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TOP MANAGEMENT CANDIDATE
Preferred Function: Project Management/ Maintenance/ Business Development
Preferred Sector: Refinery/ Oil & Gas
Chief Manager (Maintenance In-charge) offering 25+ years experience in Refinery Maintenance, Project & Operation; and currently associated with Numaligarh Refinery Limited, Golaghat, Assam.
* Knowledgeable in applicable codes such as ASME, ANSI, ASTM & API
* A certified auditor & implementer of ISO-9001, 14001 & OHSAS-18001, International safety rating system of DNV. Extensive experience in Refinery Projects (from concept to commissioning of complete Units to part commissioning and expansion, revamp and debottlenecking jobs under $250 million)
* Expert in refinery safety system, internal safety audit modulator, maintenance of all types of Refinery equipment (both stationery & rotary), Turn-Around, Management system, Technical and safety audits, energy audits, negotiating with labour unions.
TECHNICAL SKILLS
* Delayed Coker Unit Maintenance: Expertise in maintaining the unit involving all day-to-day problems like:
1. Coke cutting system (in de-coking Jet pump, Main/ bypass valves, Kelly system, top & bottom cover box-up system, 4 –way Wilson-Snyder valves, coke cutting / boring tool, Combi-tool, chute, Coker-drum jobs, Grab-crane, sump-pump, ramp, Conveyor-belt, Coke yard, Vibro-feeder etc)
2. Coker furnace tube replacement, decoking of feed-line, vapor-line & transfer lines, Quench-column & related lines and pumps
3. Fractionator feed & Quench-column bottom pumps, other equipments like condenser, cooler, exchanger (capable of retubing any tube-bundle), column (with all types of revamps, shell cutting job etc)
4. Vessels, Coker off-gas compressor (with all types of overhauling replacement of seal, rotor, bearing etc); Air-fin coolers, fans, Clarifier, Thickener, PSV, TSVs, Refractory replacement of heater, Soot-blower, Burner maintenance etc.
* Expertise in erection/ commission and maintenance of Hydrocracker & Hydrogen Maintenance: All rotary, static equipment and piping were fabricated, erected and commissioned successfully. During precommissioning stage all rotary equipment were revisioned, catalyst loading ( dense loading )and inspection of internals of reactors, adjustment of supports, pipelines were flushed, punch-list jobs were attended, pressure-testing jobs were attended.
As a part of maintenance, overhauling of all types of pump ( single / multi stage, plunger, dosing, metering, reciprocating, Sun-dyne ), reciprocating compressors (make-up / off-gas compressor), centrifugal compressors (Recycle-gas compressor ), Airfin cooler, fan ( replacement of bearing housing, change of blade angle, continuous vibration monitoring etc ), heat-exchanger / condenser / reboiler of all types including breech-lock, fired heaters ( burner maintenance, refractory lining, shoot-blower maintenance, damper / duct maintenance, FD & ID fan maintenance with fluid coupling, installation of mist-lubrication, vibration monitoring etc ), reformer furnace H2U ( tube replacement, burner maintenance, catalyst replacement etc ), filter, PSV / TSVs maintenance, filter maintenance, all types of hook-up jobs involving hot-tapping machine at certain location etc.
