Plant Manager

RAJESH KUMAR

AGARWAL

:

PERSONAL

INFORMATION

B. Tech in Chemical

1.QUALIFICATION: Engineering

Harcourt Butler

Technological

Institute(Kanpur)

2. E- MAIL ID: *************@*****.**.**

+91-935*******, +91-

3. PHONE NO: 978-***-****

A-302, Ashirwad Vaibhav,

Indra Vihar, Kota, Rajasthan,

4. ADDRESS: India-324005

5. July 1, 1961

DATE OF BIRTH:

6. Indian

NATIONALITY:

PROFILE :

• Chemical engineer with 31 years of extensive experience in the Petrochemical / Fertilizer and gas processing industry.

• Implementation of BSC and TPM techniques.

• Budget planning and techno commercial studies and execution of projects.

• Finalization of Operations and maintenance contracts.

• Successfully implemented project management from concept to commissioning of two 1350TPD Kellogg ammonia

plants at Kribhco, two Topsoe ammonia expansion projects of Kribhco, one 1000TPD Kellogg ammonia plant of

Nafcon, Nigeria. Setting up of 90 MSCFD hydrogen plant and 500 TPD Nitrogen plant.

• Planned and executed turnarounds/shutdowns and start-ups of ammonia plants of ICI. UHDE. Topsoe. Toyo, Man

Ferrostall and KBR designs.

• Operation and trouble shooting of reformers, CO2 recovery by aMDEA, Benfield and Vetrocoke, compression,

synthesis, refrigeration and cryogenic purge and PSA tail gas recovery units.

• Commissioning and operation of ammonia/Methanol export/import and storage units, utilities, N2 units, gas turbines

and boilers.

• Preparation of Standard operating procedures.

• Inspection of process equipment during shutdown and plant reliability assessment.

• Follow up of construction and maintenance jobs.

• Manpower planning and development.

• Preparation of plant business review and profit analysis sheets.

• Excellent teamwork. Communication and interpersonal relation with all nationalities from Europe, America, Middle

East and Asia.

CAREER HISTORY:

RESPOSIBILITY

COMPANY, POSITION AND DURATION

• Working as Astt Vice President of Operations.

• To set up 2300 MTD ammonia/4000 TPD Urea complex with

associated offsite and utilities.

•

Indorama Eleme Petrochemicals Limited Complete site management and implementation of HSE.

•

Nigeria Hire and train the operations team.

Nov 2012-Feb 14 • Coordinate with Process licenser, EPC contractors.

• Review the Design Datasheet, P&ID, PFD, Hazop, SIL

determination, Model reviews, DCS, Aux console configuration and

DCS graphics preparation.

• The Facility and Business Head of Plant operations, Maintenance,

Reliability, Engineering, HSE, Quality Control, Process safety

designs, Commercial, Estate, Security and admin for N500 and 90

Praxair India Pvt Limited

MSCFD Hydrogen plants for Praxair IOCL Paradip refinery.

General Manager(Operations)

• Hiring and training the N2/H2 team.

Nov 2010- Oct 2012

• Development of SOP/SMP and Complete responsibility of

managing the facility, Pre-commissioning, commissioning and start

up.

Oman Methanol Company, Oman

•

Operations Manager/Plant Manager To head plant Operations, Maintenance, Quality Control,

Nov 2008-Nov 2010 Commercial, HSE, IT, Finance and HR and Security.

• Complete responsibility of managing 3000 MTD Toyo designed

methanol plant on cost effective basis.

• Stabilization of Plant Operation of Main process plant of Steam

Methane Reforming, Synthesis and Purification of Methanol with

Methanol Tankage area, Desalination Plant, Polisher unit, Package

Boilers, Nitrogen Plant, Waste water Treatment, Sea water intake

facility and export of Methanol Jetty. Plant was optimized to run

smoothly above 108% of its capacity with work culture of Safety

First.

• Management of two Turnarounds of the plant successfully with no

incidence on safety.

