Resume - Over 14 years of experience in wide range of core refinery operations like pre-...

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Resume #50383

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Summary:

 Working with Bharat Petroleum Corporation Limited (BPCL) since 1993 i.e after graduation.

 Presently working as Deputy Manager, Operations, Aromatics Complex, BPCL

 Around 14 years experience in process engineering aspects and wide range of core refinery operations like pre-commissioning, commissioning, operating, optimisation, handling start up and shut downs etc of various process plants like FCCU, SRU, Naptha Hydro Desulphurisation, Catalytic Reforming, Carbon monoxide Boilers, Meroxes, Aromatic Extraction plants (benzene/toluene/Hexane), Nitrogen plant, along with all the administrative functions, preparation of operating procedures / safety procedures, DCS Operations, emergency handling, planning, Scheduling and blending, advanced process control etc in the 12 MMTPA Bharat Petroleum Refinery.

 Operation team leader in the revamp of High vacuum unit in 1997, revamp of the Fluidised catalytic cracking units/ reactor/regenerator/gas plant/meroxes in 2002, revamp of Catalytic reforming unit in 2005, relocation of the units of Amine treatment/sour water stripper in 2002.

 Team leader of the Operations group in the implementation of the Dynamic matrix Control (Advanced process Control) in FCCU Complex.

 Team member in the implementation of the Offsite Automation project, Manufacturing Execution Systems, SAP etc in BPCL.

 Proficiency in usage of Simulation Softwares like UniSim, HYSIS(ver 3.5) etc

 Implemented LIMS (Laboratory Information management Systems) software by Thermo Electron Corp. for automatic real time laboratory information data management.

 Managed teams up to 22 workmen in shifts in running various process units, optimizing yields, delivering complex constraint based production and delivery plans with in schedule.

 Also having knowledge of other process unit of refinery viz. atmospheric distillation units, DHDS, Hydro cracker, Hydrogen, LOBS etc. Operating knowledge of various DCS like Tosdic, Centum XL & centum cs3000 DCS, Honeywell TPS DCS.

 Trained operating personnel by giving presentations, lectures / online training etc in various aspects of the process plants, advanced process control and new technologies/projects.

 Strong industry specific knowledge in Oil & Gas and Petrochemical industries.

 Handling various administrative functions related to the personnel of the department.

 Familiar with Hazop studies, refinery economics etc

Work experience

 August 1993 to March 2001: In charge of the entire operations and the process engg aspects of Fluidised Catalytic Cracking Unit (FCCU) Complex comprising of High vacuum unit, FCC unit, Gas Concentration Unit, Merox (LPG and Gasoline) units, Amine treating unit, Sour water stripper unit, Sulphur Recovery Unit, Carbon Monoxide (CO) Boiler, 1.5 MW Turbo Generator etc.
o In charge of the revamp of FCC unit for capacity augmentation / yield optimisation.
o Implemented advanced process control (DMC Plus) in FCCU complex in Feb-August 2000.

 March 2001 to September 2004: In charge of Scheduling & Blending Operations.
o Team member in the implementation of Offsite Automation project and Manufacturing Execution Systems applications in 2001- 2002.

 September 2004 till date: In charge of Operations and process engg aspects of Aromatics Complex comprising of Reformer feed unit, Naphtha Hydro desulphurization unit, Catalytic reforming unit, Aromatic recovery unit, fractionation(High purity Benzene and Toluene)unit, Methyl tertiary Butyl Ether(MTBE) unit, New Solvent(Hexane & Special Boiling Point Naphtha) unit, Nitrogen plants, Cooling water system network etc o Team member in the revamping of Catalytic reforming unit in 2005

Roles And Responsibilities:

 As the in charge of FCCU / Aromatics complexes, the job involved o Continuous monitoring of various plants parameters for ensuring smooth plant operations, yield optimization (LPG, Gasoline, Heavy Reformate etc) and achieving the dynamic processing and production targets set by the refinery scheduling & planning dept.

