Manager – Commissioning / Senior Co-ordinator - Commissioning
PETROFAC INTERNATIONAL (UAE) LLC
Total years of experience :31 years, 4 Months
Responsible for overall commissioning of additional green field Gas Compressing Station receiving Gas from Direct Gas Manifold and Extension of Remote Manifold Station gathering Gas from new Wellheads. Responsible for overall commissioning of green field Oil Producing & Water Injection Wells. Leading an in-house team of multi-disciplined skilled engineers and outside LSTK contractor to provide technical assistance and process guidance for safe and successful commissioning of the facilities to meet client’s requirement.
• Scheduling of Pre-Commissioning activities in close co-ordination with Construction Planning and close supervision for adherence.
• Planning of Facility start up through meticulous integration of Construction activities of multi-disciplined team of highly skilled engineers.
• Scheduling vendor call out for pre-commissioning activities following to construction completion of facility systems. Co-ordinating with vendor activities on site till site acceptance and vendor close out.
• Identification of various pre-commissioning and commissioning Task Risk Assessment (TRAs) and related Method of Statements for obtaining Permit to Work system.
• On site Process checks as per P&ID and related loop, functional test for control integrity checking.
• On site Process modifications, HAZID and HAZOP studies for safe implementation.
• Preparation and Review of Documentation, Deliverables, Pre-commissioning and Commissioning procedures.
• Participation in high level presentations with client to deliver client’s expectation.
• Managing LSTK contractor to meet various pre-commissioning and commissioning milestones following high level HSE standards and pre-start up safety requirements.
• Meticulous execution of warranty jobs post performance acceptance test till issuance of final acceptance of facilities by the client.
Responsible for commissioning of 15 mmtpa grass root refinery project being constructed in Paradip, India. Leading a team of LSTK contractor to provide technical assistance and process guidance for safe and successful commissioning of Units & Offsite facilities to meet client’s requirement.
• Planning of Unit start up activities through meticulous integration of Construction activities of multi-disciplined team of highly skilled engineers.
• Scheduling path forward of start-up activities and close supervision for adherence.
• On site Process checks as per P&ID.
• On site Process modifications and HAZOP studies for safe implementation.
• Review of Documentation, Deliverables, Pre-commissioning and Commissioning procedures.
• Participation in high level presentations with client to deliver client’s expectation.
• Managing LSTK contractor to meet various commissioning milestones following high level HSE standards.
Leading a team of commissioning personnel to plan & execute commissioning activities of new Diesel Hydro-Treating Unit of LSTK Project in Mumbai Refinery.
• Meticulous planning of Unit Start up activities.
• Liaison with Licensor and Client to meet Project schedule.
• P&ID study and propose modification to suit site condition.
• Static Equipment inspection.
• Liquidation of punch points.
• Trial run of rotary equipment.
• Process stream flushing, final box-up and leak test.
• Control Loop checking between DCS and Field.
• DCS panel operation.
• Safe unit start up.
Worked as Business Management Consultant in SAP Production Planning Module.
• Responsible for integration of overall Business Activities through configuration of Production Planning Module in ERP programme of various continuous and discrete process industries.
Production Planning and Operation of Refinery Unit such as Primary Distillation, Hydrogenation, Reformers, Thermal Cracking and Lube Oil Base Stock Unit to meet Production Target, in Management and Senior Management Position.
Offsite Operation of Oil Movement, Blending and Storage. Liaison with Marketing and Pipeline Division to meet Customer requirement.
Project Execution and Commissioning Operation of Refinery Unit.
Carrying out Planned Shut Down for Maintenance and Inspection followed by safe Start Up.
Configuration and Implementation of SAP Production Planning Module in Refinery Operation.
Advance Process Control and Optimization.
Crude Oil Planning, Procurement, Transshipment and Shipping Operation.
Implementation and Maintaining ISO Standard, TPM activities to improve overall Refinery Profitability.
Process Planning and Co-ordination. Optimization of Refinery Operation to meet MOU target.
