Staff Engineer(Engg & Projects Dept/Technical Dept):Reports to: ENG Mgr/TSD Mgr.
Saudi Aramco JV
Total years of experience :33 years, 11 Months
Staff Engineer in Engineering Dept. Reports to: Engg Manager (Nov 2011- Aug 2013).
Role Dimension: Handled Structured / Unstructured Assignments in the erstwhile ENG Dept/New Technical Support Dept, to support Dept Manager and also at VP (Engg & Sup.) level, by interface-coordination with Specialists/SME’s in multi-sectional disciplines (ES& Project Execution, Asset Integrity, Reliability-Rotary Equipment, E&I, PIMS, Phase-II Petrochemicals) wherein the role focused on resolving problem solving(critical, chronic issues), Minor/Major projects development, incident investigation, workflow coordination inter-dept and intra-dept (SCM-PP, Corp. Planning, Operations) as per business needs, as assigned by DM, during organizational transformation.
Clean Fuel CFP GAsoline - FEED, EPC: Defined Project; Revised SOW, Invited Bids, Performed Bid Analysis (TBA / CBA) with Ratings of Contractors for FEED award. Worked on economic justification on Clean Fuel (Gasoline - HDS;, Conducted VGO HDT plant trials (Optimisation), LP Model Gasoline Product Blending Simulation trials, & incorporated change with Phase-II New Petrochemicals Teams.
Engg Dept Activities Handled: Coordination between multiple Sections; Periodical reports to VP Office; Handled coordination on Engg Work Request (EWR), Mgmt of Change (MOC), Trouble & Plant Trip Reports assigning for investigation, KPI reporting, Quarterly Safety Meeting coordination, Improvement in Section’s KPI with Root Cause Analysis / recommendation from Audit report analysis, & Budgeting OP BP & Control.
Assigned to participate in Health Assessment Team along with SCM-PP on LP Simulation package related improvement, HO FCC and Alkylation plants related bottlenecks besides studied disposition of Fuel Oil heavy stocks for better value addition.
Assigned to Task Force and appointed by CEO in on the task namely, Fuel Oil / Naphtha Reduction Initiative to support appointed Chairman, in a larger multi-functional team at company level. (Generate all short term ideas for quick implementation), and medium, long term ideas (like Delayed Coker with 3rd Party support) for further studies.
Assigned to participate in Incident Investigation, Root Cause Analysis (RCA). The most significant being ‘RCA on Repeated, Successive, Catalyst Batch failures in Acetylene Converter Section in Ethane Cracker plant. Coordinated and supported Chairman in a large team involving Saudi Aramco and Sumitomo members, to find direct / root causes and recommended remedial measures for implementation.
Assigned to participate in Phase-II related support activities for incorporation of lessons learnt from Phase-I project ($10 Bil); Participated in various FEED/ EPC packages, provided Review/ Comments/ Feedback. Participated in Due-diligence exercise for FID decision, by supporting the Sr Technical Advisor.
Multiple Assignments in New Technical Support Dept: Staff Engineer - TSD
Reports to: TSD Manager (Aug 2013- Dec 2014: Apr-Dec 2015): New Role Recommended due to re-organisation (New Visa-Not yet materialised).
• Supported DM in formation of evolving new department in various assigned Sections activities to support Operations of entire Refinery Complex.
• Periodical updates/reporting; Tracking Engg work requests (EWR, TSR, MOC, Trip Investigation/ Study/ RCA Reports) from the Complex;
• Scrutinize Risk Assessment Analysis done by Others (Hazop, PHA, PSSR, QRA) ) for timely support to Plant Operations;
• Assigning & Tracking Design package reviews/comments between Depts.
• Lead Dept Safety Committee with periodical presentations and tracking Safety recommendations; Budget Control, KPI reporting; Workflow streamlining, inter and intra dept coordination as assigned;
• Formulated Process Safety Management (PSM) framework in coordination with Corp. Safety/Loss Prevention Dept;Formulate Contractor Safety Mgmt -
Petrosafe (with DuPont Rep.),
* Conducted OJT (On-the-Job) training and Sharing Session; mentoring young Engineers.