* All maintenance activities pertaining to Sulfur Recovery Block (consisting of Stip-water System, Amine Regeneration Unit & Sulfur Recovery Unit). Maintained equipments like Columns ( valve-tray, packed bed, installation / revamp / repair etc ), Fired-heaters ( expertise involves burner trouble-shooting, refractory repair ), reactors ( replacement of catalysts, molecular sieves etc ), sulphur-locks, vessels ( weld-overlay, cladding etc including maintenance of level-gauges, level-troll etc ), tanks ( epoxy lining of inside wall ), pumps of all types, filters, pipeline ( all type of maintenance with adjustment of supports, repair & replacement, relaying both over-ground and underground with maintenance of valve etc ), steam-traps ( all types of maintenance & replacement based upon condensate load study etc ), heat-exchangers, reheaters and condensers ( all types of maintenance which include hydro-blasting, testing, plugging of leaky tubes, re-tubing of bundle etc ), Waste-heat boilers, structural jobs etc
* Crude-Distillation & Vacuum Distillation Units: Maintaines equipments like Columns ( valve-tray / packed bed ) expertise installation / revamp / repair etc, Fired-heaters ( both cylindrical & box-type ; expertise involves burner trouble-shooting, refractory repair, radiant & convection section tube replacement, soot-blower maintenance etc ), vessels ( weld-overlay, cladding etc including maintenance of level-gauges, level-troll etc ), pumps of all types, filters, pipeline ( all type of maintenance with adjustment of supports, repair & replacement, relaying both over-ground and underground with maintenance of valve etc ), steam-traps ( all types of maintenance & replacement based upon condensate load study etc ), heat-exchangers ( all types of maintenance which include hydroblasting, testing, plugging of leaky tubes, retubing of bundle etc ) etc.
* Tankage, Flare-gas systems Horton sphere, Power plant & Utility system: Maintenance of all types of tanks ( floating roof, fixed roof, fixed cum floating roof ) of all classes ( job involved adjustment/ replacement of seals, weather-protector, cleaning of tanks, maintenance of tank-mixers, foam-line etc ), maintenance of flare-line, acid-gas line, maintenance of Horton-sphere including maintenance of breather-valves, Relieve valves etc, maintenance of both elevated and ground flare including replacement of flare burner, cleaning of molecular and water seal etc, maintenance of Fire-water / cooling water pumps, cooling tower, effluent treatment equipment, utility compressors ( centrifugal 3 stage, 3 numbers for plant air and one reciprocating for instrument air ) maintenance of Gas Turbines (2x30 MW, Frame-6) which includes boroscopic inspection, HGP inspection, major inspection which involves replacement of nozzle, bucket, transition piece, etc and other equipment and auxiliaries of power plant.
* Turn Around Management: Directly handled around 100 small (Single Process Unit) & big (multi Unit involving revamps) turn-around, out of which atleast 40 numbers as Key Coordinator and 60 numbers as Turn Around Manager. In the last four Turn Arounds was the Refiner in-charge where all the Units (CDU/VDU, DCU, H2U, HCU, SRU, CPP, UTY, Offsites, Project hook-ups (around 152), ETP etc and lot of revamps were taken up Almost all T/As were completed with great success without any mishaps.
* Project Experience: Erected and commissioned HCU & H2U (licensor Chevron, USA); completely erected & commissioned Motor Spirit plant which was licensed by Axenx of France, M/s Toyo Engineering India Ltd was the PMC & M/s Larsen & Toubro was the main EPC contractor. Coordinated with all functions like Mechanical, Electrical, Instrumentation, Civil, Operation & Technical Services groups apart from Maintenance groups. Co-ordinate with licensor, PMC, EPC contractors, Statutory bodies for all types of project activities from pre-feasibility report, finalization of design basis, finalization of equipment vendor, line up contractors, finalization of equipment specifications, negotiate with vendors, contractors, conduct daily meetings with vendors/ contractors to expedite job-progress, coordinate with Tech. services, safety and other departments to resolve various issues, arrange to carry out periodic safety audits and liquidate any short-falls, conduct fortnightly / monthly progress meetings, give presentation to Apex body members apprising job-progress and highlight them about various hurdles, propose for various approvals, implement changes, take crash procurement / resource mobilization / vendor follow-up, resolve site-related labour unrest etc to complete the project before schedule including carrying out pre-commissioning jobs and commission the plants one by one following all safety and statutory norms and finally arrange for GTR and carry-out capitalization of all assets in SAP and closing of contracts and Pos etc.