Indian Oil Corporation Limited, Haldia Refinery.
2008 to July 2011.
Deputy Production Manager and Production Manager.
Section: Oil Movement & Storage
Responsibilities & Skill:
1. Worked as core group member to implement SAP Production Planning Module. Key activities include: ✓ Project Preparation and finalization of Business Blueprint.
✓ Configuration and maintenance of Master Data.
✓ Production Planning.
✓ Material Requirement Planning.
✓ Capacity Planning and Scheduling.
✓ Production Control.
✓ Report Generation.
✓ Configuration of Order type and its Dependant Parameter.
✓ Product Costing Run, Oil Accounting Procedures.
✓ Production Planning of Lube Oil Blend Stock in Batches.
✓ Close co-ordination with other functional modules during integration and Go Live.
2. Section-in-Charge of Oil Movement and Storage. Key areas of activity;
✓ Monthly Crude Oil allocation planning with HQ based upon availability of Refining capacity and secondary Units.
✓ Logistics line up to execute mid sea Ship-to-Ship (STS) Lighterage operation of imported crude oil and unloading operation from Ship to Shore Tanks.
✓ Crude Oil accounting in SAP.
✓ Liaison with Customs authorities for bonding of Crude Oil Tank and Crude Oil Receipt.
✓ Crude Oil Tank preparation for feeding to Primary Units.
✓ Lube Oil Base Stock Storage, Blending and Loading operation.
✓ Bitumen Storage, Blending and Loading operation.
✓ Tank Truck & Wagon Loading operation of other Petroleum Products.
✓ LPG Storage and Loading operation.
✓ Liaison with Marketing and Pipeline Division.
3. Major revamp activity carried out - Modification of Crude Oil receiving line inside and outside of Refinery Battery area, de-commissioning and removal of old Crude Oil Tanks to create space for building Hydro-Cracker Units. Key activities include: ✓ Meticulous planning of scheduling Crude Oil Tanker for line flushing to keep Refining operation un-interrupted at full capacity.
✓ Flushing of Crude Oil receiving line from Oil Jetty to Refinery Tank to make Hydro-Carbon free.
✓ Fire incident and accident free execution of modification job.
4. Crude Oil Tank M&I. Key activities include: ✓ Tank de-commissioning and Roof de-floating.
✓ Recovery of Crude Oil from residual sludge at tank bottom by BLABO method.
✓ Tank cleaning and inspection.
✓ Floating Roof replacement job.
✓ Fire and Accident free execution of M&I job.
✓ Tank re-calibration post M&I job.
✓ Safe commissioning of Tank.
5. Commissioning of Paradip Haldia Crude Oil receiving Pipeline. Key activities include: ✓ Utilization of existing Pipeline from Oil Jetty.
✓ Logistics lineup at Pipeline installation.
✓ Joint bonding activities of Crude Oil tank with Customs authorities.
6. Carried out an overall study of Crude Oil movement logistics to improve Refinery profitability. Key studies include: ✓ Load Port operation.
✓ Mid sea Ship-to-Ship Lighterage Operation.
✓ Unloading operation from Ship to Refinery Shore Tank.
✓ Crude Oil accounting from load port to discharge port.
✓ Areas of improvement to minimize loss.
7. Commissioning of new Effluent Treatment Plant (ETP) . Key activities include: ✓ Safe execution of Project job without any Fire incident or accident.
✓ P&ID study and propose modification to suit site condition.
✓ Field Acceptance Test and offline Simulation of new DCS with Yokogawa in Bangalore.
✓ Control Loop checking between DCS and Field.
✓ Process hook up of new ETP with existing one.
✓ Equipment performance check on no load.
✓ Process circuit flushing before oil in.
✓ Safe commissioning of new ETP and carry out Guarantee Test Run (GTR)
8. Flare Tip replacement job during Total Refinery Shut Down. Key activities include: ✓ Safe shut down of Flare system.
✓ Flare header and Flare Drum de-commissioning and flushing.
