Engineer Plant

Rajeev Kumar Shishodia

AMMONIA PLANT & UTILITIES - SHIFT SUPERVISOR / DCS PANEL INCHARGE

CHEMICAL PLANT OPERATION PROFESSIONAL

SEEKING A CHALLENGING POSITION AS A SHIFT SUPERVISOR / DCS PANEL OPERATOR /

PROCESS OPERATION ENGINEER / PROCESS COMMISSIONING ENGINEER / PROJECT

ENGINEER / POWER PLANT OPERATION ENGINEER WITH LEADING PETROLEUM / OIL &

GAS / FERTILIZER / CHEMICALS & ENERGY SECTOR COMPANIES

Personal Details

NAME: RAJEEV KUMAR SHISHODIA

D.O.B: 10th of January, 1978

Address: TCL Township, Phase: 3, H.No: 80, Tata Chemicals Limited

(Urea Complex)

BABRALA, District: Badaun, Uttar Pradesh, INDIA,

Postal Code - 242021

Mobile: +91 - 992-***-****, 941*******

Home: +91 - 583-***-****, 583-***-****

E-mail: ***********@*****.***, ***********@*****.***

Passport No: G-5148301 (Issued by Bareilly, INDIA Passport Office)

Marital Status: Married

Career Objective

IN THE PURSUIT OF A CHALLENGING POSITION IN AN ESTEEMED ORGANIZATION &

FINDING A SUPERIOR OPPORTUNITY TO EMPLOY MY DIVERSIFIED EXPERIENCE IN ALL

THE TECHNICAL AND MANAGERIAL FIELDS TO EFFECTIVELY SUPPORT THE OVERALL

GOALS OF AN ORGANIZATION BY PASSIONATELY FOCUSING ON DRIVING CUSTOMER

ORIENTATION IN MOST ENERGY EFFICIENT, ECO FRIENDLY, QUALITY CONSCIOUS &

COST SENSITIVE ACUMEN.

Executive Profile Summary

PRESENTLY FUNCTIONING AS PROCESS OPERATION ENGINEER HOLDING A CAPACITY OF

SHIFT SUPERVISOR IN AMMONIA PLANT & UTILITIES OPERATIONS AT STATE OF THE

ART FERTILIZER COMPLEX M/S TATA CHEMICALS LIMITED (UREA FERTILIZER COMPLEX)

BABRALA, INDIA AWARDED WITH PRESTIGIOUS MALCOLM BALDRIGE NATIONAL QUALITY

AWARD (JRDQV), ISO 9001:2000, ISO: 14001, OHSAS: 18001, ISO: 270001, SA:

8000, BRITISH SAFETY COUNCIL'S 'SWORD OF HONOUR', BSC 5 STAR IN EMS & MANY

MORE PRESTIGIOUS NATIONAL & INTERNATIONAL RECOGNITIONS IN BUSINESS

EXCELLENCE, HEALTH & OCCUPATIONAL SAFETY, ENERGY EFFICIENCY & ENVIRONMENT

CONSERVATION PRACTICES.

Key Skills & Practicum

WORKING EXPERIENCE OF ALMOST 15 YEARS INVOLVES:

> Smooth & Safe operation, troubleshooting, start up & shut downs of

Ammonia Plant & Utilities from DCS as well as from Field in rotary

shifts, production optimization & safe emergency handling of all

associated process units along with the responsibility of many

distinctive Project related assignments.

> Active partaking as Process cum Project Engineer in Erection, Pre-

commissioning / Commissioning, Start-up and Performance Test Runs of

different Ammonia Plant & Utilities process units including Fired

Heaters & Vapour Absorption Machines.

> Well versed with various Catalysts loading & unloading

procedures/activities in Inert Atmosphere for almost all the reactors

of ammonia plant. Also skilled in assorted Catalysts Reduction

procedures with practicum. Experienced in loading/unloading of Tower

Packing (in absorbers, regenerators, strippers etc.), Molecular Sieves

& Activated Alumina alongwith different Ion Exchange Resins in all

Ion Exchangers in water de-mineralisation plant.

> Also experienced in preparing SOPs, Manuals, Work Instructions for

different process operations and maintaining technical reports for

facilitating decision making by the management. Experience also

includes direction & follows ups with construction or maintenance team

to deliver the quality work on schedule, Manpower Management, Planning

of Maintenance & ATR activities, accountability for proper & safe job

execution, review of construction / modifications drawings &

specifications.

