Operations Manager
Arabian Petrochemical Company - Petrokemya
Total years of experience :7 years, 9 Months
I am recently working at compounding plant for Polymer like PP & PC at Petrokemya. We reinforced this polymers with fiberglass & some additives/pigment to make a rock like polymer compound which can be utilized mainly in automotive industries. My job is to control & manage the operation team to make sure plant delivers the production required as per plan with quality considering EHSS aspects in mind. Attend day to day morning meetings & setting up KPIs & to achieve them. Represent higher management about the progress of plant situation & capabilities. Coordinate with Maint. team timely to avoid production losses & pre plan any major activity in shutdown schedule. Provide technical support to operation team when required. Enhance EHSS culture at site & make sure each employee adhere to it. Monitor & participate in Month end closing in SAP.
Basically my job is to monitor and control polymerization reaction to manufacture Low density polyethylene LDPE. To make sure plant running at desired design capacity with SHE compliance. Expert in various grade changes procedure required as per customer requirement. Optimized process w.r.t its temperature, pressure & amount of catalyst. Well aware of process chemistry of LDPE manufacturing. Responsible for safe startup of plant in case of shutdown or emergency shutdowns. Maintained productivity and quality of LDPE throughout my shift with keeping safety in mind on top priority. Have experience of controlling reaction from DCS centum VP version during startup. Monitored catalyst and modifier flow rate during special grade changes. Overall knowledge of Extruder followed by palletizing unit to form beads/pellets of LDPE.Special take care of catalyst and modifier injection system with proper servicing of standby system. Always cross check the reaction temperature graph for its appropriate curves. To avoid decomposition of ethylene gas at initial phase of polymerization by taking proper actions and following Sops. Develop SOPs for safe production of LDPE and guide operators accordingly. Manage man power and delegate work to them with proper follow up without delay.
Train operators for Safe handling of products, utilities and raw materials. Coordinate with Maintenance personnel to ensure maintenance activities are conducted with the least disruption to production. Enhance shift operators operational skills and knowledge by regular coaching to meet operational requirements. Ensure minimum disruption to stable operation by detecting plant and equipment problems and implementing counter measures after trouble shooting. Ensure shift operation tasks meet safety, compliance and environmental requirements and report any such concerns to reporting Manager .Verify operating logs to ensure records are accurate. Monitor and ensure plant equipment integrity and reliability. Provide technical support to process department with the help of trends of reaction and possible causes of any abnormality. A successful shift engineer with complete knowledge of LDPE process and its controlling.
Working as a shift incharge for manufacturing epoxy resin and its formulations. Responsible for any failure and troubleshooting plant problems arising during production. Delegate work to operators and make sure it has been completed within the target time. Assist operators regarding production plan and to maximize production. Plan for shutdown and startup monthly. Update senior manager for any major breakdown. Follow up with maintenance for pending activities, any modification during the shutdown period. To make sure equipment changeover has been done on time. To ensure proper flushing & cleaning of equipment at shutdown tenure. To take a round through plant for monitoring filtration process, separators level, scrubber samples, filter cakes volume, emulsion quantity etc. To maintain housekeeping in the plant to avoid any unsafe condition. Responsible for packaging and drumming of epoxy resin and its proper storage. Overall handling production starting from hazardous raw materials like BPA, ECH & NAOH to finished product manufacturing and storage.
To ensure a daily desired production per day, by operating the plant with fully automated YOKOGAWA centum CS-3000 DCS version. To do safety audits weekly and to close it as soon as possible by providing work permits to the respective department. To provide technical support to plant for any breakdown or on quality issue of the product. Has done commissioning of the plant for enhancing its capacity from 44 TPD to 60 TPD.To debottleneck process for modifications & increased production. To perform loop test during the commission of plant according to its PID safely. To take pressure test for vessels like evaporators, reactor etc. to ensure no energy loss to system & for maintaining process parameters throughout. To take the hydraulic test for newly installed equipment and columns for leak-proof results. To issue a permit for various welding activities in the plant, confined space entry, electrical jobs, excavation activities, any general activates and to monitor the progress considering safe standard in mind. Practiced to convert our plant to zero discharge plant as per environmental requirements. To check effluent going out for treatment should be minimum in COD, BOD, TDS etc. contents. To do routine checkups for the effluent sample, scrubber samples, emulsion content, vacuum pump water samples etc. for monitor the plant performance.
B.TECH in chemical and studied vital subjects like HEAT TRANSFER,MASS TRANSFER,CHEMICAL REACTION ENGG,CHEMICAL THERMODYNAMICS,FLUID MECHANICS ,PROCESS CONTROL which are the basics of chemical engineering. Also GATE qualified in chemical Engg 2 times with more than 90 percentile each time.