Engineer Plant

Objective

Seeking a challenging position and continue my advancement in the field of

Process/Production Engineering in Petrochemical Industry, in which I am

working since more than 25 years.

Summary

. More than 25 years of diversified experience in various positions as

production engineer/supervisor, Process engineer etc in a large

petrochemical plant.

. Seven years of experience as a Sr. Production engineer in

Petrochemical Plants.

. Ten years of experience as a production engineer/shift in charge of

Petrochemical and Ammonia Plants.

. Five years of experience as a process engineer for Petrochemical and

Ammonia plants projects.

. Two years of experience as a project engineer for Petrochemical and

Ammonia plants.

. Two years of experience as a commissioning engineer in Petrochemical

Plant.

. Successfully completion of project right from procurement through

implementation, commissioning and smooth operation.

. Training and interactions with process licenser M/s BASF at their

production facility in Germany and Belgium.

Technical Skills

. Worked in various positions in petrochemical plant production i.e.

Plant Manager, Shift in charge and DCS engineer.

. Handled all types of Unit Operations and Unit Processes in highly

complex Petrochemical plant involving highly toxic and hazardous

chemicals.

. Responsible for consistent quality products with minimal deviation as

per customers need and to make continual improvement as per growing

expectation of customers as per ISO 9001 guidelines.

. Responsible for environment concerns as laid out by ISO 14000

guidelines, identifying various environmental aspects which may affect

environment and studied in detail their impact on environment, check

the existing control measures, identify the gaps etc.

. Responsible for OH & S concerns as laid out by ISO 18000 guidelines,

with hazards identifications based on their likelihood of occurrence

and possible severity and carried out Risk Assessment.

. Make organized and meaningful report based on data and observation.

. Computer proficiency in Microsoft Excel, Word Document, PowerPoint,

Access, Internet Fundamental, sequel server, DBQ, DBMS etc.

. Worked as process engineer for a petrochemical plant reviewing

customer drawing and specifications, sizing and select all equipments,

preparing P & ID and process flow diagrams.

. Actively involved in preparing equipment layout design, in preparing

estimates and developing quotations during project stage.

. Resolved technical problem regarding construction and design,

monitored and controlled process parameters and conditions to achieve

optimum quality and throughput with higher efficiency.

. Actively involved in process modification and alterations for trouble

shooting actions, from basic engineering to heat/mass balances.

. Participated in P & IDs freezing with process licensers, lead a team

for preparing punch list of P & IDs with detail engineering

contractor.

. Monitor environment checkpoints i.e. stack contents, liquid effluent

conditions and take corrective actions if required.

. Successfully lead a team in commissioning of petrochemical plant right

from flushing activities to trial runs with desired throughputs and

achieving product specifications.

Professional Experience

Ferro Corporation, South Plainfield, NJ

Pilot Plant Operator

04/2012 -

11/2012

I was promoted and given individual charge of Pilot Plant where my

responsibilities were: -

. Initiating batch operation in Pilot Lab. Based on laboratory scale

trials.

. Establishing critical parameters like flow rates, quantity of raw

materials, operating temperatures, pH, reaction timings etc in

consultation with R & D scientist.

. Arrange required quantity of raw materials, check their

acceptability with all required specifications, expiry dates etc.

. Take samples at various stages of reactions, analyses them in

laboratory and take corrective actions in process parameters based

on deviation in results.

. Discuss these analysis and corrective actions with scientist to

enable him to consider further course of action in subsequent

batches.

. Filter, wash, dry the batches, find the yield and transfer the

result to production group.

. Interact with customers, get their feedback about our product and

take corrective actions based on it.

. Summarize all data in MS excel, MS access and correlate them for

different batches and products.

Ferro Corporation, South Plainfield, NJ

Production Operator

03/ 2011-04/2012

After my immigration to USA, I started my first job in New Jersey where my

family is settled wherein I was responsible for: -

. Attending daily shift meeting in beginning of the shift and taking

instructions and planning schedules during the shift.

Implement this schedule and if any deviation, inform Plant

Supervisor with reasons.

