Madhu Prasanth Korubilli

• Lead asset risk assessment and criticality analysis to identify high-risk assets,
develop risk registers, and support Risk-Based Inspection (RBI) and investment
planning.
• Ensure implementation of corporate Asset Management policies and procedures
across clusters in coordination with O&M teams and contractors.
• Manage asset data collection, validation, and enrichment, including operational
logs, maintenance history, and asset performance records.
• Monitor and improve the utilization of the Oracle Enterprise Asset Management
(EAM) system and develop KPIs and dashboards to track maintenance activities,
work orders, and asset reliability.
• Support the development and optimization of preventive maintenance strategies,
including planning, scheduling, and monitoring maintenance execution.
• Evaluate contractor performance, maintenance compliance, spare parts costs, and
operational efficiency through system-based reporting.
• Develop management dashboards and performance reports integrating data from
systems such as EAM, GIS, WFM, and SCADA.
• Support asset lifecycle management, capital investment planning, budgeting,
forecasting, and maintenance cost analysis.
• Conduct periodic site visits and QA checks to validate asset data, project handover
information, and maintenance implementation.

• Supported EPC project activities, focusing on comprehensive project life cycles.
Activities include strategic planning, procurement, construction execution, and
rigorous technical coordination with internal teams to deliver fully operational
infrastructure within budget. Projects, such as the AlDur Water Plants and BAPCO
Refinery Modernisation Programme (BMP)
• Reviewed engineering documents and deliverables such as PFDs, P&IDs,
datasheets, specifications, and technical drawings.
• Prepared cost estimates, proposals, and tender documentation for process
packages and project bids
• Managed sales and procurement of chemicals, mechanical, and instrumentation
spares for refinery and water treatment plant projects.
• Supervised purchasing activities, including vendor selection, RFQs, tender
participation, bid evaluation, and contract negotiations.
• Developed and implemented procurement strategies, cost analysis, and budgeting
to optimize purchasing efficiency and reduce costs.
• Maintained supplier relationships, monitored supplier performance, and ensured
the timely delivery of materials and equipment.
• Coordinated logistics, inventory management, invoice validation, and order
closure in collaboration with warehousing and forwarding teams.
• Participated in technical meetings with clients, vendors, and subcontractors to
resolve technical and commercial issues.
• Conducted technical bid analysis, vendor document review, and compliance
checks with international standards (ASME, ASTM, API, DIN, BS, NACE).

• Managed full-lifecycle CAPEX projects from initial visualization and cost
estimation through to physical erection and final commissioning of process units.
• Supervised the safe handling and processing of hazardous chemicals, including
Anhydrous Ammonia, Urea, Nitric Acid, and Sulfuric Acid within fertilizer
manufacturing environments.
• Prepared and reviewed engineering documents, including PFDs, P&IDs,
isometrics, process datasheets, and detailed engineering drawings for high
pressure systems.
• Conducted risk assessments for production, pre-commissioning, commissioning,
and startup activities, ensuring strict compliance with Process Safety Management
(PSM) standards.
• Managed process safety programs, incident investigations using Root Cause
Analysis (RCA), emergency response planning, and HSE compliance, including
PSMS and IMS audits.
• Overseen the installation and maintenance of specialized fertilizer equipment such
as Ammonia Converters, Granulators, and Heat Exchangers.
• Supervised plant operations and site teams during critical shutdowns,
turnarounds, and pre-commissioning activities to ensure operational integrity.
• Performed detailed process engineering calculations, equipment sizing, and
material & energy balances to optimize plant productivity.
• Supported technology transfer and product scale-up, transitioning R&D pilot
plant processes to full-scale commercial fertilizer production.
• Coordinated with cross-functional teams (procurement, finance, and logistics) to
manage project budgets, investment requirements, and timely equipment delivery.
• Designed and planned equipment layouts and PFDs for new product scopes,
ensuring optimized material flow and safety clearances.
• Monitored site hazardous waste disposal programs and environmental protection
measures to ensure 100% regulatory compliance.
• Managed contract workers and maintenance activities at pilot plants, ensuring all
modifications met stringent chemical industry safety standards.

• Led pre-commissioning and startup for Rare Earth refineries, deposition plants,
and advanced water systems (WTP, WWTP, and ZLD).
• Orchestrated full commissioning lifecycles, managing schedules, budgets, and
resource allocation to ensure on-time plant handover.
• Directed site integrity testing, including hydraulic testing, flushing, leak
detection, and chemical cleaning to verify system readiness.
•
Authorized technical engineering reviews of PFDs, P&IDs, and datasheets to
ensure installation complied with design specifications.
• Supervised multidisciplinary site teams and contractors during high-stakes
installation, shutdown, and commissioning activities.
• Commissioned complex rotating equipment, including various pumps,
compressors, blowers, and cooling towers.
• Managed the startup of thermal and reaction units, specifically reactors, kilns,
dryers, and heat exchangers.
• Stabilized separation systems, overseeing the initial operation of centrifuges,
evaporators, and industrial mixers.
•
Validated environmental and filtration systems, including scrubbers, membrane
systems (Reverse Osmosis), and specialized filters.
• Developed and enforced HSE frameworks, including SOPs, Risk Assessments,
and Permit-to-Work (PTW) systems for commissioning safety.
• Bridged technical gaps by coordinating with vendors and cross-functional
departments to resolve commissioning bottlenecks.
• Executed plant stabilization using DCS (Yokogawa) and PLC/HMI systems to
transition from startup to steady-state operations.
• Troubleshot startup deviations, performing root-cause analysis to optimize feed
rates, tank levels, and product quality.
• Compiled comprehensive commissioning dossiers, including inspection reports,
progress tracking, and final punch-list clearances for clients.
• Managed shutdown and tie-in activities, ensuring seamless integration of new
equipment into existing process streams.