Experience & Detailed Work History Total

Experience: 15 years

TATA CHEMICALS LIMITED, UREA FERTILIZER COMPLEX, INDIA February, 1997 -

( Ammonia Plant & Utilities - As Shift Supervisor, DCS Present

Incharge & Field Operator )

Experience in Ammonia Plant Operations:

I started my career as a field operation engineer in year 1997 & presently

functioning in Ammonia Plant as a Process Operation Engineer holding a

capacity of Shift Supervisor / DCS Incharge. Plant is based on low energy

Haldor Topsoe Technology with a option to run on mixed feed (Natural Gas+

Naphtha) in any ratio. The centralized Distributed Control System (TDC3000,

Release 530) is supplied by M/S Tata Honeywell along with advance emergency

shutdown system (FSC). Recently the organization also has upgraded DCS with

integrated Advance Process Control technology (APC) supplied by M/S

Honeywell for superior & predictive controlling of critical process

parameter as an energy optimization initiative.

Plant is based on Natural Gas and Naphtha (Fuel & Feed) mixed process. By

design, plant's original ammonia production capacity was 1350 MT/day but

recently in year 2008, it has been augmented to 2000 MT/day through

Debottlenecking Project & various Equipment Retrofits. Presently, plant

consists of following process units-

> Natural Gas Skid & Distribution System

> Naphtha Pre Desulphurising Unit (NPDU)

> Adiabatic Pre-reforming section

> Natural Gas / Naphtha Hydro-desulphurization unit (Feed Gas

Sweetening)

> Natural Draft Fired Heaters for reformer feed preheating

> Tubular Steam Reforming section (Side fired reforming furnace)

> Reformer's Waste Heat Recovery Section (WHR)

> Catalytic Auto Thermal Reforming (ATR)

> Synthesis gas purification (CO shift conversion - MTSC & LTSC)

> Amine process system for Carbon Dioxide Removal ( Giamaarco -

Vetrocoke Technology)

> Conventional Catalytic Methnation section

> Ammonia Synthesis & Refrigeration Section

> Central Compressor House Area - Synthesis Gas Compressor, Process Air

Compressor, Ammonia Refrigeration Compressor, Flash Ammonia compressor

(Screw Type supplied by M/S Howden), Natural Gas Booster Compressor

> Ammonia Recovery and Cryogenic Purge Gas Recovery (PGRU) Unit

> Process Condensate Stripping Unit,Steam PRDS section & BFW

preparation area

> Vapour Absorption Machines (chillers) for synthesis gas cooling

Experience in Offsite & Utilities:

Also well hands on experience of process control & troubleshooting of all

Offsite & Utilities Plants through DCS as well as from Field includes:

Distributed Control System (Centralized): Hands on experience of process

control & troubleshooting of all O&U plants through centralized Distributed

Control System console - TDC 3000 ( Release 530 ) by M/S TATA Honeywell

including Emergency Shut Down system (FSC).

Captive Power & Steam Generation Plant: Mark-VI simulated, Frame-5 Gas

Turbines (2x25 MW) by M/S Thomassen, Holland including HRSGs (2x100 TPH).

Operation of dual fuel (NG & naphtha) Steam Boiler having a capacity of 110

TPH of HP steam generation by M/S Thermax Bibcock & Wilcox Company

Water De-mineralization Process & Raw Water Distribution: DM plant with a

capacity of 800 M3/Hr of polished water; supported by different resin base

anion & cation exchangers, mixed bed units, activated carbon filters &

effluent neutralization section.

Compressed Air Generation & Dehumidification process: Handling of two

multistage centrifugal air compressors by M/S Ingersoll-Rand, Germany & one

double acting reciprocating air compressor along with air dehumidification

adsorbers.

Cryogenic Air Separation Plant: Operational control of nitrogen generation

process (600 NM3/Hr) along with cryogenic inert liquid storage, distribution &

loading/ unloading.

Effluent Treatment Plant & Waste Oil Recovery Section: Operation of two

ammonia strippers. Controls of waste lube oil recovery unit & rainwater

harvesting pond.

Ammonia Gas Refrigeration, Storage & Distribution: Handling & Storage of

liquid ammonia; (2 X 5000 MT) well equipped with vapour reliquifaction units

facilitated by screw compressors of M/S Alfa Label. Distribution & loading /

unloading of liquid ammonia from road or railway tankers.

Flare Stack Systems: Operation & emergency handling of main flare stack

(reformer & synthesis gas blow down) & ammonia storage flare stack systems.

Cooling Towers (Urea & Ammonia): Operation & troubleshooting of two mega open

recirculatory, cross flow induced draft cooling towers & two counter flow

glass reinforced polymer made cooling towers commissioned by M/S Marley

Cooling Towers with cooling water supply pumps.

Naphtha Bulk Storage & Handling System: Storage & handling of naphtha storage

tanks (3X6300 KL) naphtha distribution system equipped with submersible barrel

pumps including unloading from railway tankers. Naphtha Tanks are having

Floating roof Pontoon Type with Neoprene Seal" Breathers, Roof drains are

located in the roof. Foam pourer and Water sprayers are provided for Safety.

