Resume - A seasoned engineering management professional with 11 years experience in petro...

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Resume #86345

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Job Roles & Experience – 11 years in Petrochemical plants, Refineries and Energy/Reliability Consultancy
* Shell Global Solutions, Malaysia – Jan' 08 – March '09
Shell Global Solutions, East – March '09 Onwards o Consultant – Energy, Asset Management and Reliability in Process Plants
* Bahrain Petroleum Company, Bapco - Mar'07 to Dec'07
o Reliability Specialist – Meridium Systems for Reliability Management–
Loss Prevention and Risk Management of Oil & Gas Units
* Reliance Industries Limited (Indian Petrochemicals Corporation Ltd) – Jun'98 to Mar'07
o Manager – Technical Services – Value Addition and Optimisation
Vinyl Chloride Monomer, Ethylene Oxide/Glycol and Steam Cracker Plants

Skill Set:
Process Simulation, Optimization, Troubleshooting, Reliability Modeling, Energy Management, Site Pinch Analysis, Utilities modeling, Root Cause Analysis (Incident Investigation), Operations Management, Risk Management (PHA, HAZOP, SIL Studies and LOPA)

Professional Qualifications:
* B.E (Chemical) Honors, Department of Chemical Engineering and Technology, Panjab University, Chandigarh, India, June 1998 (73.5% marks -1st Division)
* Manufacturing Management programme for Engineers of Reliance industries Limited (Residential) from Indian Institute of Management –Bangalore, India, April 2005

Certification:
* BOSIET and HUET till May 15, 2012 approved by OPITO.

Awards:
* Shell Global Solutions' Special Recognition Award for extra-ordinary contribution in Pinch Technology application in Energy Master plan at Shell Bukom Refinery, Singapore, 2009.
* Shell Global Solutions' Special Recognition Award for Innovation in implementing utilities Linear Programming based Optimization Tool at a refinery in Indonesia, December 2008.
* Ranked 'Excellent' among galaxy of plant utilities related professionals in Three Week long Intensive training programme on water utilities conducted by Reliance Industries Limited
* Best project Award on Manpower benchmarking by independent Jury comprising Indian Institute of Management, Bangalore Professor Judges and Reliance Industries representatives
* National scholarship holder and Top scorer in Science subject (10th Standard CBSE)

Current Professional Responsibilities:
* Generate and develop ideas for profit improvement by reliability enhancement, heat integration and basic energy efficiency in oil, gas and petrochemical units
* Propose best maintenance practices and perform reliability modeling for process plants
* Analyze systems, optimize unit operations; propose energy efficiency improvements
* Identify and design basic solutions for design improvements in process equipments
* Define requirements for control/instrumentation improvements for loss prevention
* Define test runs, comply with the site's management of change procedures
* Get the proposed changes implemented, document performance improvements and get these approved by the customer;
* Leading and organizing information exchange meetings & training courses.
* Develop and Implement strategies to help customer meet tightening environmental regulations around Green House Gas emissions and reducing overall carbon footprint
Projects:
Risk and Reliability modeling focus-
* Sulphur recovery unit configuration for 97% Availability
* Crude Distiller, HVUs and HDT/HDS availability modeling for sustaining 15% more than current intake at Shell Refinery in Singapore identifying bad actors and forward path for investment decisions
* Refinery unit reliability/availability modeling of TGU, HDS, SRU and Shell Claus off gas treatment units and criticality analysis of units and equipments for conceptual and FED stage
* Steam or Gas Turbine based drive selection for LNG plants meeting best availability targets
* Determining best configuration for expansion projects and installing a third party power generation block, Power plant availability analysis
* Implementing advanced applications of Reliability Management software system like auto generated bad actors listing, maintenance alerts, RAM modeling and Weibull analysis in Bahrain Petroleum Refinery.
* SIL Studies and LOPA for Process heater in a Crude distillation Unit.
* Risk assessment for siting of a refinery process control building
* Overpressures, safe distances and other calculations for Vapor cloud explosion, BLEVE calculations for LPG Horton Spheres
Energy focus-
* Heat Integration in CDU, HCU and HVU units in 560000 bpd refinery including opportunity mapping, Driving force optimization, and new/modified heat network design based on best practices.
* Power generation optimization by steam turbine Linear Programming based model development in state run refinery power plants in Indonesia to yield optimal configurations
* Fired Heaters' energy saving opportunity identification
* Optimizing BFW pre-heat in boilers by fuel quality management
Emissions focused-
* Steam turbine drive replacement by electric motors based on energy efficiency, reliability and CO2 abatement.
* Tipping point Analysis for abatement project risk management and decision analysis.
* Carbon abatement studies and strategizing for investment options in Sakhalin LNG plant.
Process Simulation/ Engineering focused-
* Aspen Plus converged flow sheeting for purification section for Vinyl Chloride Plant(HCl, VCM, Light ends and stripping columns), sensitivity analysis for troubleshooting.
* Debottlenecking Light Ends Column and Wet EDC processing capabilities in VCM plant
* Pressure drop in a line, line sizing, and pump pressure requirements
* Ethylene oxide Catalyst selectivity, Oxychlorination catalyst performance
* Trial with different feed rates and designated reflux trays of Light Ends distillation column for the purpose of debottlenecking
* Fixed bed reactor catalyst life study by temperature and steam generation rate profiling to suggest the increase of suction pressure in reactor chain to improve conversion
* Management of corrosion in Steam cracker and Ethylene oxide/Ethylene glycol plant
* Improvement of Tar still on stream factor by developing flow schemes
Benchmarking focused-
* Benchmarking Manpower in polyester plants in Reliance Industries Limited
* Benchmarking of maintenance practices in process plants with KPIs like maintenance cost per ton, manpower benchmarks, cost per unit ERV and cost of unreliability, maintenance costs and practices in petrochemical plants