• Replacement of damaged Pre reformer with water jacketed,

refractory lined and Vertical design Pre reformer.

• Repaired the Methanol rectifying column Bottom Trays.

• Chemical Cleaning of Desalination Plants.

• Replacement of Reformer, Pre-reformer and synthesis Converter

Catalysts.

• Repair of synthesis machine expansion bellow, Replacement of dry

seals and Turbine Rotor.

• Optimizing the performance of the Reformer and Control of

Convection Coils and reduce the Carbon formation.

• Decommissioning and Commissioning of Methanol Tank of 40000

Tons capacity.

• Introduction of Thermography and routine CMMS inspection and

LDAAR audits.

• Co-ordination and Implementation of findings from Internal,

External HSE, Commercial, Financial, Technical and insurance

audits.

• Chairing the Incidence Investigations on Near-miss, Injury, Plant

Trips and equipment failure.

• Implementation of Management of Change process.

• Identification of Services and Jobs for Outsourcing, Development

of Vendors, Negotiations and finalization of Contracts.

• Development of Standard Operating Procedures, Standard Maint

Work Practices, Emergency Handling Procedures, Job Safety

Analysis and Equipment Handover Procedures.

• Hiring, Training and Development of Local and Expat Manpower.

• Emphasis on OJT (On the job training), Process Simulation, Cross

Function Training, Internal and External programs on HSE and

Participation in seminars.

• Compliance of International, National and Local rules and

regulations on Environment, waste management, Safety.

• Implementation of Work to Permit system and its Compliance.

• Emergency preparedness, Mock drills with nearby industries and

Local authorities.

• Development of good relations with the Nearby Industries for

sharing the Infrastructure in case of Emergency and Turnarounds.

• Budget Planning, Resource Monitoring and effective Utilization for

improving the Residual Life of the Plant and Reliability.

• Implementation of suggestion scheme, Conduct Brain Storming,

Foster the Transparency and Knowledge sharing among employees

and management.

• Build the team spirit, Confidence to deliver, Adherence to Integrity,

Develop the Trust among All.

• To head ammonia plant operations and maintenance and quality

control.

• Complete responsibility of managing ammonia plant on cost

Shriram Fertilizers and Chemicals, Kota effective basis.

•

Additional General Manager (Fertilizer) Reliability of ammonia plant was improved and it made record

Nov 2004-Oct 2008 productions consecutively for 3 months of my joining in the history

of the plant maintaining good inter personal relations with all

sections of employees.

• Handled very successfully turnaround and LNG conversion project

of ammonia plant and commissioned it.

• To look after operations of Uhde designed 1200TPD ammonia plant

Sirte oil Company, Libya

with 34500NM3/Hr methanol plants purge gas recovery PSA unit

(Formerly known as Exxon Mobil co.)

by Linde, Germany.

Unit Operations Supervisor

• Operations trouble shooting, planning of turnaround and

2001- Oct 2004

coordination of maintenance and plant process modifications .

• Advising plant management on operations of 1000TPD Kellogg

National Fertilizer Co. Of Nigeria Ltd. ammonia plant, 1500TPD Stamicarbon granulation based urea

(NAFCON) Nigeria plant, utilities and export of ammonia and urea.

•

Operations Advisor Training of operations staff, planning for shutdown, trouble

1996-2000 shooting and modifications

• To look after plant operations in shifts.

• Preparation of standard Operating procedures.

National Fertilizer Co. Of Nigeria Ltd.

•

(NAFCON) Nigeria Training the staff and local engineers on the job for handing over

Ammonia Shift Supervisor / Advisor job responsibilities and duties.

1992-1995 • Monitoring of plant operational efficiencies.

• Trouble shooting of ammonia plant.

o Participated in installation, erection, Pre-commissioning,

commissioning of these plants under the guidance of department of

atomic energy, GOI.

o Distributed digital control system supplied by Siemens, Germany.

o This ammonia expansion project consisted of:

o 2 units attached to two 1350 TPD ammonia plants of KRIBHCO.

o 550 M3/hr water pre-treatment plant, 11500 M3/hr water circulation

Krishak Bharati Cooperative Ltd

rate cooling tower having chromate treatment.