✓ Fire and accident free execution of Flare Tip at high altitude.
✓ Flare header hook up of new Hydro Cracker Unit with existing Flare KO Drum.
✓ Hook up of Flare Gas Recovery Compressor piping.
✓ Safe commissioning of Flare system and Flare Light up.
9. Commissioning of Bitumen loading facility in Ship Tankers. Key activities include: ✓ Laying of new Pipeline from Refinery to Oil Jetty.
✓ Pressure Testing of new Pipeline.
✓ Logistics lineup for stock transfer and statutory requirements for loading export parcels.
10. Commissioning of Group II Lube Oil Base Stock loading facilities in Ship Tanker, Barge, and Tank Wagon following to successful completion of Catalytic Iso De-Waxing Unit production. Key activities include: ✓ Laying of new Pipeline and Pressure Testing.
✓ Logistics lineup for ship tank loading.
✓ Pigging operation to segregate Group I and Group II LOBS loading in Ship Tank.
11. Participation in seminar on Crude Oil handling, in Singapore. Key areas of subject: ✓ Crude Oil transport logistics from Load-Port to Discharge-Port.
✓ Crude Oil Loading / Unloading operation in Ship Tanker.
✓ Ship-to-Ship Lighterage Operation.
✓ Crude Oil unloading operation from Ship to Refinery Shore Tank.
✓ Tank calibration method.
✓ Crude Oil Accounting.
✓ Areas of Improvement to minimize loss.
Indian Oil Corporation Limited, Haldia Refinery.
2003 to 2008.
Deputy Production Manager.
Section: Delayed Coker Unit.
Responsibilities & Skill:
1. Worked as shift supervisor in Process Units namely;
➢ Delayed Coker Unit
➢ LPG Recovery Unit
Key activities include: ✓ Day to day monitoring, emergency handling, trouble shooting of unit process parameters, equipment.
✓ Shift supervision of Operating Personnel.
✓ Impart training to Panel & Field operator.
✓ Meeting Production Target.
✓ Monitor DCS operation to maintain process parameter.
✓ Process Troubleshooting.
✓ Co-ordination with Maintenance department to plan and execute preventive maintenance jobs in order to improve plant reliability.
2. Carried out planned M&I shut down job of Delayed Coker Unit A. Key activities include: ✓ Safe shut-down, flushing and handing over the unit for carrying out M&I job.
✓ No major fire incident or accident reported during shut down or start up.
✓ Steam Air De-Coking of Furnace.
✓ Execution of in-house Process Modification job to improve plant reliability.
Indian Oil Corporation Limited, Barauni Refinery.
2002 to 2003
Senior Production Engineer and Production Engineer.
Section: Lube Oil Complex.
Responsibilities & Skill:
1. Worked as shift supervisor in Process Units namely;
➢ Solvent De-Waxing Unit
➢ Phenol Extraction Unit
➢ Wax Hydro-Finishing Unit
Key activities include: ✓ Day to day monitoring, emergency handling, trouble shooting of unit process parameters, equipment.
✓ Shift supervision of Operating Personnel.
✓ Impart training to Panel & Field operator.
✓ Meeting Production Target.
✓ Monitor DCS operation to maintain process parameter.
✓ Process Troubleshooting.
✓ Co-ordination with Maintenance department to plan and execute preventive maintenance jobs in order to improve plant reliability.
✓ Carrying out planned M&I jobs.
2. Implementation of Digital Control System (DCS) in Solvent De-waxing Unit, replacing old Mechanical Control System. Key activities include: ✓ Receiving user configuration & operation training on DCS from TATA Honeywell, Pune.
✓ Preparation of graphical interface.
✓ Mapping of control loops in the graphics.
✓ Field Acceptance Test of DCS.
✓ Field control loop checking.
✓ System migration from Old to new DCS.
3. Revamp activities of Solvent De-waxing Unit and successful commissioning to produce Paraffin Wax. Key activities include: ✓ P&ID study and propose modification to suit site condition.