Areas of Professional Experience:
Process Reliability Support:
* Reliability Block Modeling, Weibull Analysis, Human Reliability analysis
* Life cycle cost analysis, Asset Management
* Analyzing the financial impact of the Lost Profit Opportunities (LPO) due to incidents
* Bad Actor identification and elimination, Defect Elimination by Root Cause Analysis
Risk Management/PSM:
* Incident Investigation to develop loss prevention strategies
* PHA, HAZOP Studies and Safety Integrity Level Studies for Fired heaters in Refinery.
* PSSR, Semi-Quantitative Risk Assessments for Industrial Installations
* Consequence Analysis for Vapor Cloud Explosion and BLEVE conditions
* Dispersion Modeling and Calculation of quantities in case of petrochemical leaks
Technical Support:
* Steady State Simulation, Process Optimization, and generating Operating Envelopes
* Debottlenecking Studies, Preparing and modifying PFDs and P&IDs
* Process monitoring, Troubleshooting and Technology Evaluation
* Pressure surveys, Pressure drop calculations, Line sizing, and Piping Design
* Catalyst Selectivity Calculations, Catalyst Studies and Performance Monitoring
Operations and Turnaround Support:
* Optimizing specific consumption of raw materials, catalyst-chemicals & utilities
* Water systems Troubleshooting and Analysis (Raw water to Effluent generation)
* Start up and Shut down, Operation of cracker furnaces, distillation columns, fixed bed catalytic reactors, centrifugal and reciprocating compressors, Emergency handling, Decoking operations, and writing Standard operating procedures
* Preparing Gantt charts and scheduling shutdown activities
Costing:
* Utilities Economics modeling
* Process Budgeting and Production Planning
* Calculating payback period, NPV and IRR of the projects

Simulation/Software:
* Process Simulation: Pro-II, Aspen Plus, Design II, chemCAD, AFT Fathom
* Dispersion Modeling and Risk Analysis: ALOHA/CAMEO, HAMSAGAR & PHA-Pro 7 for
* Incident Investigation and RCA: TapRooT, ProACT
* RAM Modeling: SPARC, Meridium V3.0.3, MAROS
* Arena package, @Risk, MATLAB, SCILAB, FORTRAN and C language coding
* MS projects, SAP R/3 (PPPI module) and EMPAC for CMMS

Training/Courses:
* BOSIET/HUET – MSTS, member Falck/Nutec, Johor Baru, Malaysia
* Meridium APM Training - Dubai
* Aspen Plus steady state simulation - Aspentech-Pune, India
* Modeling, analysis and optimization of industrial processes - IIT Mumbai, India
* Advanced Process control - IIT-Mumbai, India
* Distillation Column design, rating, control and energy analysis - IIT Mumbai, India
* Course on water utilities – Reliance Industries Limited, India
* Health and Safety training - Bahrain Petroleum Company
* Management of Change (PSM Element#10) - Bahrain Petroleum Company
* Six-sigma orientation - Breakthrough Management Group, India
* TDC-3000 DCS 'Implementation Training' - Tata Honeywell-Pune, India
* C language certification - INFORMATICS Institute, Bharuch, Gujarat, India
* Certified 'Outstanding' in English reading, vocabulary, grammar and writing - CIEFL

Professional Affiliation:
International member of American Society of Safety Engineers

Papers /Presentations:
* Hydrogen energy in future, and Thorium as an alternative nuclear fuel
* Benchmarking manpower productivity across Polyester sites of Reliance Industries Ltd presented at Indian Institute of Management, Bangalore
* Oxychlorination catalyst performance – monitoring & variable optimization at Reliance Industries Inter Site catalyst and Adsorbent meet-2007

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