THEJAS TM

Dcs operations
Handling HCl synthesis ovens involving steam co-generation,
Chlorine liquefaction units
Caustic concentration units
Troubleshooting and process optimization.
Operating evaporation systems to concentrate
caustic from 32% up to 50% using multiple-effect evaporators.
Chemical dosing management and water treatments.

• Operated and monitored a 250 TPD continuous chlor-alkali plant encompassing electrolysis cells, brine purification,
HCl synthesis, chlorine liquefaction, soda bleach, and caustic concentration systems.
• Controlled critical process parameters including cell voltage, current density, brine concentration, temperature, pH,
flow rates, and current efficiency, maintaining operations within design and safety limits.
• Executed DCS-based plant control (Yokogawa Centum VP) for start-up, normal shutdown, emergency shutdown, and
steady-state operations, ensuring high operational reliability.
• Operated multiple-effect evaporators to concentrate caustic soda from 32% to 48-50%, achieving consistent product
quality with optimized steam and energy consumption.
• Responded to process alarms, equipment trips, power failures, and emergency conditions; minimized production
losses and ensured safe plant recovery.
• Conducted RCA for process upsets, equipment failures, and safety incidents; implemented CAPA measures to reduce
recurrence and improve overall plant availability.
• Monitored water treatment plant operations including pH control, turbidity, residual chlorine levels, and chemical
dosing to meet quality and environmental discharge standards.
• Ensured full compliance with EHS regulations, SOPs, PTW systems, and statutory requirements, contributing to
incident-free operations and robust process safety management.

Operated and monitored 250 TPD continuous chlor-alkali plant operations, including electrolysis cells, brine
purification, HCl synthesis unit, chlorine liquefaction, soda bleach, and caustic concentration systems, ensuring stable
and safe production.
 Controlled critical process parameters such as cell voltage, current density, brine concentration, temperature, pH, flow
rates, and current efficiency, maintaining operations within design and safety limits.
 Executed DCS-based plant control (Yokogawa Centum VP) for start-up, shutdown, and steady-state operations,
ensuring high operational reliability and process stability.
 Operated multiple-effect evaporators to concentrate caustic soda from 32% to 48-50%, achieving consistent product
quality with optimized steam and energy consumption.
 Responded effectively to process alarms, equipment trips, power failures, and emergency conditions, minimizing
production losses and ensuring safe plant recovery.
 Conducted root cause analysis (RCA) for process upsets, equipment failures, and safety incidents; implemented
corrective and preventive actions (CAPA) to reduce recurrence.
 Coordinated closely with maintenance, electrical, instrumentation, quality control, and production teams to resolve
operational issues, improving plant availability and equipment reliability.
 Ensured compliance with EHS regulations, SOPs, permit-to-work systems, and statutory requirements, supporting
incident-free operations and process safety management.
 Monitored water treatment plant operations, including pH control, turbidity, residual chlorine levels and chemical
dosing optimization to meet quality and environmental standards.

• Supported field operations and monitoring of continuous chemical processes under senior engineers in a process
safety-critical environment.
• Conducted process sampling and data analysis to monitor brine quality, impurity levels, and operating trends.
• Analyzed cell voltage and performance trends to identify membrane degradation and electrode fouling, supporting
preventive maintenance planning.
• Participated in alarm rationalization initiatives, reducing nuisance alarms and improving operator situational
awareness.
• Assisted in testing and validation of interlocks, safety instrumentation, and trip systems; actively participated in mock
drills and emergency response training.
• Prepared daily production reports, shift logs, SOP updates, and incident investigation documentation.