(KRIBHCO) Surat

o 800 NM3/hr inert gas N2 plant.

Ammonia Expansion project, Hazira

Shift engineer HAEP Kribhco o 768 TPD of synthesis unit supplied by HaldoreTopsoe having radial

1989-1992 flow converter.

o Side fired Ammonia crackers of HaldoreTopsoe.

o Centrifugal compressors of BHEL, MANGHH, Kawasaki makes.

o Reciprocating compressor of Kobe, Khosala make.

o Sophisticated absorption, extraction and distillation tower.

o Diaphragm pumps of Nikkisso and Lewa having torque converter

• At NAFCON, I took part in pre-commissioning / commissioning of

1000 TPD gas feed based Kellogg ammonia plant, NAFCON was

managed by Kellogg Plant Services (KPS), a subsidiary of M/S M.

W. Kellogg.

National Fertilizer Co. Of Nigeria Ltd. • My job was to maintain smooth and efficient operation of the plant

(NAFCON) Nigeria working alone on a centralized control panel.

Ammonia Board man/Sr. operator • As a part of KPS, I was responsible for technology transfer to local

1987-1989 natives on the panel.

• I made suggestions resulting in millions of dollar of saving to the

company.

• NAFCON was run well above 117% of capacity.

• Worked as a responsible assistant Shift Engineer-in-charge of 1350

TPD Kellogg Ammonia Plant.

• I was involved in pre-commissioning / commissioning jobs of pipe

Krishak Bharati Cooperative Ltd fit up, hydro testing, chemical cleaning, steam blowing, loading of

(KRIBHCO) Surat catalysts, commissioning of turbines and motors and catalyst

Junior Production Engineer reduction of two 1350 TPD NG feed based ammonia plants for

1985-1987 KRIBHCO.

• I maintained smooth operation and follow up of maintenance jobs

with good safety record.

• Attended the best training course offered in Indian Fertilizer

Industry.

• Took part in seminars on ammonia, urea, management and safety.

• In SPIC I took part in the turnaround of ammonia and urea plants.

Southern Petrochemical Industries

• In the ammonia, I took part in changing almost all catalysts,

Limited (SPIC)

cleaning and inspecting all exchangers, vessel s, packing, cooling

Tuticorin (Tamilnadu)

water and lube oil piping and commissioning the plant afterward.

Graduate Engineer Trainee

• I learned a great deal of professionalism to which I was a proud

1983-1984

partner.

• I gained the confidence to operate and supervise any process plant.

• SPIC has 1100 TPD ICI designed, Davy Power gas engineered

Naphtha feed Ammonia Plant

• I worked in IPCL for fulfilment of B.Tech in Chemical Engineering.

Indian Petrochemical Industries Limited. • IPCL is a giant petrochemical complex with 300000TPd ethylene cracker,

(IPCL), Vadodara, India. polypropylene plant, LDPE, HDPE, Ethylene glycol, acrylic fibre and PVC

1982 plant.

REFERENCES:

Eng. Alloy Onnochie Shri H. S. Kohli

Plant Manager, Executive director,

NAFCON, Reliance Industries Ltd. Hazira,

Onne, Port Harcourt, Nigeria. Surat, Gujrat, India.

Shri J. R. Singh Shri K. K. Kaul

Sr. General Manager, Sr. Executive Director

Zuari Agro Chemicals Ltd. Shriram Fertiliser and chemicals,

Zuari Nagar, Goa, India DCM Shriram Consolidated Ltd. Kota, India.

Mr. Mike Edwards Shri I. N. Bansal

Director-Operations Excellence Director Operations

Praxair Inc. Houston KrishakBharati Cooperative Ltd.

USA Hazira, Surat (Gujarat) India

Mr. Clinton B Ramberansingh

MD IPSL

Trinidad and Tobaggo

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