Sr Engineer (GM) - Manufacturing Planning, Strategy & Performance Mgmt
Reliance Industries Ltd
Total des années d'expérience :29 years, 5 Mois
A Process Chemical Engineer, Senior Management Program from Indian Institute of Management Nagpur, Advanced Diploma in Industrial Safety (Navi Mumbai) & MBA(IV) having Design Review, Project execution, commissioning, Establish Steady State Operations and Operations Excellence of Refinery, Petro Chem. & Chemical Units.
Very good team player.
Have handled Unions nicely & have set operational records.
• Troubleshoot, propose performance/process improvement to resolve technical problem/De bottleneck of Plant.
• To reduce plant effluents/ emissions/ flaring/ losses/ Utility consumption & cost.
• Ensure uninterrupted supply of feed stocks/ Intermediates/ Chemicals/products to units/customers respectively.
• Lead routine Planning, approve & safely execute Permit to Work (including OmPro System).
• Define & Coordinate PSM activities including critical equipment, SAP based PM, audit & its compliance.
• Maintenance & Inspection, prepare SOP, Risk Assessment, Job Cycle Check, update manual & Oil Accounting.
• Expansion/ hook up new facility after achieving steady state, Hand Over-Take Over.
• Plant product (Crude/Inter mediate/ By-/ Final Product) change by modifying existing plant.
• Determine training needs & filling the Gap (Train & guide the team of Engineers & operators).
• Promote workplace safety & Process Safety Management activities, Review reliance standards.
• Participate in PHA, HAZOP, Risk Analysis & Carry out Audits of plants including utility plants (Certified RIL 2nd Party/Inter site Work-Place Safety & Process safety Auditor).
• Learning from incidents & Carry out root cause / failure analysis/ incident investigation & Compliance (including across industry incidents).
Refinery Project Execution, Monitoring & Commissioning:
• Ensure installation of equipment, Electricals, instruments & civil construction as per design.
• PFD/P&ID Review: Isometric drawing, Engineering Audit & update the same.
• Risk Analysis preparation, learning by incident across industry & its compliance.
• Safe Project execution, its monitoring, Commissioning and steady State Operation.
• Hydro test/Pneumatic test/Leak test, Mechanical Completion & take over facilities.
• Pre -commissioning activities: Planning, Procedure writing, Guide Engineers & Operators, Line/ Equipment cleaning-Card Board Blasting/Water Flushing/steaming/ Pigging/ Air& moisture removal.
• Pre- Start up Safety Review & Punch list Generation & Compliance.
• Contractor personnel audit, ReSOP, Motivate & coordinate for safety competitions.
• Coordinating all safety/Fire/Third Party audits & its compliance.
• Commissioning of FCC, & Tank farm including OSBL
• BSC 5star, ISO accreditation & its compliance.
Additional Hook up/Modification projects:
• Vacuum Residue tank bottom plate replacement.
• Crack slop tank modification for service change.
• LSO tank execution and hook up.
Process improvement initiative in the Plant:
• Suggested change in feed system of ethylene chlorination which can bypass recovery compressor and has potential to save Rs. 200 MM.
• Suggested modification for PTA#5/6-3rd stage crystallizer agitator/shrouding- Model study carried out, accordingly corrected & normalized.
• Modification suggested to stop liquid carry over to HTC vent recycle gas compressor of VCM plant, marginal maintenance cost reduction.
• Resolved cracker slowdown, due to caustic tower varying Dp problem by modifying SOC.
• Improved Cracker plant reliability by resolving lube oil fluctuation of Crack Gas Compressor.
• Suggested C2R mech. seal oil pressure reduction of Cracker plant, to maximize throughput.
• CGC PHA was done in case of mech. seal flushing line choking- suggested safe running.
• Refinery Propylene stream passing into LPG stream investigated-corrected.
• Resolved F.O. tank problem of LP Steam Condensate line hammering.
• Design deficiency of V.R. Tank goose neck PCV delayed opening identified, Modified for correction.
• Resolved Oil-water separation problem in slops tank after V.R. tank decommissioning.
Chemical/Pharma. intermediate/Specialty chemicals Plants, Plant Manager of 3 plants)
•Ensure efficient operation of plant (Norms, Operational, PSM and HSEF procedures), Maximize Capacity & minimize shutdown.
•Ensure SOC compliance & its optimization (Liquification, Fluorination, Chlorination, Nitration, Hydrogenation).
•ISO-9002, 14001, 5star-British Safety Council, OHSA & legal compliance & promote safety culture.
•Prepare & implement Annual Operating plans & achieve Quality Production target safely.
•Prepare monthly -Production deviation report with reasons and its recovery plan.
•Ensure quality products, address quality complain and make improvements.
•To provide purchase/sell input (monthly/yearly) for raw materials, chemicals & catalyst/ products, By-products, spent catalyst respectively to commercial department.
•Filling station- Cylinders, Tonners & Iso container cleaning, legal compliance & dispatch.
•Ensure healthiness of safety and trip logic systems, instrumentation and process control systems & equipment through SAP-PM/Field analysis.
•Carry out test run, analyze performance & establish optimum operating parameters.
•De bottlenecking, trouble shoot problems & cost reduction.
•Carry out Plant Shutdown on time & safely.
•Key Projects Executed & Commissioned to steady state:
Execution & Commissioning of HF Recovery from HCl in Fluoro Methane Plant.
Fluoro Ethane Plant Expansion - Freon-113 capacity enhancement by 25%.
•Key Accomplishments through process improvements:
Plant product (Crude/Inter mediate/ By-/ Final Product) changed to new one due to, govt./International body directives by modification and new SOC & norms established.
NaOH Column Packing chocking eliminated & reduced Dp and channeling.
Improved CHClF2(Freon-22) Recovery up to 200 Kgs/day.
Raw material CHCl3/HF norms: 1.65/0.6T improved to 1.5/ 0.5T respectively per ton of CHClF2.
Catalyst plant frequent chocking problem resolved, leading to increased production & reduced cost.
Eliminated H2SO4 Pump frequent seal failure.
Modified & Increased product CHClF2 Production to 5Ton /Day without Catalyst carryover.
Pilot Plant Operation at Indian Institute of Chemical Technology, Hyderabad and recommended modification.
Filling line Modified to resolve quality complaint.
Modifying reactor stripper column of M-113 Plant.
Lead role in 5 star -British Safety Council accreditation
In charge of Production
Ensure smooth operation of plant in shift.
Carry out Plant Turn around jobs safely.
Filling station- Cylinders, Tonners & Iso container cleaning, legal compliance & dispatch.
Successful process improvement in the plant:
Crude feed pump troubleshooting done for frequent seal failure.
DCS operation & Operation of plants (Chlorination, Nitration, Extraction, Crystallization).
Research, International exposure, New project development, Case studies, skill development, decision making
Post graduate advanced Study in Industrial Safety, Health and Environment. Focus on improving individual safety, workplace safety, following regulatory requirements and reducing pollution.