The project was successfully commissioned within cost & time constraints.Partly seen all types of civil construction jobs under AFE, installation of a river-jetty with product pipeline tap-off job along with marketing Y dispatch terminal. Currently overseeing the entire Maintenance Department as Chief Manager (Maintenance-I/C) which includes departments like Mechanical, Civil, Electrical, Instrumentation Maintenance and Maintenance Planning.
* ISO / OHSAS / ISRS Systems: Subject matter expert in the field; instrumental in facilitating the organization to get accreditation of all the prestigious certificates in record time and presently recipient of prestigious level-9 of ISRS system which is very rare in the industry.
WORK EXPERIENCE
Numaligarh Refinery Limited, Golaghat, Assam, Jun 1998 onwards
Career path:
Sr.Project Manager, 1998 to 2001
Chief Maintenance Manager (Mech & Civil), 2001 to 2004
Chief Manager (Operation-Refy), 2004 to 2005
Chief Manager (Project), 2005-2007
Chief Manager (Maint-I/C), June 2007 onwards
Achievements
* Repaired a 3.3 MW motor inhouse during HCU project which was declared damaged by vendor (Ansaldo) expert (the motor toppled during transportation) saving purchase of a new motor costing around $ 0.3 milllion.
* Replaced a blower in SRU by modifying,designing, piping eliminating recurring plant outage due to breakdown and power consumed by the driver.
* Commissioning of Isomerization (which enabled prodution of EURO-III MS) was enhanced by seven months by design and installation of a steam heater in place of electric heater with saving of $ 15 Millions.
* By adopting systematic & improved methods, fabrication of piping (including HP impulse piping), quality acceptance method, hydrotesting, loop (instrument lines) testing & inspection procedure, accurate planning, daily meetings, mechanical completion was expediated by atleast two months.
* By implementing mist-lubrication in critical ID/FD fan fluid-couplings, (reliabilty of heaters were improved), reduced tripping and saved lot of lube-oil leaks & bearing life; with net saving of around $ 2.5 Millions.
* Installed stepless regulation ( from M/S Hoerbiger, Austria ) in one make-up compressor of HCU thereby facilited operation of these compressors matching capacity of the plant requirement which was earlier operated at steps incurring continuous venting / running the compressor at a higher capacity than required.
Responsibilities
Reporting to the SR. G.M / Advisor, and lead 65-Officers & 150 Staff( Non-Officer)
* Leading the project mechanical group to erect & commission all mechanical equipment, piping of hydrogen & hydrocracker plant including preparation of hardstand for 600 T crane movement for lifting ultra-heavy reactors, vessels, heavy schedule piping, heaters, stacks, all rotary equipment etc at the initial stage.
* Carrying out stage wise all precommissioning activities like solow-run of all rotary equipment after shop revisioning, stage-wise leak-testing of all pipings & loops after making all arrangements for card-board-blasting and flushing and finally commission both the units without any leak, fire or accident.
* Commissioning the CDU/VDU, DCU, SRU and all utility equipment.
* Developing the mechanical, civil and planning department which includes buying all infrastructure machines like lathe, milling, grinding etc, welding generators and other accessories, train technicians for qualifying welders certification for variety of jobs, carrying out retubing of exchanger retubing job, training technicians for rotary and condition monitoring job etc; line up contracts for all types of AMC jobs, training officers for all jobs connected to documentation, recording of history card, preventive maintenance schedule, ISO/OHSAS system etc.
* Preparation of revenue / AFE budget, contingency plan, spare parts / inventory management, execution of AFE jobs, plan for turn around jobs etc. Working in SAP environment.
* Carry out all types of in-house audits like safety, energy, ISO, ISRS, OHSAS etc execution of jobs emerging out of all audits at the earliest. Finally facilitate necessary assistance for all types of external Govt. Audits, national contests, certification & recertification for ISO/OHSAS & ISRS audits.
* Preparation of board notes, proposals, give presentations, accord approval, give guidance to various operating heads to match their unit product mix with marketing, take necessary measures to reduce fuel & loss, increase yield etc.