(A Large, Diversified Business Group -Global Front-runner in Titanium Di-Oxide producer with their Subsidiary Co. - Petrochemicals Company ambitious to make foray into Oil based Petrochemicals)
Sr. Consultant (Integrated Refinery & Petrochemicals): Reports to: VP-Planning &Studies / VP-Business Development/Vice-Chairman Group Companies. Period: (Aug 08 - Oct 2010)
• Jizan Refinery & Petrochemicals (Jizan Economic City): Master Plan / Bid Proposal (RFP): Project Development (BOO type) from Conceptual till Ministry’s License Award stage, thru detailed techno-economic feasibility / sensitivity analysis, to build Master Plan & Bid Proposal (RFP), by selecting a viable Refinery Configuration (LP Model Optimisation) with various Product Pattern integrating with Downstream Petrochemicals (Polymers/Plastics, Aromatics (BTX) Chemicals, PX, Cumene-Phenol, Acetone, Caprolactum, SynGas based Chemicals et.al.), Power Generation (Vacuum Residue - Gasification IGCC 400 MW). Developed several investment options with economic indicators (RoI, IRR, RoCE, NPV), in association with external Consultants / Engg Contractors /Process Licensors / Local KSA partners / Int’l IOC Partners in a small cross functional team (Investment: $ 10 Bil. to $ 17 Billion).
• Proposal for Over-the-fence (OTF) Refinery Diversification/Business Clusters - Developed Conceptual, Preliminary Studies with several product-mixes, aligning with investors criteria, as part of Kingdom’s socio-economic strategy, acquiring /assessing inputs from external consulting companies. (An addendum to MinPet’s RFP to enhance Master Plan). The objective of the proposal was to diversify into Petrochemicals sector, by forming Business Clusters in Jizan Economic City, with local JV partners / Investors.
• Niche Petrochemicals (TASNEE): Conceptual / Initial Evaluation studies performed in a small team before awarding FEED contract to Engg company for detailed studies.
Consultant - Downstream Petrochemicals, based in Dubai: Period: (Nov ’09 - Oct 2010)
• Developed portfolio of projects in SME segment in an outsourced small team by carrying out screening / evaluation of host of identified niche products, based on Market Research / Study reports done by various agencies.
Independent Consultant-Free Zone Companies, Dubai. Jan 2011-Oct 2011
Undertaken range of assignments related to Process Engg, Market Economics / Pricing Trends (Petrochemicals), Project Development support to SME Engineering Services companies in Dubai / Sharjah free-zone areas. (before joining Saudi Aramco JV).
Head-Technical (Oil & Gas JV projects) - Technical Manager (As Team Leader / Member)
Reports to: Head - Projects Finance / (partly) Chairman / MD of Group.
Group Company Profile: Closely held, diversified business group ($ 700 Million+) dealing in Trading, FMCG, Reality, Mfg. sectors since 35 years, and embarked on diversification into Oil & Gas JV investment projects in MENA region.
a) JV Project-1: LPG Recovery Plant (Av.1200 tpd) from associated gases, & C3 C4 Export Terminal with ship loading facility, in Yemen, on BOOT basis, with investors & JV State Gas co. in a 3 member team. (As Team Leader)
Project Development from Conceptual till EPC contract award stage, thru feasibility, FEED, in coordination with Contractors - FEED/ EPC / PMC, State JV Gas co. (YGC /Crescent Petroleum), Block Operator (Hunt Oil), Legal Advisor, Professional Consultants & Strategic Investors.($ 225 to $ 275 Mio) in a 5 member team. (As Team Leader)
• Initiate, coordinate, review, analyse, evaluate, manage the Conceptual design, Feasibility, Cost Recovery Model (JV entity / State Gas Co.); Develop project strategy.
• Co-ordinate, review, comment, approve the FEED detailed design; Process design / simulation / optimization checker, of engg contractor’s proposals, in coordination with PMC.
• EPC contract development / negotiations, in coordination with JV.
b) JV Project-2: Project Development from Conceptual till EPC contract award.
