Sanjay Kulwal

ad2hxb@r.postjobfree.com

DOB: **/May/1969

Nationality: Indian

Professional Degree: B. Tech Chemical

EXECUTIVE SUMMARY

Technical Professional with over 33 years’ experience in petrochemical & Refinery division. Well conversant in plant operations and technology.

Deep analytical skill with strong background in plant optimization, troubleshooting and strategic planning to meet larger organizational goals.

Strong leadership skills and leading teams to outstanding business successes. Adept at mentoring teams and providing technical training to engineers.

Optimize processes and establish a viable plant and process safety management system that supports in reliably preventing incidents.

Professional Experience Details:

(A)Since Oct’08 with Nayara Energy (Essar Oil Ltd) JAMNAGAR (2011 to till date)

Technical Service (Process Head)

Monitor Hydrotreater & Sulphur recovery unit, ARU, SWS & Tail gas treating unit Performance and suggests performance improvement initiatives to optimization of operations.

Using all modern tools like SAP, LIMS, PIMS and Pro-steam model to optimize the process.

Process Units Monitoring and Optimization, Plant Modifications schemes, preparation of PFD’s / P&ID’s, Technical evaluation of Chemicals & Catalysts loading & Performance monitoring of Reactors / Heaters / Turbines, etc.\

Using all computer-based and modern tools to achieve optimum plant performance, including IP 21 (ESPEN), LIMS (Laboratory Information Management System) & PIMS (Plant Information Management System).

Provide training new incumbents in the best interests of organization in meeting the regular organizational needs.

Organizing the training in accordance to the requirement of employees for the accomplishment of tasks.

GM operation of DHDS(ULSD & ATF), SRU, ARU, SWS & SPU Units

Good knowledge of Safety rules & regulations, Operating Procedures, thereby ensuring safe & smooth operations of Process Units.

Unit Start-ups / Shutdowns and handling of Emergencies like Power failure, Cooling water failure, etc.

Preparation of specific consumptions, production report and maintenance planning through application of SAP R/3 software package.

Coordination with service and support Departments for smooth Operation of Process Plants.

Process Units Monitoring and Optimization, Plant Modifications schemes, preparation of PFD’s / P&ID’s, Technical evaluation of Chemicals & Catalysts Performance monitoring of Reactors / Heaters / Turbines, etc.

Commissioning and Start-up

Fully involved in Pre-commissioning / Commissioning activities, Start-up and Performance Test of Units.

Process Optimization, modification of Standard Operating Procedures as per operation, equipment evaluation, nitrogen run of compressors, and Reactor and high pressure system.

Preparation of Detail Feasibility Report (DFR) for Grass-root Refinery Project UGANDA

Selection of Refinery Process Configuration

Study of different Process Configurations suitable for heavy & waxy Crude Oil, with short listing and finalization of best suited Process configuration for new green field Refinery Project.

Preparation of Refinery Material balance, Product slate for Euro IV quality of MS / HSD.

Development of Over-all Refinery Utility balance, Power requirement, Crude & Product Storage & Dispatch facilities.

Calculation of all elements (Utilities, Chemicals & Catalysts, Maintenance & repairs, etc.) of Refinery Operating Cost for all Process Units.

Preparation of detail Project Schedule and development of Project execution methodology for execution of Refinery Project on fast track basis.

Kenya Refinery (KPRL) Modernization Project KENYA

Provided Technical assistance to Kenya Refinery for Process Trouble-shooting and Optimization.

Selection of suitable Process Configuration for the Modernization Project of KPRL for Euro IV quality Products, while retaining the existing Refinery Process Units.

Fully involved in the preparation ITB documents for KPRL Modernization Project and analysis of Technical / Financial Bids.

Participated in Pre-bids / Kick-off Meetings and provided Technical assistance to KPRL for carrying out cost estimation.

Technical Evaluation for Process Licensors selection, Revamping of existing Process Units as well as Basic Design & Engineering of new Open art Units.

Essar Refinery – Jamnagar

VGO-HDT & DHDT unit Process Experience (Expansion Project)

Worked as a lead Process Engineer for new unit VGO-HDT & DHDT Units.

Interacted with Detail Engg Contractor and reviewed Licensor’s Documents.

3D-Model review of VGO-HDT & DHDT at 30%, 60% & 90% completion stage.

Prepare Technical report for VGO-HDT & DHDT

Review of Vendor Process packages and PFDs / P&IDs, participated in HAZOP study

Prepared Operating Manuals and Pre-commissioning / Commissioning Procedures, Equipment check lists, etc.