o Analyzing the plant parameters, laboratory sample results etc to check, predict and rectify the plant problems.

o Trouble shooting of the day-to-day process upsets due to process or non-process conditions / equipment problems. Use of Simulation to analyze/predict plant conditions/parameters.

o Conducting test runs in various plants for generating data on quarter yearly basis.

o Handling plant upsets, emergencies and bringing the plants back on stream safely in the minimum possible time with minimum off grade product/streams generation.

o Provide and initiate innovations / modifications in the existing plant design and hardware for enhancing plant productivity, yield improvement, energy utilization, minimizing equipment downtime and operating cost, enhancing process control and monitoring.

o Optimizing the consumption of utilities, catalysts, lube oils and chemicals by constant monitoring.

o Energy conservation and Minimization of fuel and loss on shiftly basis.

o Implemented the Advanced process control (DMC Plus) in FCCU complex through the various stages like identifying the controller objective functions and the variables like MV/CV/FF, preliminary plant test [pretest], plant test, model identification, assisting in DMC model building, offline simulation, controller configuration, commissioning of the controller, provide operator training, ensuring the running and maximizing the uptime of advanced control systems.

o Review and optimization of operating procedures, advanced process control systems, seek economic applications of new technologies, monitoring and control of corrosion control in plants, monitor and strive for economic performance of the plants.

o Maintaining the plant, systems, records as per the norms for the compliance of ISO 9002,/SO 14002 / OISD etc. Worked on requisite norms to achieve ISRS safety rating of 8.

o Involved in Hazop studies, safety audits, ISO 9001: 2001, ISO 18001: 1999, OHSAS 18001:1999 audits of process plants. Involved in the pre assessment studies/audits /documentation for OHSAS 18001:1999 certification for BPCL.

o Implemented Aspen Process Explorer software for plant monitoring and designed the graphic pages for the same, created various data monitoring files in MS-Excel (configured with Aspen Process explorer) for plant monitoring/calculation purposes.

o In charge of the entire revamp the FCC unit (UOP) and Catalytic Reforming Unit. Involved working with licensors/consultants, P&ID reviews, handing over the plant for revamp, preparations of checklists, operating manuals and procedures, training of operations personnel, pre commissioning, commissioning and stabilization of the units.

o Undertake planned plant turnaround (shut down). Preparing various procedures like shut down / start up / chemical cleaning / catalyst regeneration / Furnace decoking etc, handing over of the equipments/process lines after freeing the hydrocarbons for maintenance / revamps / modifications & subsequent start up the unit conforming to the time bar charts.

o Supervision of day to day routine shift activities (pump change over, exchanger change over, regular maintenance/check list job, catalyst loading & off loading, chemical injection o Operating as well as start up knowledge of major equipment viz. wet gas compressors, main air blowers, recycle gas compressors.

o Taking charge/responsibilities of the different areas and operating positions in the process plans like panel operator, field operator etc in the event of contingencies, unmanned conditions and emergencies.

o Delivered lectures/gave presentations, trained plant personnel on various topics on FCCU, SRU, CRU, Advanced process Control, Safety, ISO standards, MES Applications, Plant revamps etc.

o Presently involved in the P&ID updation /review of Aromatics complex

 As in charge of Scheduling and blending section, the job involved o Planning and scheduling of the crude oil receipts, product deliveries, various intermediate products for the right product mix, communication between the various units for the smooth functioning of the Refinery, ensuring the right mix of crude oils for processing to increase the gross margins, preparation of the product batches with minimum time delay and strict adherence to the delivery schedule, monitoring the give away in product batches, minimization of the off grade inventory generation owing to the plant emergencies monitoring the losses involved during the receipts of crude oil and deliveries of the finished products.

o Enabled monitoring of tank farms in the plant and at the terminals for logistics management, using spreadsheet models.