Setting up an Export Refinery (45K - 100K bbl per S.day) & Prod.Terminal with Ship Loading facility, in Yemen, planned on BOOT basis, with strategic investors ($ 475 to $ 550 Mio)in coordination with Contractor’s team (Samsung /SKC consortium), Technical & Financial Advisors, in a 4 member team. (As Team Member)
• Supported in Crude workup; firming up refinery model; Process Design /Simulation / LP Models Optimisation proposals checker, in coordination with Consultant; Economic analysis;EPC contract development /facilitation.
c) JV Project-3: Performed technical due-diligence, for an Asset Acquisition of old refinery (Cyprus) SHELL / BP's Assets; Assessed LSTK construction contractors, and advised investors with techno-economic viability study(that involves process simulation study) in a 3 member cross functional team.
d) JV Project-4: Performed Conceptual, Feasibility with Capital program definition / scoping study on developing gas based Methanol & allied products(incl. MTO: Methane to Olefins) in Algeria with investors, and Engg Contractor.
e) JV Project-5: Lube Base Oil Blending Facility& Lubricants Business (Egypt): Conceptual, Feasibility, Coordinate - Market Study & Establish Detailed Project Technical Viability with external Consultants /Oil Company, & Product Marketing / Logistics - Distribution.
f) JV Project-6: Investment in Upstream (E&P) Development: Assisted in securing awards (PSA / Licenses) from Yemen for exploring, developing blocks for potential oil-gas finds; Coordination in selecting E&P Engg partner for development works ($50 to $100 Mio over 3 to 5 years spread) in a 4 member team.
KRA / Achievement
a) Successful in developing a gas plant project upto EPC award in Yemen.
b) Spearhead the group company’s foray into investments in O&G businesses, in MENA region.
HINDUSTAN DEVELOPMENT CORP. Ltd, Mumbai, India Period: Jul 1998 to Feb 04
SBU Head (Vice President) reports to CEO (Chemicals)
Group Co. Profile: Chemicals Business Unit (ISO: 9001) of a large, diversified Group
($250 Million+)
Responsibilities :( with P&L accountability)
Plan, Direct, Facilitate, Coordinate, Control the entire gamut of techno-commercial business & operations of multi-product, specialized chemicals company, by influencing People’s processes in Operations/ Manufacturing, with a special emphasis on ‘R&D Product Development, New Project Development, Business Process Re-engineering, Operational
Improvement, Business Development (exports), Q-HSE, Contract Mfg. /Custom Synthesis, Supply Chain Integration-Business Processes to improvise growth and profit objectives, in accordance with Board’s directives / guidelines.
KRA / Duties / Achievements
• Visioning emerging opportunities; Formulating strategic growth plans; Champion product Development & Launching value added products with R&D initiatives; Restructuring manufacturing Operations; Business development by retaining & adding new customers to achieve increase in turnover (2.5 times; $25 Million) & turned around the SBU with enhanced profitability with a significant increase in Operating Profit (~ 4 times).
• As functional process expert, facilitated the team by providing technical direction / guidelines to identify and develop various new Specialty products (Building Block: HCN), to cater customers in Agro, Dyes, Pharma & Polymer segments.
• Business Plan-Enhanced New Product Portfolio: Formulated growth plan with business development efforts, by initiating path breaking projects for commercialization, with niche products portfolio (Pharma Intermediates- DAMN; MMA, PMMA et.al) to enhance revenue by several folds, with significant addition to bottom line.
• Integrated end-to-end business processes with customized ERP model.
• Reviewed, Implemented QMS Quality Mgmt System (ISO: 9001) & initiated efforts for ISO: 14001 certification; Implemented HSE Plan /Initiatives (PSM / Process Safeguarding) for the highly hazardous (toxicity) process industry.
Project Manager (R&D, Process /Project Development/Project Execution) / Sr. Manager (Process-Projects)
Reports to Sr. GM /Asst. VP /Director
Project Manager (R&D, Process /Project Development)|Sr. Manager (Process-Projects) Reports to Sr. GM /Asst. VP /Director
(Progressive Roles: Cross functional: Technology Transfer & Engg - R&D Process Dev./ Engg, Projects, Technical Services/ Mfg. & Operations, and Commercial Support)
Company Profile: An Indian Pharma MNC ($ 1.3 Billion+ Revenue): Later, a JV with Daiichi Sankyo, Japan; Now, acquired by Sun Pharmaceuticals.
Responsible for commercializing several bulk drugs - Pharma (API) by scale-up from R&D Lab scale (mg) to Kilo Lab (Kg) to Commercial scales (Tons) and transfer process technology to Manufacturing Division, with process validation by working with R&D
Scientists.