Handling, storage & distribution of Chlorine Gas, Sulphuric & Hydrochloric

Acid, various Cooling Water Treatment Chemicals & operation of

Chlorine-Di-Oxide Generation unit.

Current Job Responsibilities

IN MY CURRENT ASSIGNMENTS, I AM RESPONSIBLE FOR:

Day to day's extensive operational / maintenance Jobs Planning and safe

execution including the issuing the Safety Work Permits (PTW) for routine

maintenance jobs, performance monitoring, optimization, trouble shooting and

coordination with various maintenance departments.

Primary accountability to Ensure / Implement Safe Work Practices by following

all safety, health, environmental and operation procedures.

Maintaining the Operations Integrity to meet Production Demand and effectively

Manage Expenses and to minimize the Production Cost.

Review all Facilities Data taken to be within the limit ranges to avoid

failure of facilities and create correction effort on any abnormalities found

and Implement work management procedures consistently at all time.

Creates Work Orders, MIVs, Store Request and Purchase Requisitions when

a facility needs repair, material from warehouse and a non warehouse stock

material is needed.

Creates reports, such as Production Reports, Safety Meeting Report, Incident

Report and other reports related to facilities failure.

Preparation of Checklists, Safe Operating Procedures (SOPs), carrying out Risk

Assessments (JSA), HAZOP studies, FMEA and ensuring robust safety standards at

the work place.

Ensures all Safety Facilities are available at site and in ready mode at all

time, and also responsible to organize Periodic Trial Run of all passive

drives / machines & keeping records of their status to maintain the integrity

of facilities.

Implementing various HSE Programs as per company & department

objectives/targets.

Timely and Safe start-up and Shutdown of ammonia plant.

Providing Operational & Technical Advice/Guidance of operations activities

to maximize operational and production requirement.

Review and Updating of all the Risk Assessments, SOPs, Work Instructions,

Formats and Checklists on a periodic basis.

Inspection of Critical Equipments & Machinery during shutdowns and failures.

Maintaining Readiness all equipment within responsibility.

Developing the detailed Bar Charts & Handover Procedures for shutdowns &

turnarounds.

Training and Re-training of plant operating personnel & new / lateral

employees.

Accountability to ensure the compliance of Legal Requirements as well as

control of disposable effluent / hazardous materials quality within the given

acceptable limits.

Suggestions and Implementation of Process Modifications which improve plant

productivity & reliability

Achievements in Special Projects and Assignments

> Assisted as Project Engineer in Debottlenecking Project at urea

fertilizer complex. This capacity augmentation project comprises of

fabrication, erection, pre-commissioning & commissioning, test runs

for a variety of major process equipments like vapour absorption

machines (chillers), bulk flow coolers, heat exchangers, compressor &

pumps, fired heaters, GRP made cooling towers, water demineralization

units, conveyor gantries etc. Also includes controlling the parameters

and taking appropriate corrective measures for nonconformity;

adjusting and amending the technological flow in accordance with the

process design parameters.

> Experienced as Process Facilitator in major mechanical rehabilitation

works of S50 Ammonia Synthesis Convertor executed to re-weld the leaky

site weld joint. This project includes bypassing the reactor from main

process stream, catalyst loading / unloading, dismantling of reactor

internals, lifting & shifting, cutting & re-welding of leaked joint,

hydro testing with many other NDT (condition monitoring) as well as

fabrication activities.

> Involved with Civil Construction Cell as a Quality Control Supervisor

in Earth Preparation Works including 10 meter deep; 30000 nos. of

Stone Column Installation by Vibro-Flotation method. Supervision of

various traditional & specialized civil construction activities like

heavy duty rotary & static machines foundations, construction of Water

Retaining Structure for Cooling Towers, Water Proofing & Injection

Grouting works, RCC Core Cutting, Controlled Dismantling, Shotcreting,

Acid Proof Brick Lining Works etc.

> Worked as dedicated Process cum Project Engineer with M/s THYSSEN

KRUPP UHDE managing major de-commissioning & re-commissioning

activities for atmospheric ammonia storage tanks (2X5000 MT).

> Deputed as Project Engineer for complete rehabilitation of refractory

works at 'Primary & Secondary Reformers' in ammonia plant & service

boiler in CPSGP executed by M/s Plibrico BV, The Netherlands.

> Experienced in working with Fire & Safety (HSE) cell as Unit

Facilitator for a project commenced to analyze the existing safety

standards of the company as compared to OSHA Workplace Safety

Standards (29.CFR.1910). Includes, detection & analysis of gaps;

accordingly preparation & review of various SOP's, work instructions,

check lists. Recommendation of appropriate action plans & continual

tracking to improve the overall safety standards which now could meet

the OSHA standards.