(B)Dec’03 to Sept’08 with Petronet LNG Ltd., as a Operation Manager – BHARUCH

Terminal Commissioning and Startup

Pre-commissioning, Commissioning & Start-up of LNG Re-gasification Terminal.

LNG Ship unloading and cooling-down of unloading line, cryogenic Tank and entire low temperature system.

Handling of high pressure system and optimization in operation to increase send out.

Terminal Operational Experience

Storage, pipeline transfer and distribution network and reconciliation on daily basis.

Monitoring Plant performance, capacity utilization, operating parameters and achieving best economic and cost effective output and safety integrity of entire asset during operation.

Identifying process bottlenecks for increasing Plant throughput and analysis of Plant performance including feed gas & product quality, Equipment performance, Troubleshooting, etc.

Prepared reconciliation, budgeting, monthly reports and specific consumption through SAP.

Adroit in preparation of SOP, providing training to new trainees as well as updating the process knowledge of existing members on new techniques.

(C)Dec’98 – Nov’03 - Haldia Petrochemicals as Sr. Engineer Naphtha Cracker Unit- HALDIA

Technical Experience

Review of Licensors Documents, Vendor Proposals.

Review of PFDs / P&IDs and coordination with Licensors & DEC.

Technical support in Project phases with the objective of maintaining plant wide quality and consistency.

Fully involved in Pre-commissioning / Commissioning activities, Start-up and Performance Test evaluation of Naphtha Cracker Unit.

Optimization, modification of Standard Operating Procedures as per operation, equipment evaluation, air-run / nitrogen run of compressors – CGC, Propylene / Ethylene Refrigerant Compressor and Dry-out of Hot & Cold Section.

Identify long term issues in the plant and provide solution and help Technical and Operation team for trouble shooting short & medium term issues.

Ensure quality Process Monitoring – early detection of issues and fixes

Operational Experience

Responsible for safe and smooth operation of Naphtha Cracker Unit and maintaining steady feed supply to down-stream plants.

Handling emergencies like power failure, steam failure, fire and equipment breakdown in the Ethylene plant.

Preparing specific consumption, production report and maintenance planning through application of SAP R/3 software package.

Possessing sound post commissioning experience like controller tuning, optimization, modification of standard operating procedures as per operation, equipment evaluation, air-run / nitrogen run of compressors – CGC, Propylene / Ethylene Refrigerant Compressor and Dry-out Complete Cold Section.

Experienced in many start-ups and shutdown operations of the plant.

Proficient in product quality audit through LIMS and machine monitoring through Bentleys Nevada DM-2000 for compressors and turbines.

Handling pre-commissioning activities like chemical cleaning of Super High Pressure Boilers and Steam Drum PSV Pop Test, dry-out of cold section in Ethylene Plant, water run of pumps, acid pickling, steam network like SHP, HP, MP, LP and solo run of all types of turbines.

Performing technical studies to achieve optimal production and smooth operation like monitoring performance of reactors / heaters, fouling of turbines / heat exchangers, etc.

Steering the commissioning and operation of automated computer controlled systems, valve sequence control system for regeneration of reactor / dryers.

Assisting in post commissioning experience like improving efficiency of heaters and improving performance of reactors, modification of parameters for optimization, etc.

Instrumental in operation of major equipments like distillation column – both vacuum and super fractionators, steam turbines driven compressors and pumps, 1200kw BFW pump and turbine, hot oil pump, High Pressure Naphtha and Hydrocarbon, compressors like axial compressor, centrifugal compressor – both oil and dry gas seal type, fired heaters – liquid fired and gas fired, storage tanks, etc.

Preparing standard operating procedures for equipment operation and plant operation as well as reviewing plant operating procedures.

Gearing improvement plans to actions to operate unit in consultation with technical and engineering support disciplines.

Achievements & Training

Contributed to record production in successive three years by influencing organization on feed quality and operating conditions of steam cracking furnaces.

Increased throughput without any major modification.

On the Job training to Naphtha Cracker Unit of Mitsubishi Chemical Corporation Kashima, Tokyo, Japan in 1998

(D)Dec’91 – Nov’97 with J. K. Synthetics, Kota as Shift Engineer of DMT Unit KOTA

Operational Experience

Shift In-charge of Ethylene Glycol, Methanol recovery & Distillation unit; hands on experience of Decanter Centrifuge, Crystallizer and High Pressure Reactor.

Implementation of energy saving scheme and increase in DMT Production.

Rresponsible for planning and production activities, preventive & breakdown maintenance of mechanical equipment

Achievements

Achieved daily production targets as well as specific consumption norms and designed the scope for minor plant modifications.

Increased plant production through modifications.

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