revenue and Capital Budget and its review.
4. Planning for major Maintenance Issue in the complex and Major maintenance planned jobs.
5. Shut down planning (material, services, Preparation of Procedure cum check list,Risk assessment for all major
job)
6. Co-ordination with Purchase section for required materials by all users and ensure the procurement of general
consumable items for mechanical department.
7. Take additional charge for routine jobs in field also in absence of Manager- Mechanical & Condition Monitoring
Cell.

5. Specific Tasks Handled:
• I have lead team for standardization of all Mech. Item codes (around 22000 items codes) to complete
technical information required for the procurement.
• Complete Vendor grouping and link all material codes with unique vendor group.
• Review of duplicate item codes
• Review of all items to identify the NPA (obsolete items, extra qty available) and explore the potential buyers
for the same.
• I was leading member to define Maintenance process in ISO as per the EPM guide lines.
• VED analysis of all mechanical items
Shut Down Experience (9 shut downs: 6 Ammonia & 3 Urea):
Ammonia Plant ( 6 shut downs):
Annual Turn around Planning (Material, Man power and other resources) 3 times and Job Execution in 6 ATR.
Static Equipments
1. Partial Replacement of Cold Collector
2. Primary reformer / Secondary reformer/ Waste heat recovery Boilers/ G.V. towers.
3. All Exchangers of Ammonia Plant (Straight Tube fixed tube sheet, Straight tube Floating tube sheet, U
tube Bundle)
4. Many a time held responsibility of opening & box-up of high pressure (working pressure>110 kg/cm2)
exchanger of ammonia plant. End covers of these exchangers are opened with “pneumatic bolt
tensioning device” only.
Urea Plant (3 shut downs):
I have worked 4 years in Urea plant Annual Turn Around jobs and handled jobs of following equipments:
• Maintenance of Urea Reactor,
• Maintenance of Urea Stripper (Titanium Welding), Modification in Tube to Ferrules fit-up to avoid bypassing.
• Maintenance of Carbamate condensers
• Maintenance of other exchanger
Routine Maintenance Experience (6 years):
Ammonia Plant :-
Headed Ammonia plant mechanical Maint. Team. and Responsible for the below:
• Day to day plant Maintenance. (Preventive / Predictive & Breakdown Maintenance) Bar chart preparation
& RCA of the failures.
• Rotary Equipments
1. Maintenance of Single Stage pumps / Mechanical Seals / Reciprocating Pumps
2. Over Hauling of 11 Stages Horizontal casing Boiler Feed Water pump & 6 stages Vertical Naphtha
Transfer pump.
Specific Task Handled:
• Over Hauling of 11 Stages Horizontal casing Boiler Feed Water pump &
• Over hauling of 6 stages Vertical Naphtha Transfer pump.
• Overhauling of GV circulation pumps ( Double suction, single stage centrifugal pump)
Urea Plant :-
Assistant Manager in Urea plant mint. Team. and was responsible for the following:
• Day to day maintenance in Urea Plant.
• Maintenance of High Speed (16000 RPM) Carbamate Solution transfer pump in Urea Plant.
• Maintenance of Single Stage pumps / Mechanical Seals.
• Maintenance of high pressure Reciprocating type Ammonia feed pump.
Product Packaging Plant :-
Assistant Manager in Product Packaging plant maint.and responsible for the following:
• Belt Conveyors

6. • Slat Conveyors
• Stitching Machines
• Operation & Maintenance of Locomotive Engine
Offsite & Utility area :
Assistant Manager in O&U mechanical Maint. Team. and held responsibilities as mentioned below :
• Was responsible for Day to day maintenance of Off-sites and Utilities Plant Area (Cooling Tower,
D.M.Plant area, Power Plant, Service Boiler, Naphtha Handling, Ammonia Storage & ETP area).
• Major Jobs handle in O&U area are as follows:
• Maintenance of cooling water Pump (double suction, single stage centrifugal pump)
• Maintenance of Double Stage Reciprocating Compressor.
• Maintenance of Cooling Tower Fans and Gear Box.
• Maintenance to multistage Naphtha transfer pumps
• Rubber lining Jobs in DM Plant area.
• Over Hauling of multistage Naphtha transfer pumps
Work Shop & Fabrication Shop:
Worked as Assistant Manager and held responsibilities as mentioned below :
• Was responsible for day-to-day fabrication and erection jobs for maintenance / Modification jobs.
• Was In-Charge of Mechanical Work shop and responsible for the day to day machining jobs and learn
about repairing of equipment parts by welding and machining
• Responsible for Operation and Maintenance of Mobile cranes (Hydra, 35T & 50T OMEGA crane and 75 T
& 100T crawler cranes).
Specific Task Handled:
• I was fully involved in re-tubing of Straight Tube Heat exchanger and U-tube bundle of the
exchanger
Performance Improvement Program ( 06 Months):
I worked as Deputy Manager- Manthan before my selection for International Projects.
Tata Chemicals had developed a methodology to optimize the operation cost and increase the plant efficiency. A
separate dept. (Manthan) is established to work on this methodology for all Techno commercial study of existing
plant / activities and identify the improvement to reduce deficiencies in the system.
I was leading member of team working for “Reduction in energy consumption” for per Ton of Urea production.
MATERIALS DEPARTMENT (2.5 years):
I had Worked as Assistant Manager- Purchase section (in charge- purchase section) and reported to Manager –
Materials.
I was responsible for the followings routine works:
 Maintaining Minimum inventory levels of Critical chemicals,
 Day-to-day Indigenous procurement and general Stock Items
 Review of RFQ, Orders, and ARC for the correctness of technical information & commercial terms.
 Procurement (Planning, Order preparation and Follow up with vendors) for material required in Shut Down.
 ABC and VED analysis (to decide reorder & minimum stock qty of GST items)
 Inventory control plan along with user dept
Specific Tasks Handled:
• Ensure the implementation of Purchase related reports and transaction in MM module of SAP.
• Up-date vendor database for correctness of addresses and other regal information (Sales tax no. etc)
• Develop a system to track GST items on daily basis for better control.
• Gathered business interest of vendors and start vendor grouping.
• Procurement for Customized Fertilizer Project ( specially in-bond logistic for project material from different
location)
Other Professional Achievements:
 Certified PSM Auditor

7.  Certified ISO Auditor.
 Certified Six Sigma Green Belt (% of planned jobs in maintenance) holder from Motorola University, USA.
 Qualified for External assessor for Tata Business Excellence Model (TBEM).
 I leading member to rollout Behavior based safety concept in Babrala.
 I was leader for Risk-assessments carried out first time in Mechanical.