o Preparing inputs in co-ordination with the supply chain group as regards the crude availability, crude blends, products off take scenario and plant capabilities/constraints for the short/medium/long term business plans.

o Worked on Loss reduction strategies for interplant product movements. This involves mapping the Business process for various Plants, tank farms, Dispatch section, and oil accounting o Analysis of daily Gross refinery margin and Quality give away.

o Preparing and Making technical presentations for various forums on the refinery products, technical capabilities etc.

o Faculty member for training the Panel operators / other users on the Software applications.

o Finalizing the operational philosophies vis-à-vis operations, control logic and Blending schemes review for the oil movement and storage areas with various vendors like Aspentech.

o Made a continuous blend properties prediction model in MS-Excel, which was being used for the predicting and testing the blends.

o Trouble shooting in the Oil movements / tank farm area, with the support of Engineers & Operators. Compliance with all HSE related matters.

o Implemented Yokogawa's Fuel Manager, to automate the inventory gauging system in storage tanks.

o Provided basic data, field support and procured infrastructure for Fuels Manager system.

o Implemented SAAB radar gauging system to automate the black oil tank gauging o Commissioning new Motor Gasoline online analyzer and Furnace Oil blend analyzer to optimize the product blend and to reduce the cycle time o Involved in implementation and testing of AspenTech products OMS, Process order, process explorer, MES-SAP connect.

o Trained more than 50 end users in using various functionalities of AtOMS, SAP LIMS system and its importance.

o Interacting with Operation department users comprising of Production planners and schedulers, for mapping the as-is and to be planning processes based on various planning scenarios and specific user requirements o Designed various reports for analyzing everyday cut off inventory levels for keeping track of material movements accurately for the purpose of reconciliation o MES- ASPENTECH oil movement and supplies implementation team member Designing and incorporating various scenarios of oil movements from crude oil receipt to final product delivery from storage tanks. Designed various reports for analyzing everyday cut off inventory levels for keeping track of material movements accurately for the purpose of reconciliation

PERSONAL DETAILS:

Date of Birth: 2nd April 1970
Sex: Male
Marital Status: Married
Nationality: Indian
Languages Known: English, Hindi, Malayalam, Marathi, Tamil.
PASSPORT No: A 3240511

Academic Summary:

o B.Tech in Chemical Engineering from Laxminarayan Institute of Technology, Nagpur in 1993.
o Advanced Diploma in Business Management from IIAM, Mumbai.
o HSC (Maharashtra Board) from Guru Nanak Higher Secondary School, Mumbai.
o SSC from Central School Koliwada, Mumbai (CBSE).

Computer/Software Knowledge:

o Operating Systems: Windows98/ME, Windows 2000, Windows NT 4.0, DOS
o Languages: Basic, Java & Advaced Java,C, C+, HTML, DHTML, Web Page designing o Software Applications: MS Office, UniSim/HYSIS version 3.5, SAP Various applications of Manufacturing Execution systems like PIMS, ADVISOR, LIMS, OMS, Aspen process explorer, DMC Plus etc.

Training courses attended:

o FCC Symposium by UOP in Nov 1997.
o Course on "Catalytic Reforming Process Technologies and Clean fuels" by Petroleum Processing Consultancy Centre in 25-27th July 2006.
o Workshop on "International Trade" in April 2005.
o Course on " Fluidised catalytic cracking" by Shell global solution, Holland.
o Course on "DMC plus" by Aspen Tech technical support, Japan in March 2000.
o Course on " Pressure Swing Absorption" by UOP in June 2004.
o Workshop on "Fugitive Emission monitoring and Control" in Sept 2003
o Auditors course for OHSAS 18001:1999 certification o Various other training programmes on safety, personal developments, ISO 9001,ISO 14001 and OHSAS 180001, TPM etc o Course on "Steady State Simulation using UniSim (HYSIS Technolgy Ver 3.5)" in June 2007.

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