Arif Desai

Roles & Responsibilities (Process Safety management)
Establishing, implementing, and sustaining the Process Safety Management framework across the site. Ensuring that all process safety risks are effectively identified, evaluated, and controlled in line with corporate standards, local regulatory requirements, and best industry practices (OSHA 1910.119, CCPS). Serve as the site’s technical authority on process safety, providing leadership, oversight, and assurance that operations are designed and executed safely throughout the plant lifecycle.
 Act as the focal point between Operations, Engineering, Maintenance, Projects, and HSSE to ensure process safety integration in all activities.
 Provide process safety input to Management of Change (MOC), Project Reviews, and Operational Readiness programs.
 Develop, implement, monitor and strengthen OSHA PSM elements - PSI (Process Safety Information), PHA (Process Hazard Analysis), Trainings, Operating Procedures, Contractors Safety, PSSR, Mechanical Integrity, Permit to Work, Management of Change, Incident Investigation, Emergency Planning & Response.
 Champion process safety culture and ensure alignment with the organization’s HSSE strategic direction.
 Ensuring full compliance with regulatory requirements, PSM standards, and international benchmarks.
 Develop and maintain site-level PSM procedures and records.
 Lead internal and external PSM audits and surveys.
 Lead and/or support the investigation of process-related incidents, near-misses, and deviations. Ensure root cause analysis (RCA) is properly conducted and preventive actions are established and implemented. Establish mechanisms for sharing lessons learned across site teams and contractors.
 Deliver training, awareness sessions, campaigns, and workshops to reinforce process safety culture.
 Deliver coaching and mentoring to engineers, supervisors and operations staff to build technical competency and ownership.
 Develop, implement, monitor adherence to department approved procedures & formats, Management of Change (MOC), Pre-start up Safety Reviews (PSSR), Isolation & Lock Out Tag Out (LOTO) procedures.
 Develop and maintain LOTO & Line Break programs in accordance with OSHA and Global/company standards. Train employees and contractors in proper LOTO & Line Break procedures and safety protocols.
 Audit and inspect LOTO & Line Break practices across departments to ensure compliance.
 Regularly review and enhance site PSM systems based on performance data, audits, and new regulatory or industry developments.
 Lead or contribute to regional and corporate PSM initiatives and forums.
 Maintain process safety Database. Integration of Incident Investigation, Management of Change, Process Hazard Analysis modules on OESuite and successful implementation with training.
 Conduct awareness campaigns and communications across the site on Process Safety.
 Co-ordinate/Focal point of annual Insurance Risk engineering survey with surveyors & track, monitor risk survey actions on monthly basis.

Significant Highlights
 Appreciation award for launching & speeding up growth of Process Safety Management program on site.
 Appreciation award for actively participating in the completion of PCW recycling project.
 Appreciation award for key individual/high contribution to Process Safety Management on site.

Process Safety Management and Operations Support:
 Develop, assist, tract and monitor Process Safety Management Elements (PSI, PHA, Trainings, Operating Procedures, Contractors, PSSR, Mechanical Integrity, Permit to Work, Management of Change, Incident Investigation, Compliance Audit) actions progress, PHA and HAZOP actions, Risk Engineering survey actions monthly and present report to Management.
 Develop, implement, monitor adherence to department approved procedures & formats, Management of Change (MOC), Pre-start up Safety Reviews (PSSR), P&ID Control, Lock Out Tag Out (LTCT), Line Break, Permit to Work, Incident Investigations.
 Lead pre-start up safety reviews (PSSR) and implement in all projects.
 Provide engineering assistance on technical aspects as required.
 Coordinating with operations for test/trial runs and implementing changes/modifications in plant.
 Ensuring all modifications via management of change (MOC) procedure.
 Evaluating and controlling potential hazards and risks within processes including hazard identification, risk assessments, risk analysis, mitigation planning and project implementation.
 Participate and provide process engineering support to RCA, HAZOP, HIRA, and process safety issues. Experienced in leading process related Root Cause Analysis & process safety related Incidents Investigations. Ensure that incidents root causes are identified, action plans and lessons learnt are established and communicated to avoid incident re-occurrence.
 Participate and assist in OESuite module implementation.
 Participate & facilitate in PHAs (Process Hazard Analysis) activities like PHA revalidations for existing facilities.
 Provide process engineering guidance, training to junior engineers including process calculations, projects, codes & standards, process safety, MOC, PSSR.

Roles & Responsibilities (Site Process Engineering)
 Concept study, reviewing design, detailing, project execution, construction, installation, pre-commissioning and commissioning of DPET Lines expansion project, PCW (Post-Consumer Waste) Pelletizer project, FTR (Flakes to Resin) project, Utilities expansion project (Chillers, Cooling Towers, Wastewater Treatment Plant, DM water plant) and Storage Tanks Expansion project.
 Participate & Review EPC deliverables, design, technical documents, drawings, PFDs, P&IDs, UFDs, Material & Energy Balance, C&E diagrams, Fire Protection Drawings, HAZOP, HAZID, 3D models.
 Lead, execute & provide inputs throughout all stages of project life cycle.
 Ensure all stages of projects are done within project requirements i.e., cost, time, quality & HSE.
 Knowledge of international standards such as ASME codes, API, EN, DIN standards, NFPA.
 Preparation of ITB (Invitation to Bid) technical documents for projects.
 Preparation of scope of work, BOM, tender documents for projects.
 Evaluation of contractor Pre-Qualification documents. Techno-commercial comparison and evaluation of Bids.
 Evaluation of contractors (FEED, EPC), suppliers and recommending the same for Tender Board.
 Cost estimation for CAPEX projects.
 Provide engineering assistance on technical aspects as required.
 Coordinating with operations for test/trial runs and implementing changes/modifications in plant.
 Provide process engineering guidance, training to junior engineers including process calculations, projects, codes & standards, process safety, MOC, PSSR.

Growth Path
17 DEC’ 2012 to 17 DEC’ 2013 - Trainee Engineer
18 DEC’ 2013 to 15 NOV 2017 - Process Engineer

Gasification: High calorific value Syngas (Carbon Monoxide, CO - 60%, Hydrogen, H2 - 30%), BTX, Methane.

Roles & Responsibilities:
 Design, detailing and commissioning of entrained Bed & fluidized Bed Coal Gasification, Pyrolysis pilot plant.
 Reviewing design, detailing and commissioning of Coal Gasification and Pyrolysis demo scale/full production scale plant.
 Design and development of Gasification, Pyrolysis & Liquefaction trials on pilot scale and implement in-house changes in process.
 Day-to-day operational activities, troubleshoot problems. Operation of entrained flow Gasifier, fluidized bed Gasifier, Reformer, Reactors, Distillation Column, Absorber, Quencher, Crushing equipment’s, Dryers, IC Engine, Gas Cleaning Equipment, Relief System, Flare Stack, and Utilities. (Handled ALLEN BRADLEY SCADA, YOKOGAWA DCS). Monitored operating parameters and optimized the process.
 Thorough knowledge of Gasification process chemistry.
 Knowledge of sampling systems, analysis of lab results.
 Prepared Process Flow Diagram (PFD) & Piping & Instrumentation Diagram (P&ID).
 Prepared SOP for the trials.
 Equipment and Line Sizing.
 Procurement activity and vendor development.
 Prepare summary of project status weekly / monthly basis and report to the Process Engineering Manager.

Process Enhancements
 Streamlined new process concepts for production optimization and adopting various cost reduction techniques.

Significant Highlights
 Energy conservation.
 Mapped major cost savings strategies, productivity enhancements.