✓ Safe shut-down, flushing and handing over the unit for carrying out modification job.
✓ No major fire incident or accident reported during project execution.
✓ Installation and hook up of new Rotary Vacuum Filters and connected piping pump with existing Process.
✓ Revamp of existing Rotary Vacuum Filters.
✓ Internal modification of Solvent Recovery Column and Stripper Column with improved efficient Valve Trays to increase capacity.
✓ Installation and hook up of new Chiller with existing train.
✓ Internal modification of existing Ammonia and Regenerative Chiller to improve crystallization.
✓ Modification of existing Ammonia Condenser to increase heat transfer area.
✓ Commissioning of new Nitrogen PSA Unit.
✓ Field Acceptance Test of modified DCS with TATA Honeywell in Pune.
✓ Instrument Loop checking between DCS and Field.
✓ Pressure Testing of New Equipments and modified circuits.
✓ Accident & Fire free safe unit start up post modification.
✓ Unit stabilization to produce on grade Paraffin Wax, a feedstock to Wax Hydro-Finishing Unit.
4. Commissioning activities of new Wax Hydro Finishing Unit. Key activities include: ✓ Receiving unit operation training.
✓ P&ID study.
✓ Incorporate necessary modification during project work to suit site condition.
✓ Safe execution of Project job without any Fire incident or accident.
✓ Process circuit pressure testing.
✓ Field Acceptance Test of DCS.
✓ Control Loop checking between DCS and Field.
✓ Equipment performance check on no load.
✓ Process circuit flushing.
✓ Moisture and Oxygen removal from system.
✓ Safe commissioning and carry out Guarantee Test Run (GTR)
5. Extraction Unit - Process package review for conversion of Phenol to NMP as Solvent for extraction, incorporating implementation of Digital Control System (DCS) replacing old Mechanical Control System. Key activities include: ✓ P&ID study.
✓ Preparation of graphical interface.
✓ Mapping of control loops in the graphics.
6. Developed a software package on integrated data management system using Visual Basic as front end computer programming tool with Microsoft Access as backend database and HTML with client side VBScripting. Developed few other automated office packages for day to day data entry.
7. Participation in workshops on Lube Oil Base Stock (LOBS) Production by Center of High Technology.
Indian Oil Corporation Limited, Barauni Refinery.
1994 to 2002
Graduate Engineer Trainee.
Responsibilities & Skill:
1. Received classroom and workshop training in Mathura Refinery and Indian Institute of Petroleum, Dehradun.
2. Worked as Process Engineer in Technical Services department in Refinery Process Planning & Co-ordination cell during on the job training. The job mainly covered;
✓ Month wise production planning to meet MOU target.
✓ Day to day production monitoring to meet certified product availability to Marketing & Pipeline as per Refinery commitment.
✓ Generation of Daily Operation Report (DOR)
✓ Regular participation in Pre Industrial Co-ordination meeting and Crude Slate meeting at Refinery Headquarter, New Delhi.
Indian Oil Corporation Limited, Mathura Refinery.
1993 to 1994
Sales Engineer.
Section: Marketing Division (Process Pump)
Responsibilities & Skill:
1. Marketing Strategy and direct sales of Process Pump.
2. Carried out Process Pump selection in Turn Key Projects of various Industries.
3. Technical study and troubleshooting of Process Pump supplied to different Process Industries.
Full Title of Award Institution Awarding Body Date From/To Grade Bachelor of Chemical Engineering Jadavpur University 1987 to 1991 First Division West Bengal Board of Higher Secondary Examination. Subjects taught: English, Bengali, Physics, Chemistry, Mathematics and Statistics.
Bachelor of Chemical Engineering
St Lawrence High School 1985 to 1987 First Division Madhyamik Examination. Subjects taught: English, Bengali, Physical Science, Life Science, Mathematics, Geography, History and Additional Mathematics. Nava Nalanda