. Initiating batch operation for making noble metal complexes,

controlling feeds, reaction progress and monitoring from

computerized panel.

. To see that all persons working with me uses all personal

protective appliances like hard hat, goggles, face mask, face

shield, gloves and protective clothing required to perform the job

depending on materials handled.

. Avoid loss of precious material that we are handling like silver,

palladium etc by precision working while decanting solvents,

cleaning vessels, delumping dried powder etc.

. Achieve product quality by feeding right quantity of materials,

maintaining correct parameters as per standard operating

procedures.

. Monitor on daily basis, all required raw material stocks available

and make necessary arrangement for next day wherever required.

. Monitor all effluent streams and toxic exhaust generated and to

ensure that these streams and exhaust are diverted to assigned

destinations.

. Monitor that all processes are progressing under established safety

margins in concentrations, temperatures, pressures etc, to avoid

any untoward incidences.

. Analyze any deviations from set procedures for timely actions and

inform such deviations to team leader.

Gujarat State Fertilizers & Chemicals Ltd,

Vadodara, India.

Sr. Production Engineer, Caprolactam-II Plant

06/ 2003-10/2010

I was promoted, transferred back to operation group as in charge of plant

with responsibility as: -

. Planning of daily, weekly etc targets, organize resources required

and implement successfully.

. Organize daily production meetings, discuss loopholes in

implementation of planned schedules.

. Identify manpower requirements and decide workforce scheduling.

. Liaison with other departments, contractors, agencies etc.

. Conduct monthly safety, health & environment committee meeting and

discuss issues involved and remedial actions required.

. Tackle labor and work related issues.

. Conduct monthly safety, health & environment committee meeting,

discuss issues involved and take remedial actions required.

. Watch for raw material and utility consumption figures and take

corrective actions to keep them in range whenever and wherever

needed.

. Make reports identifying routine bottlenecks and remedies, discuss

such solutions with technical, design and other concerned

departments.

. Planning / scheduling of various activities related to plant

modification.

Gujarat State Fertilizers & Chemicals Ltd,

Vadodara, India.

Process Engineer, Caprolactam group of Plants

08/ 1998-06/2003

After successful commissioning of Caprolactam-II Plant, I was transferred

to Process Engineering group and was responsible for: -

08

. Review customer drawing and specifications.

. Size heat transfer, drying, pumps, blowers, compressors and other

equipments.

. Select and size auxiliary equipments.

. Preparation of Process Flow Diagrams (PFDs), Process &

Instrumentation Diagrams (P&IDs), piping and equipment layout

specific to the system.

. Use process engineering simulation software CHEMCAD to perform

engineering calculations, choosing chemical components, specifying

feed streams, unit operations, size equipments, investigate cost

estimates etc.

. Prepare equipment layout design.

. Prepare estimates and develop quotations.

. Development of Equipment summary, Control valve summary, utility

summary Battery limit summary.

. Calculation of relief load, relief valve sizing and restriction

orifice sizing.

. Conduct laboratory and pilot testing, analyze data and submit lab

reports.

. Responsible for process development and project engineering.

Gujarat State Fertilizers & Chemicals Ltd,

Vadodara, India.

Commissioning Engineer, Caprolactam - II Plant

03/ 1996-08/1998

During commissioning of new Caprolactam plant I was made a part of

commissioning team and was working in following area: -

. Training at BASF Caprolactam plants at Antwerp, Belgium &

Ludwigshafen, Germany for 2 months in commissioning activities and

day to day plant operation and trouble shootings, with BASF team

which was subsequently involved in commissioning of GSFC

Caprolactam-II Plant.

. Punch-listing of P&IDs for corrections, alteration as per the

physical orientation and operatability.

. Preparations of check list/ Piping / Equipment

. Preparations of loops for flushing / cleaning and lead a team for

actual flushing /cleaning activities.

. Hydro testing / Leak test of various loops / equipment

. Commissioning and GTR of various machineries along with the process

licenser team of M/s BASF and other package vendors.

. Water run, Plant startup and GTR

Gujarat State Fertilizers & Chemicals Ltd,

Vadodara, India.

