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SHIFT SUPERVISOR

Location:
United Arab Emirates
Posted:
April 30, 2016

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Resume:

ARIYAPPA MOHANAN

Telephone: +971******** (House), +971********* (Mobile)

E-Mail: acuku7@r.postjobfree.com, acuku7@r.postjobfree.com

Managerial Assignments in Operations and Maintenance

An astute professional with 28 years of experience in Operation/Production, Project Management, Process Integration, Maintenance Management & Safety in Petrochemical Industry; Ammonia Plant

Ability to lead all Operators in performing pre-commissioning, commissioning and turnaround activities safely and efficiently; having rich experience in operating various types of boilers until maximum heating surface of 10,120 M2

Holds expertise in troubleshooting and failure analysis with in-depth knowledge about the latest maintenance techniques

Having 4 commissioning & 1 de-bottlenecking project experience which were so great & challenging

Having Degree in Mechanical Engineering (Associate Member of Institution of Engineers, AMIE)

Familiar & experience with International Standards & Engineering Practices, and other methodologies such as Flawless Start-Up / Shut Down, HSE Case, HAZOP, IPS, RCM, JSA, MOC, RCFA, Risk Assessment

Excellent interpersonal, communication, management skills with demonstrated abilities in driving motivated teams in achieving organisational goals

DOMAIN SKILLS

- Project Management - Plant Optimisation - Maintenance

- Budgeting - Materials Management - Equipment Failure Analysis

- Energy Conservation - Safety & Compliance - Quality Implementation

- Condition Monitoring - Process Enhancement - Liaison & Coordination

- Cost Reduction - Trouble shooting - Man Management

ORGANISATIONAL EXPERIENCE

Ruwais Fertilizers Industries Ltd (FERTIL), Abu Dhabi January, 2012

Company Profile: (Subsidiary of ADNOC Group of companies)

Growth Path:

Shift Supervisor

Key Result Areas:

Directs on-shift operations activities in the Ammonia Plant that includes monitoring process activities, providing advise and instructions to alter operating parameters, controlling routine and emergency shut-down and arranging Plant maintenance activities

Highlights:

Functioned as Active Team Member in pre-commissioning and commissioning of UDHE, GERMANY designed single stream Ammonia Plant with a capacity of 2000MT/Day. M/s Samsung Engineering Co. Ltd was awarded contract for the Provision of Process License, Engineering, Procurement and Construction (LEPC) of the FERTIL-2 Project. Production milestone was achieved on 21st April,2013

Monitors the routine operation of the Ammonia Plant by discussing process parameters and operating conditions with Field and Senior Operators, taking timely steps to change parameters and discussing major anomalies with the Ammonia Operation Department manager in order to ensure all set KPIs are met

Monitors, in the field/DCS, the performance characteristics of all equipment and processes to ensure that where necessary, steps can be taken to rectify equipment abnormalities.

Ensures at all times that steps are taken to optimise operating conditions and thereby minimise costs while maintaining the quality

Participates in detailed operational training of new employees, developees, reviews their training work assignments and comments on their progress to the Ammonia Operation Department Manager

Directs and participates in the routine or emergency shut-down or start-up of the process.

Provides detailed instructions to all personnel working in the Ammonia Plant to ensure that safety regulations and procedures are adhered to at all times.

Ensures the safe operation of the process to avoid activities which could result in emergency shutdown or potentially dangerous situations.

Identifies, through regular monitoring of the Plant, equipment which requires “shutdown” maintenance or repair, discusses requirements with the appropriate Maintenance Engineer and Ammonia Operation Department Manager. Raises work request for such jobs.

Carries out administrative duties related to Ammonia Plant which include preparing shift & leave schedules

Reviews standard operating procedures regularly and prepares for updating the same by concerned authority.

Reviews the shutdown and turnaround jobs list/programme and propose any changes to the Ammonia Operations Department Manager

Participates in achievement of HSE objectives and compliance to Company HSE Management System, Policies and Procedures.

Participates in HSE related studies including HAZOP, HAZID, Root Cause Analysis, Risk Assessment and Audits.

Enforces HSEMS compliance, promotes awareness for subordinates and responds to emergencies.

Reviews periodically the HSE performance of staff under area of responsibility and takes appropriate measures. Takes part in the periodic evaluation of his subordinates.

PETRONAS AMMONIA SDN BHD, Malaysia since Dec’99

Company Profile: (Subsidiary of PETRONAS)

Growth Path:

Lead Compressor Dec’99-Feb’05

Team Leader Mar’05-Mar’07

Shift Executive (Shift Superintendent) Apr’07-Dec’11

Key Result Areas:

Planning, directing, controlling and supervising a team of Process Operators involved in operating of the Ammonia / Syngas plant on shift basis to ensure that the plants are commissioned and operated in a safe and efficient manner in accordance with the established PETRONAS standards and procedures.

