Manager Operations & Process
Resume:
Core Competencies
Operations & Process Management
Pre-commissioning & Commissioning
Operations & Maintenance
Plant Operations(Field & DCS)
Process Optimization & Control
Project Coordination & Execution
Project Engineering
Reporting & Documentation
Recruitment & Training
A result-oriented professional, targeting senior level assignments as Area Manager / Section Head with an organization of high repute, preferably in Oil & Gas Refinery and Petrochemical Sector
Location Preference: India / Overseas
Profile Summary
An accomplished professional with over 16 years 09 months of experience in Operations & Process, Pre-commissioning, Commissioning, Maintenance and Plant Operations, Process Optimization & Process Control.
Expertise in devising & incorporating effective plans & schedules for operations & maintenance and reducing downtime in order to enhance operational efficiencies, & capacity with optimum utilization of manpower & materials.
Deployed various methodologies to analyze processes, and recommended modifications & changes in the processes to minimize escalations, Fuel & Flare Losses, Utility Losses, control costs and cycle-time thereby improved operations efficiencies
Skillful in HAZOP Study & 3D Model Review (30%, 60% & 90%)
Expertise in techno-commercial activities, vendor identification & development, resource management and analytical assessment
Skillful in executing ‘DCS FAT’, Reviewing ‘RFQ’ for ‘Operator Training Simulator’, Reviewing ‘Operating Manuals’, ‘P&IDs’ and developing ‘SOPs’
Involved in the Recruitment & Training of the Operations Personal.
Expertize in enhancing the operations, optimizing resources & capacity and augmenting productivity & operational excellence
Expertize in managing operations of the all Refinery Blocks including FCCPC, CDU-VDU, DCU, VGOHT, DHDT, HGU, SRU, MSB, CPP, ETP, PPU & Utility Off-sites as RSS
Skilled in using Refinery application software such as ‘Process Historian’, ‘MES’, ‘LIMS’ and thereby troubleshooting process problems
Expertize as RSS - Monitored ‘Fuel & Loss’, Utility & Power Consumption; Coordinated for the ‘interplant activities’; Served as Incident Commander for ‘Onsite’ & ‘Offsite’ emergencies
Skillful in supervising refinery meetings for major critical process problems & maintenance jobs and helped Senior Management Team in deciding the forward path for troubleshooting the same
Skillful in preparing Daily Production Report for the entire Refinery complex & guiding the Senior Management Team for taking proactive actions in various units in view of troubleshooting
Skilled in implementation of SOP and quality & safety guidelines
Skillful in Startup, shutdown, Revamp and Commissioning of Petrochemical complex; developed new graded as per market demand
Worked on Biodiesel project during Graduation Project activity
Education
B.Tech. (Chemical Engineering) from Nagpur University in 2003
Certificate Course- Piping Engineering from IIT, Mumbai.
Certifications
Certificate Course- Data Science & Artificial Intelligence, INSAID
Career Timeline
Supreme Petrochem Ltd., Nagothane, Raighad as Shift-In-Charge (Sr. Engineer-Production)
HPCL-Mittal Energy Ltd., Bathinda as Day Shift Supervisor-FCCPC/CDU-VDU (Assistant Manager)
Dangote Oil Refining Company, Lagos, Nigeria as Manager - Operations & Process(RFCC/CDU/SRU
Aug'03 – Apr’07
Apr'07 – Aug’10
Aug’10 - Sep’14
Sep’14 - Apr’18
Apr’18 – till date
Reliance Industries Ltd., Jamnagar as Shift-Field-Engineer (Manager)
HPCL-Mittal Energy Ltd., Bathinda as Refinery Shift Superintendent (Deputy Manager)
Notable Accomplishments Across The Career
At Dangote Oil Refining Company:
Completed DCS FAT for ‘SRU’ & ‘RFCC’ Blocks at Sneighder Office Mumbai and suggested & implemented Logic Changes in the DCS in accordance with P&ID revision and previous experiences
Performed ‘3D Model Review’ & ‘HAZOP’ for systems in RFCC, SRU, Alkylation, and CDU Blocks
Prepared ‘Advanced Solutions’ Operations documents for ‘CDU’ & ‘SRU’ Blocks (KPI’s, J5-Elogbooks, Graphics documents)
Reviewed RFQs for ‘Operator Training Simulator’ Vendors and provided inputs for developing ‘OTS’
Developed Vendor Graphics using Vendor P&IDs, Reviewed ‘Operating Manuals’, and ‘IFC P&IDs’
Involved in the vendor technical evaluation for RFCC Catalyst, in view of selecting best suited catalyst for the RFCC.
Developed Start up loops, Circuits and plans for safe startup of the RFCC & CDU Plants.