Project Engineer, Caprolactam - II Plant

09/ 1994-03/1996

I was selected for project of commissioning of new Caprolactam plant and

was working in following area: -

. Coordinating of all technical activities on Petrochemical and

Ammonia plants project.

. Actively participated in fridge in P&ID and PFD with process

licenser M/s BASF at Germany.

. Involved in procurement activities of reactors, vessels,

distillation columns, heat exchangers and process valves.

. Carried out mass and energy balances across various equipments of

the plant like distillation columns, heat exchangers and reactors.

. Developed Standard Operating Procedures (SOP) for process units of

the plant.

. Checked PFDs and P&IDs of the plant and suggested modifications.

. Performed Hazard and Operability Studies (HAZOP) analysis for

process units.

. Ensure effective communication and coordination on assigned

projects between all disciplines and all other project

participants.

Gujarat State Fertilizers & Chemicals Ltd,

Vadodara, India.

Production Engineer, Caprolactam - I Plant

08/ 1989-09/1994

I was promoted and was working in day shift and was responsible for

following: -

. Make reports identifying routine bottlenecks and remedies.

. Discuss such solutions with technical, design and other involved

departments.

. Take approvals from seniors and implement the same.

. Take various steps possible to optimize raw material & energy

consumptions.

. Execution of Plant Shutdown activities. Co-ordination with various

agencies for shutdown related activities.

. Tackle issues of Distributed Control System (Centum-XL of Yokogawa

Keonics Ltd, Japan) with Instrumentation department.

. Control raw material and utility consumptions figures and take

corrective actions to keep them in range.

. Train new joiners for smooth assimilations in plant operations and

implement use of personal protective appliances while performing

various jobs in hazardous conditions by self example.

. Monitor environment checkpoints i.e. stack contents, liquid

effluent conditions and take corrective actions if required.

. Involved in overall supervision of shift activities like

controlling process parameters and conditions, quality control,

improvement in efficiency of the plant, reducing effluent

generation and routine maintenance of chemical equipments.

Gujarat State Fertilizers & Chemicals Ltd,

Vadodara, India.

Assist. Production Engineer, Caprolactam - I Plant

11/ 1984-08/1989

After successful training at graduate engineer, I was given charge of

rotating shift in Caprolactam-I Plant and was responsible for: -

. Handling of routine plant operation during the shift.

. Handling of various emergencies (Power failure, Utility failure,

Leakages, unsafe operations etc)

. Preparation for carrying out maintenance/ breakdown jobs.

. Organize safe isolations and prepare different permits for handing

over such jobs.

. Enforce use of personal protective appliances while performing various

jobs in hazardous conditions by self example.

. Attend daily production meetings; discuss loopholes in implementation

of planned schedules.

. Identify routine jobs to be taken up with various departments &

agencies.

. Identify process upsets in advance and take corrective actions to

avoid downtime.

. Train new joiners for smooth assimilation in plant operations.

. Handling of routine plant operation and various emergencies during the

shift, preparations of carrying out maint/breakdown jobs.

. Worked closely with operators and engineers to develop a plan to

improve production by fine tuning feedback control loops on DCS

system, changing operating parameters, and reducing down time due to

frequent pipeline and flange joint leakage of heat-exchangers and

distillation columns by preventing corrosion.

Professional Training

. Dimethyl Monophthalate Plant operation, IPCL, Vadodara, India.

. Ammonia/Urea Plant operation, GSFC, Vadodara, India.

. Distributed Control System, Yokogawa Keonics Limited, Bangalore,

India

. Caprolactam Plant operation training at BASF Plants at Ludwigshafen,

Germany and at Antewerp, Belgium.

. IBM-PC & its application, MS office, MS Sequel Server, at GSFC,

Vadodara, India.

. Integrated Management System, at GSFC, Vadodara, India.

. SAP Training at GSFC, Vadodara, India.

. Process Technology course by Ferro Corporation, South Plainfield, NJ,

USA.

.

Education

. Regional Engineering College BS in Chemical Engineering

June, 1983

(Rourkela, India)

Miscellaneous

. I am a Lawful Permanent Resident and legally authorized to work in US

on a regular full-time basis without restrictions.

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