Addressing plant emergencies (fire / toxic) as Incident Commander and coordinating with process chemical charging as well as training of new operators.

Ensuring that all plant equipment and Machinery conditions from CCR and field to ensure that all conditions are maintained according to PETRONAS' standards and procedures in order to run the plant in the most efficient manner possible.

Monitoring closely all operating parameters and take necessary preventive / corrective actions to avoid any production upset to deviations from the optimum plant conditions and that the plant parameters remain within the safe design limits.

Coordinating with suppliers and customers to exchange information with regards to interlinked plant parameters, raw material supplies, in-process parameters and final product analysis in order to maintain optimum plant conditions.

Evaluating the effectiveness of isolations systems applied to work permit control including checking that the correct steps and procedures relating to Lock Out / Tag Out (LOTO) are being strictly adhered to.

Confirming Risk Assessment and Job Safety Analysis are provided for critical jobs and involved in preparation of RA and JSA. Conducting regular PTW audit to make 100% HSE compliance.

Developing the skills and knowledge of staff in HSE, with responsibility for delivering training covering Permit to Work compliance, PPE compliance and job safety analysis.

Addressing & taking lead in emergency response situations (Fire Incident / Toxic Gas Release / Flammable Gas Release) as On Scene Commander from field in close cooperation with Incident Commander & ensured zero non-compliance.

Reviewing / amending start up & shutdown procedures & checklists as per PASR schedule.

Maximizing product recovery through disciplined & structured monitoring and troubleshooting exercises

Effectively minimized the consumption of raw materials and utilities whilst maximising production to reduce unit variable cost

Administered shift team which includes mentoring, counselling, competency assessment, discipline, overtime, leave requests, back-up for absent employees, shift rotations, shift swaps and the vacation schedule as well as monitoring Operator training and generating development plans and performance appraisals

Ensured zero LTI and zero non-compliance to HSE Regulations by conducting regular PTW audit, UAUC submission, BBS observation, and weekly shift walkabout & 5S methodology implementation for plant housekeeping

Instilled a culture of high HSE awareness in shift team i.e. ensure Permit to work compliance, PPE compliance and appropriate job safety analysis

Functioned as prominent team member in pre-commissioning and commissioning of centrifugal, reciprocating & diaphragm compressors of different types and capacities with maximum power of 17.5MW

Cost saving initiatives Undertaken:

oModified CO Compressor High Radial Vibration Trip Logic and saved 200,000 USD per day by way of preventing compressor from spurious trip & consequent loss of production.

oTook initiative to provide bypass isolation valve across DMW pressure control valve which saved tripping of whole plant & 300,000 USD production losses.

oModified compressor LO pump start permissive to include buffer N2 pressure to dry gas seal healthy to avoid damage of DGS due to LO entry and consequent production loss & maintenance cost. Cost saving - 100,000 USD (DGS cost) & 300,000 USD (production loss per day).

oSuggested for procuring standby H2 compressor for reliability improvement and prevent ammonia production loss due to shut down of running compressor. Cost saving – 75,000 USD per day with pay back in 3 years.

oCost saving of USD 5000/day by reducing HHP/HP steam consumption of turbines after changing cooling medium for ejector condenser from turbine condensate to cooling water. Steam turbines were consuming more steam than design due to low vacuum.

oTaken reliability improvement initiative for Ammonia Product Pump (Cryogenic Pump) by providing priming line at pump suction. Frequent mechanical seal failures were experienced due to improper priming during start up and plant upset.

oSuggested and implemented another 50 cost saving reliability improvement and operations friendly initiatives in the plant.

Chief Assignments Handled:

Production volume for Oxogas, CO and NH3 all exceeded business target for FY2009/10.

Functioned as active member from Operations department for execution of 1050MT/day capacity revamped plant project designed by Haldor Topsoe in 1995.

Executed 1380MT Ammonia Plant project in PETRONAS Ammonia Sdn Bhd, 2000 for all compressors installations and commissioning.

Assigned as Operations Representative for RL-1 & RL-2 projects to maximize NH3 plant capacity by utilizing external H2 available from neighbouring industries in 2005/2006.

Functioned as Operations Trainer for conducting class room training in HDS, Reformer, CO2 Removal, Cold Box, Ammonia Synthesis & Refrigeration and Compressors. Conducted On Job Training (OJT) & coaching to new Operators & Fresh Engineers.

Effectively managed as Internal and External Assessor for Non-Executives Competency Based Assessment (CBA) Program & won Best Internal Assessor Award for 2007/2008.

Appointed as:

o“Technical Coach for Accelerated Capability Development (ACD)” for Executives to guide & coach young Engineers since 15th March, 2009.

oEmergency Respond Incident Commander and HSE Subcommittee Member for Shift Group since 13th July, 2005.

