Resume - Construction, Pre-commissioning, Commissioning & Operations of Gas Cracker Unit ...

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Resume #31481

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CAREER OBJECTIVE:
To evolve as a successful professional, consistently mapping business knowledge to the latest technology with my skills and abilities in a dynamic, professional and creative environment

EDUCATIONAL PROFILE:
B.E. (Hons). Chemical Engg.
M.Sc. (Hons.) Chemistry
BITS, PILANI
1991-1996 batch
CGPA – 7.63 / 10

Interests: Cricket, Badminton, Swimming

WORK EXPERIENCE: Gas Cracker Unit – Ethylene Plant (120 Months)

DESIGNATION:
Manager (Chemical) In The Petrochemical Complex Of Gail (India) Limited, U P.

Brief Description Of The Complex:
The UP Petrochemical complex is designed to produce 160000 TPA (Tons per Annum) of Linear Low Density Polyethylene (LLDPE) / High Density Polyethylene (HDPE) (Novacor, Canada) and 1,00,000 TPA of HDPE (Mitsui, Japan) from natural gas. The complex also consists of an ethylene plant of 300000 TPA capacity (Stone & Webster, USA), an acid gas removal unit (SNEA, France) handling 12 MMSCMD of natural gas, an ethane propane (400000 TPA) & LPG (258000 TPA) recovery unit along with off-sites & utilities.

PROJECT COMMISSIONING EXPERIENCE:
(Gas Cracker Unit - Ethylene Plant)
- Construction, Pre-commissioning, Commissioning & Operations of Gas Cracker Unit (4,00,000 TPA Of Ethylene) which consists of the following units:

* Cracking Furnaces (Five no.s with a capacity to generate 40 TPH of 105 KSCG Super-heated Steam each)
* Quench Tower, Water Stripper & Dilution Steam Generation unit
* Cracked Gas Compressor (Ebara, Japan)
* Acid Gas Removal Unit - Caustic section
* Ethylene Refrigeration (Ebara, Japan)
* Propylene Refrigeration (Ebara, Japan)
* Expander – Compressors (Mafi-Trench, USA)
* Hydrogen Compressors
* Acetylene Hydrogenation unit
* Cold Separation units

- Pre-commissioning, Commissioning & Operations of the following package units of Gas Cracker Unit:
* Dispersed Oil Extraction Unit (Natco, USA)
* Pressure Swing Adsorption Unit (KTI, USA)
* Condensate Polishing Unit

- Coordination with consultants and contractors for expediting the early construction of the unit
- Study & review of Process Flow Diagrams and Piping &Instrument Diagrams and check listing of the Plant along with STONE & WEBSTER ENGINEERS
- Coordination and follow up with the contractors for salvaging check list points
- Preparation of schemes and carrying out the jobs of chemical cleaning of the pipelines coming under Indian Boiler Regulatory (IBR) Act.
- Preparation of schemes and carrying out the jobs of chemical cleaning of lube oil & seal oil circuits of Cracked Gas, Ethylene refrigeration & Propylene refrigeration compressors
- Segregation of vast sections in to sub-systems for ease of carrying out pre-commissioning jobs
- Preparation of schemes and carrying out the pre-commissioning jobs like water flushing, cardboard blasting, nitrogen dry-out & leak checking of various sections of the plant
- Internal inspection of vessels, columns, dehydrators & reactors
- Loading of molecular sieves, catalysts & other packed media in respective packed beds of the plant
- Control Logic checking for Cracked Gas Compressors, Ethylene & Propylene Refrigeration Compressors
- Preparation of the unit for the smooth start-up of the plant
- Stable start-up of the unit including trouble shooting
- Project co-ordination for capacity expansion of the Gas Cracker Unit.
- Review and modification of the plant operating logics, trip interlocks in accordance with Hazard and Operability studies
- Preparation and review of standard operating procedures and work instructions for ease of operation.
- Training of staffs during different phases of pre-commissioning, commissioning & operations of the plant.

OPERATIONS EXPERIENCE:
(Gas Cracker Unit - Ethylene Plant)
- Continuous monitoring of the critical plant parameters ensuring smooth and stable operations of the unit
- Regular Operations of al sections / units of Gas Cracker Unit in a safe and reliable manner with a focus to:

* Meet and exceed all MOU targets and benchmark parameters, set by management
* Reduction in specific consumptions of Catalyst / Chemicals and other consumables
* Reduction in Specific energy (Steam, Fuel & Power) consumptions
* Reduction in Specific Utility (Air, Nitrogen, Cooling water) consumptions

- Sound knowledge in the operation and trouble shooting of
* Expander compressors (MAFI TRENCH, USA)
* Multistage centrifugal compressors (EBARA, JAPAN)
* Steam turbines controlled by Woodward Governor
* Multistage centrifugal Pumps

- Well versed in the operation of the plant by using distributed control systems (Centum XL) and programmable logic controllers (Allen Bradley PLC)

PROCESS ENGINEERING EXPERIENCE:
(Gas Cracker Unit - Ethylene Plant)
- Gathering, filtering and displaying of data including trends, profiles and schematics
- Consolidation of alarms and event notification data based on their importance for repair and maintenance
- Interpretation of important plant data and carrying out diagnostic analysis and giving feedback and recommendations to the operation group
- Technical / Process monitoring, analysis, review, trending and auditing on regular basis of all critical process equipments and machineries with a focus to improve operations, process parameters and for quick implementation
- Process calculations such as material and energy balancing, efficiency of static and rotary equipments, modeling and simulation using ASPEN Plus thereby increasing reliability and reducing downtime and maintenance cost
- Increasing productivity by optimizing capacity utilization and maximizing efficiency
- Preparation of process reports involving hydrocarbon accounting
- Budgeting and stocking of the unit
- Asset management and preparation of tender documents.
- Material and services planning and execution.
- Co-ordination for quality, environmental, occupational health and safety audits and maintenance of ISO systems in the Gas Cracker Unit.
- Co-ordination & follow-up with maintenance groups for salvaging audit recommendations and regular maintenance jobs with a view to maintain good house keeping for safety of plant and personnel
- Preparation and review of aspect impact analysis, hazard identification and risk assessment sheets of the Gas Cracker unit processes.
- Preparation and review of standard operating procedures and work instructions for ease of operation.
- Operator training and development.
- Process modification review and preparation of road map for implementation.
- Implementation of change management initiatives such as Business process re-engineering and benchmarking studies.
- Co-ordination of all chemicals, catalysts & consumables procurement, line-up and issue from stores etc
- Planning of shutdown jobs, resource requirements and micro planning for analyzing and monitoring the critical path activities ensuring smooth execution of shutdown activities and reducing the down time.

SPECIAL SKILLS AND STRENGTH:
- MS-Office package
- Handling of emergency situations
- Fire fighting techniques
- Excellent presentation & Communication skills
- Participated in Managers Development Course conducted by IIM, Kolkata
- Well versed with the SAP Production & Planning module
- Well versed with the SAP Plant maintenance module
- Well versed with the Lab Information Management Systems (LIMS)

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