• R&D Concept to Completion, with process validation: Commercialized successfully several in-house Process Technologies, embracing total project life cycle viz. Conceptualize, Develop Process Design Package, In-house Engineering, Coordinate/Supervise Construction, Commissioning Support to produce several bulk drugs (API-Active Pharma Ingredients) with in-house efforts, within specified time frame and budgeted cost, to achieve desired yield & quality parameters, and on time market delivery, in Generic API categories (Antibiotics, CNS segments). (As Project Leader)
• Coordinated, influenced the people processes within Process / Engg / Construction / Mfg. team for IQ, OQ and thereby process validation, & facilitated regulatory filings in compliance with cGMP and US FDA norms. (As Mfg-Team Member).
• Strategic Cost Reduction: Implemented SCR policy initiatives, with LEAN mfg. concept, Kaizen, TPM, Continuous Process Improvement (Six Sigma), QMS processes; Improved process repeatability, by implementing PLC / SCADA /DCS type automation, for batch, semi-continuous processes resulting in significant quality improvement (by eliminating re-processing) and reduction in Operations manpower.
• Due diligence: Assessed, evaluated several Facility Acquisition / Equity partnership proposals (Contract Mfg./Custom Synthesis), with Corporate Finance, and Legal team members, resulted in one business-win proposal for implementation. This improved company’s SCM (Supply Chain Mgmt) effectiveness in the particular portfolio of products and Cost Competitiveness over competitors and also eliminating setting up (long gestation) capital projects.
Sr. Engr. | Deputy Mgr. | Manager (A) Reports to President / Sr. VP
Roles: Progressive, Cross functional: Greenfield Project Development, Project Execution, Process
Engg Studies, Manufacturing & Technical Services, Operations / Operational Troubleshoot, Project Capacity Expansion Studies, Engg Support to Parent Company-VAM
Group’s Profile: (A diversified, chemical major: earlier, VAM Organics-now, Jubilant Life Sciences Ltd: $450 Mio+)
• Ethylene Oxide / Ethylene Glycols: Performed grassroots project planning & development from initiation stage till financial closure (FID) & beyond in a small startup team, with selection of Process Licensor, and Engg. Contractor, by supporting project finance team. Coordinated with DPR / FEED Study Contractor.
• Project Execution - EO / EG (Polyester grade): Participated in Planning. Reviewing, Monitoring, and Implementing Glycols derivatives project, in coordination with Licensor (SD inc, US), & Engg contractor (TEC/TEIL) in an Owner’s startup team of 8 members; Proactive right from design stage, till complete absorption of process know-how after Startup/Commissioning, thru EPC stage, in a cross functional/multi-disciplinary team.
• Waste Treatment (Biogas) plant; Implemented (Schemes: Anaerobic / Aerobic) from Start to Completion thru’ in-house engineering / scale up efforts with promoter company’s support, yield significant fuel saving in Boilers/Fired Heaters.
• Technical Services /Operational Troubleshoot Support / Technical Auditing: Proactive in supporting successful startup / commissioning - Operations, Troubleshoot, Technology Absorption, HSE Plan by coordinating with Licensor; Champion process Upgrade with various catalysts; Supported marketing / finance teams in product pricing strategy.
• Petrochemicals Expansion EO/EG Projects (In house Engg & Projects dept.): Developed project definition, detail studies with Licensor’s input; Supported budgeting efforts for Plant Capacity Expansion.
• Petrochemicals Diversification-Ethoxylates (Owner’s team): Various process technologies evaluation / selection methodologies, Project scoping, Techno-economic analysis with investment plans for mgt. decision.
• Revamp Acetyl Plants (Ethanol based derivative Chemicals): Proactively Supported parent company in Capacity addition, developing downstream PVA, EVA projects from conceptual stage upto Investment decision stage(FID); Participated in R&D efforts for developing various VAM / PVA /EVA based ‘Specialty / Performance Chemicals’.
Responsibility:
Process Engg & Design, Detail Engg, Startup/Commissioning Support, Project Appraisal, and Business Dev.: Fired Heaters / Furnaces, Energy Conservation systems (Air Preheat) for Refinery /Petrochemicals clients, Indirect Heating Systems- Dowtherm, Marlotherm, Santotherm, Polyester Film / PETP chips projects-Engg & Execution, Aromatics - BTX project development / appraisal for client, process pkg :Waste Lube Oil Re-refining& Sulfur Removal from Natural Gas projects.
KRA / Achievement:
-Process Design, Detail Engg, Commissioning of Fired Heaters / Furnaces, and Indirect package heating system (Thermic Fluid) for polyester clients, to meet the specified, client process objectives, in association with KTI Rome.