> Also dedicatedly worked in Total Quality Management cell in

instituting major cost of quality elements & also establishing

systematic 5S System approach in all departments of the organization.

Personal Attributes & Core Managerial Competencies

> THOROUGH UNDERSTANDING OF ALL ASPECTS OF PRODUCTION ACTIVITIES IN

MANUFACTURING UNITS WITH UPDATED KNOWLEDGE OF LATEST TECHNOLOGICAL

ADVANCEMENTS, REGULATIONS/ GUIDELINES AND STATUTORY COMPLIANCES IN THE

INDUSTRY.

> Highly motivated, positive and goal-oriented, with demonstrated

professionalism, attention to detail, highly developed analytical

faculties as well as the ability to build and lead effective teams.

> Perfect team leader, trainer and a motivator with ability to generate

high levels of team productivity. Self-driven, diligent and detail

oriented with strong analytical & troubleshooting skills. Articulate

and assertive with superior communication skills.

> Handling sourcing through identification of cost effective

vendors/suppliers for the procurements with an aim of reducing cost

while improving quality & reliability.

> Identifying areas of quality failures and taking steps to rectify the

system wide preventive and corrective actions to avoid the

reoccurrences.

Supplementary Work Experience

> DEPARTMENTAL RESPONSIBILITY FOR DOCUMENTATION, IMPLEMENTATION & UP

GRADATION OF IMS LIKE ISO9000: 2000, ISO: 14001, OHSAS: 18001, BRITISH

SAFETY COUNCIL MANAGEMENT SYSTEMS, TATA BUSINESS EXCELLENCE MODEL, 5S,

& OTHER IMPROVEMENT METHODOLOGIES (CIPS) LIKE DEMMI, FMEA, RCA, HAZOP,

JSA ETC. DRIVEN BY COMPANY TIME TO TIME.

> Member of Cost of Quality & Energy Reduction cross-functional team

(CFT) of the organization.

> Process Facilitator for IT- Enablement of the processes & APEX 'HSE'

Committee Representative. Involved in process modifications &

implementation of modifications.

> Hands on experience of SAP R/3 (ECC 6.0) PP (for Process) & PM (for

Maintenance) Modules in practical working in process operations as

well as services / maintenance processes.

> Nominated representative of Community of Business Practices Cross

Functional Team organized to expedite Knowledge Management (KM)

initiative across the entire organization.

> Computer Proficiency: Hands on experience of Windows - XP, Vista, 7 &

MS Office-2007 / Project

Academic Qualifications

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI, RAJASTHAN, INDIA-

Bachelor of Science in Chemical Engineering

Agra College, Agra affiliated to Agra University, Agra, INDIA-

> Masters of Science in Organic Chemistry

Brilliant School of Management, Chennai, INDIA-

> Post Graduate Diploma in Business Administration (Honours)

National Institute of Labour Education & Management, Chennai, INDIA-

> Diploma in Industrial Safety

Additional Industrial Courses & Trainings

> BUSINESS EXCELLENCE STEWART TRAINING (BEST) FOR MALCOLM BALDRIGE

QUALITY MODEL (JRDQV)

> Qualified First Aider by St. John's Ambulance,U.K

> Training in Second Line of Defence, Fire Fighting and Emergency Rescue

Team

> Training on 5S Systems, ISO & Refractory Rehabilitation Works in

Industrial Furnaces

> Basics of Heat Exchangers by Mr. C Mukhargee

> Confine Space Training by Regional Labour Institute, Kanpur

> Work Permit System (PTW) & Hazardous Job Procedure Training

> Completed Himalayan Trekking Expedition Program by M/S Tata Steel

Adventure Foundation designed to polish managerial skills like Time

Management, Decision-making & Discipline etc.

> Prevention and control of Fire in Industries, Central Labour

Institute, New Delhi.

> Hazard Communication (HazCom) & Risk Assessment & JSA Training by M/S

Ensafe Technologies

> Training on Materials of Construction used in Fertilizer Industry by

Mr. C Raghavachari

Languages Known

VERY FLUENT COMMUNICATION SKILLS (ORAL, READING & WRITING) IN ENGLISH AND

HINDI

Extra Curricular Activities

EX. SECRETARY OF COMPANY'S CULTURAL CLUB, PLAYING BADMINTON, MUSIC, NET

SURFING & READING DIVERSE LITERATURES

Willingness to Relocate

ANYWHERE WORLDWIDE (PRESENT EMPLOYER'S NOTICE PERIOD - MINIMUM ONE MONTH)

References Salary

Employer Company's Website

AVAILABLE ON REQUEST NEGOTIABLE

WWW.TATACHEMICALS.COM

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