* Plan, execute and control turnarounds as overall TA Coordinator for ten times where all unit, utility and power was taken shut simultaneously. All of the TAs ended without any time or cost over-run and without any accident or fire.
* As incharge of maintenance give necessary guidance to all departmental heads of Mechanical, Instrumentation, Electrical, Civil & planning for day-to-day and long term activities.
BONGAIGAON REFINERY & PETROCHEMICAL LTD, DHALIGAON, ASSAM
Graduate Engineer Trainee To Maintenance Manager (Mech-Refy), Dec 1982 to Jun 1998
Achievements
* Could reduce commissioning of CDU & DCU by 22 & 18 days compared to plan, saving around $ 10 Million
* Carried out CDU revamp job for capacity enhancement and incorporated SAD facility without engaging any EPC contractor saving around $ 5 Million
* Retubed around 70 exchanger bundles saving around $ 5 million
* Carried out around 35 turn arounds before time ( average two days ), with net savings around $ 12 million.
Responsibilities
* Reported to the General manager ( Refy & Pet.) and headed 100 employees.
* Planned and executed routine breakdown, preventive maintenance jobs of units like CDU, KTU, DCU, CCU & off-site areas of the refinery for all types of rotary and stationary equipment / piping keeping unplanned breakdowns to minimum.
* Analysed root cause of any breakdown or problem and take corrective actions at the earliest.
* Raised material indents for all types equipment and piping maintaining minimum average inventory & no-stockout condition. Prepared contract proposals with estimates, obtained approvals, participated in negotiation meetings with contractors, finalized the contracts, executed the jobs through them following strict safety and quality norms, prepared the bills after taking measurements, recommended for payments and closed the contracts.
* Prepared Revenue, Purchase & Non-Plan Capital Budgets, presented them to management for approval, and carryied out the jobs with proper control.
* Maintained records of all activities including the history card, PM card, breakdown reports, back-log statement, ISO and safety documents; prepared resource planning for liquidation analysing the jobs as per work order issued and priority.
* Maintained departmental staff overtime to minimum, planned for their development training, imparted inhouse and external functional trainings, conducted periodic safety and ISO audits and conducted plant-level safety meetings, energy audits and took corrective actions to minimize fugitive emmisions to minimum.
* Managed Turn around as mechanical coordinator around 20 times and as overall coordinator around 50 times. Prepared for the turn-arounds of various units and execute them as per plan without any time and cost over-run or fire & accidents.
* Assisted in smooth commissioning of new units, attended to various leaks and carried out the necessary modification jobs as suugested by process.
ASSAM STATE ELECTRICITY BOARD, LTPS, MAIBELLA, ASSAM, INDIA
Assistant Engineer (Generation), May 1982 to Dec 1982
Achievements
* Averted loss of power generation due to critical reasons through timely actions.
Responsibilities
* Reported to the Project manager and led a team of 20 emloyees
* Was shift-in-charge of a 16 x 2 Westinghouse make gas-turbine operating unit.
* Ensured stable power supply to the grid without any frequency / voltage fluctuation.
* Maintained law & order amongst all working persons with discipline.
TRAININGS UNDERGONE
* Two weeks training in 'Advance Management' by ICPE, Slovenia that included industrial tours to countries like France, Germany, Belgium, Switzerland, and Italy etc.
* Several trainings on ISO, ISRS by DNV
* Many trainings on Management and technical subjects like Finance, Personnel, PERT/CPM, Prima-vera, TA, IR, Failure –Analysis, Remaining-life analysis, Condition Monitoring, Preventive & Predictive Maintenance, Vibration analysis, Compressors, Seals, packing, bearings and many others.
EDUCATION
B.E (Mechanical), Jorhat Engineering College, Dibrugarh University (1981)
PGDBM, All India Management Association, New Delhi (1989)
PERSONAL INFORMATION
Date of birth: 1 January 1957
Language Skill in: English, Hindi, Bengali and Assamese
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