Successfully achieved Zero LTI and HSE incidents during May and July 2009 PASB total plant shutdown.

Major emergencies faced:

oReformer Tube Failure.

oAmmonia Syngas Compressor Fire.

oBoiler Feed Water Pump Failure.

oCooling Water Pump Failure.

oaMDEA Solution Pump Failure.

oNatural Gas Preheating Coil Explosion.

Madras Fertilisers Limited (MFL), Manali, Chennai Feb’88-Nov’99

Growth Path:

Technical assistant Feb’88-Jan’95

Senior Technical assistant Feb’95-Nov’99

Key Result Areas:

Performed safe and efficient operation of HDS, Reformer, CO2 Removal, Methanation, Synthesis & Refrigeration, Boilers and Compressor sections on a shift basis in accordance with established company standards and procedures by performing error free start up and shutdown, monitoring / optimizing and handling of plant upsets

Highlights:

Functioned as Team Member in pre-commissioning and commissioning work of Halder Topsoe designed major revamped Ammonia Plant in January, 1995 which produces 1050MT/Day.

Actively involved in commissioning of:

o110 Bar Steam Extraction Four Stage Centrifugal Ammonia Syngas compressor driven by condensing turbine (Make-Mitsubishi Heavy Industries Ltd.) of capacity 425000 Nm3/hr with pressure 200Kg/cm2g and power 17954KW

oHigh pressure four stage air compressor driven by condensing turbine Make-Hitachi (compressor), Siemens, Germany (Turbine) of capacity 45,000 NM3/hr with discharge pressure 37Kg/cm2g and power 9892KW

Involved in Pre-commissioning and commissioning of 110Bar, Thermax Babcock & Wilcox, oil fired burners, Balanced Draught furnace 100MT/hr capacity boilers and 70MT/hr, 43Kg/cm2g boiler

EDUCATION

AMIE-(Mechanical) from The Institution of Engineers (India), Kolkata (Equivalent to Bachelor Degree in Engineering) in 1992.

Diploma in Mechanical Engineering from RKM Technical Institute, Mylapore, Chennai in 1986

Diploma in Maintenance Management from Annamalai University, Annamalai Nagar, Tamilnadu in 1992

Diploma in Fertilizers Technology from Annamalai University, Annamalai Nagar, Tamilnadu in 1993

Boiler Operations Engineer (BOE) Certified by Inspector of Boilers, Tamil Nadu, India in 1999

IT Skills: Well versed with MS Office and MAXIMO.

TRAININGS & SEMINARS ATTENDED

Ruwais Fertilizers Industries:

Attended:

oCatalyst Training by JMC on 21st & 23rd October, 2012

oDifferent Safety oriented training by Samsung Engineering between 6th May and 7th October, 2012

oUDHE Process training between 13th and 21st April, 2012, Dortmund, Germany

oPractical Training at SAFCO IV between 13th & 21st April, 2012, Jubail, Kingdom of Saudi Arabia

PETRONAS Ammonia SDN BHD:

Participated in:

oCBA Implementation & Assessment Guideline review workshop on 31st Oct to 2nd November, 2007

oICC Training on 10th & 11th September, 2007

oNESP Coaching for Success Seminar on 6th to 8th August, 2007

oOn Scene Commander training on 25th & 26th February, 2007

oTwo days Fire Team Development Programme from 25th & 26th March, 2000

oAuthorized Gas Tester (AGT) training on 24th April, 2000 and Refresher Training every year

Attended:

oChemical Handling training on 14th & 15th August, 2007

oHSE Procedure training on 19th July, 2007

oHTAS Process training on 29th march, 2007

oPTW training on 21st & 22nd February, 2007

oFirst Responder Life Support training on 11th & 12th July, 2000

oFamiliarization of PASB Emergency Response Procedures on 11th April, 2000

oBasic Fire Fighting & Breathing Apparatus Training in TSTC SDN BHD on 8th & 9th March 2000

Madras Fertilizers Ltd:

Attended Executive Programme on In-house training on Productivity in November, 1996 conducted by Tamil Nadu Productivity Council

Attended Training Programme by Halder Topsoe on Revamp of Ammonia Plant in July, 1997

PERSONAL VITAE

Date of Birth: 2nd April 1967

Languages: English, Tamil, Malayalam, Hindi and Bahasa Melayu

Address : T-13712, Ruwais Housing Complex, P.O.Box: 11882, Ruwais, Abudhabi

Nationality: Indian

Passport No. & Validity: Z 2110083 & unto 10th May, 2021

Martial status: Married

No. of Dependents 3

Visa Status Employment visa

Driving License Motor cycle and Car (India, Malaysia & UAE)



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