-Detail Engg, process co-ordination for polyester Film project based on know-how from Didier Engg GmbH / Cellier Spa; Assisted the client in firming up process design basis.
-Supported client in developing & appraising Aromatics (BTX) projects- study on various technologies and their feasibility, project costing based on Naphtha Reforming for seeking financial assistance & implementation thereafter.
-Developed Strategic Planning Initiatives in package heating system involving assessment of competitor's products and market intelligence, and launched a new product with a complete redesign of package system for medium / large heat duty process applications.
-Defined, developed, prepared a process design package and business proposals for Waste Lube Re-refining Unit( min.economies of scale of 5000 TPA to 15000 TPA capacity) to suit Indian client's needs, by scaling down from the standard KTI Holland's higher tonnage capacity.
* Tendering & Estimation, Mktg. & Business Develop.- Fired Heaters & Engg Consulting Services.
* Perform planning studies - Grass root projects: process pkg. for Sour Gas Treatment-Sweetening (Sulfur removal), Detailing Poly Film ex. PET chips, BTX - Aromatics: client project support, Scale down process pkg. for Waste Lube Re-refining (Hydrofinishing); Process pkg PSA Hydrogen plant.
Responsibility
-Engineer In-charge of Refinery Operations (Shift Duty -Day/or Night as assigned): Fuel (CDU, Kerosene, Delayed Coker), Lubes, Paraffin Wax sectors.
• Refinery Operations: Fuel (Crude units, KTU, Delayed Coker), Lube, Wax production facilities; Deputed to other IOC Refineries (BRPL-KTU, Mathura - FCC, CPL - Wax & Coker Unit) for Project Study / Development work & Process Improvement work.
-Production Planning & Control using LP Model (Linear Programming - Custom-built Model) : (Integrating Production - Marketing Distribution); Safety &Energy Audit; Coordination with Oil India (GOSP facility).
-Planning Refinery Modernisation and Revamp / Expansion in two phases.
KRA / Achievement
a) Plant Operations - Engineer-in-charge
Performed plant operations / assisted in turnarounds, by coordinating with staff / contractors, and monitor plant parameters with QC. Handled emergency operations diligently. Co-ordination with Oil India for crude and Natural Gas receipt, and Accounting.
b) Tech Services & Programming : Dy. Chemical Engineer / Sr.Engineer
Planned weekly, monthly, quarterly, annual production with inventory / turnarounds, with Production Planning & Control (LP- Model), in coordination with Production & Marketing / Distribution Depts.
Performed Energy Auditing in the Refinery-Developed, Implemented Crude & Lube preheat train Optimisation, during annual turnaround, that reduced fuel consumption in the furnaces by 15%-18%.
Revamped, augmented process facility: KTU Extractor for improvement in quality of Kerosene; Bauxite finishing of Paraffin Wax for reduced regeneration time / cycle time; Upgraded ATF jet fuel facility with optimizing distillation cuts.
-Plant Performance Analysis, Identify bottlenecks & suggesting remedial measures.
-Co-ordination with Plant Engg dept for annual inspection/overhaul
c) Refinery Expansion / Modernisation: Sr. Engineer
Planned a Mega Project in a small Task Force, instrumental in coordination with professional Engg consultant, parent company IOC-Indian Oil Corporation Ltd, refining experts and in-house oil company team, to ensure proposal submission for budget approval from Govt., for policy decisions.(Performed capital scoping in two phases:Phase-I: $300 Mil.; and Phase-II: $500 Mil. with small Hydro Cracker & Captive CCGT Power Plant)
Executive MBA Program Executive Masters in International Business (1 year course). Jan 1997-Jan 1998
Sponsored Training Program by Indian Oil Corporation Ltd
M.Tech (Chemical Engg) specialised in Process Engg & Design;Period:1978-80 Computer Aided Design / Simulation used in Master Thesis, in the field of Cryogenics / Distillations./Separation Processes/Gas Treating Processes.
B.Tech (Chemical Engg) : Five years course 1973-78
Second Prize Award for Design of CO2 Absorber and Desorber for 10 tons per day gas plant, at the national level, organised by Inst. of Engineers, for all Engg Students- year 1998 batch. All India SECOND in National Design Competition for ENGG STUDENTS-1977