At HPCL-Mittal Energy Ltd as RSS
Received Performance Award for reducing Flare Loss & Odor Complaints, and recovering Propylene without FCCU Absorber overhead Cooler with Strategic Plan
Decreased Fuel & Loss to 10.35% against the design of 10.92% by optimizing steam consumption, utility consumption, streamlining the processes & reducing the flare loss
Scheme implemented in Offsites to control Crack Feed to VGOHT in order to reduce Flare Losses.
Reduced flare loss by splitting the overlapping activities in DCU(Drum Switch-Over) & FCC(PRU Dryer/Sulfur Bed Regeneration)
Reduced ETP Slop Generation by identifying the leakages in CDU-VDU overhead system and troubleshooting it.
Optimized Hydrogen generation by timely diverting the off gases from NHT to VGOHT Sweet Gas Stream.
Optimized Steam consumption in SRU during start up.
Reduced ‘Odor Complaints in Surrounding Villages’ by improving processes in the Refinery Units - ETP & SRU
Successfully managed emergencies such as HP Steam Failure, Partial Power Failure, Total Instr Air Failure, WGC Failure in FCCPC, Propylene Heavy Leakage in PRU section, SRU RF leakage, and OWS fire in CDU
Involved in Interplant Coordination during Turndown- Optimized utility, power consumption & reduced flare & fuel losses during shut down and start up.
At HPCL-Mittal Energy Ltd (As Day SS- CDU-VDU & FCCU)
Executed Pre-commissioning, Commissioning and Stabilization of FCCPC & CDU-VDU unit
oPlayed Key role in takeover of the FCCPC/CDU-VDU unit from project phase
oProcess Control through ‘YOKOGAWA’ DCS System.
oTroubleshot process problems & Improved the PGP Yield
oOptimized PRU Dryer/Sulfur bed regeneration system against design specifications
oPerformed ‘Post Guarantee Test Run’ with licensor and executed FCCPC runs with trials using different catalysts in order to improve PGP Yield
Successfully commissioned New FCC Unit of UOP design at HPCL Mumbai having capacity of 1.45 MMTPA
Supervised the ‘Pre Startup & Safety Review’ of the FCCPC after the turndown in the year 2014
Involved in Precommissioning & Commissioning of CDU-VDU for in year 2010- 2011.
At Reliance Industries Ltd. in FCC Block
Successfully managed emergency post expander fire
Involved in the startup, shutdown, & partial shutdown of the Block
Involved in the Pre-commissioning, Commissioning and Stabilization of new Clarified Slurry Oil Stripper
Led Field team in troubleshooting, process optimization, & safe Maintenance of the equipment
At Supreme Petrochem Ltd.
Commissioned Swing Line of Petrochemical Complex, producing General Purpose Polystyrene as well as High Impact Polystyrene
Successfully executed plant change orders to conserve energy and to improve the product yield
Work Experience
Dangote Oil Refining Company, Lagos, Nigeria
as Manager - Operations & Process (RFCC/ CDU/SRU/ALKYLATION) Apr’18 – till date
Key Result Areas:
Debottlenecking process issues during various phases of Project Engineering work, such as 3D model review, HAZOP, & P&ID Review
Devising operational procedures in view of pre-commissioning & commissioning by keeping in mind to improve the process Safety standards & to improve the efficiency with strictly ensuring adherence to preferred standards.
Creating SOPs, while complying with safety norms, code of conducts, rules & regulations
Assisting Engineering Team in determining engineering scope, setting up an engineering work plan for complex new projects & new tasks, & contributing for vendor selection
Defining & implementing best practices, strategies, policies, processes and procedures to aid & to improve operational performance
Formulated Advanced Solutions systems for ‘SRU’ & ‘CDU’ Blocks and conducted FAT of those systems at Sneighder Mumbai
Reviewing Operating Manuals and Vendor Manuals of ‘CDU’ & ‘SRU’ Blocks
Developing ‘OTS RFQ’ & ‘OTS’ proposals as per organization requirements
HPCL-Mittal Energy Ltd., Bathinda
as Refinery Shift Superintendent & Day Shift Supervisor(CDU-VDU/FCCPC) Aug’10 - Apr’18
Growth Path:
Sep’14 – Apr’18: Deputy Manager (Refinery Shift Superintendent)
Aug’10 - Sep’14: Assistant Manager (Day Shift Supervisor- FCCPC)
Key Result Areas:
As Deputy Manager (Refinery Shift Superintendent)
Managed the inter-plant routine & non routine activities of the entire refinery cum petrochemical complex
Contributed in Shutdown & Startup of the entire refinery complex by minimizing the Fuel & Loss, improving the Safety Standards, Directing the plant personal in managing the emergencies
Acted as ‘Incident Controller’ during ‘Onsite’ & ‘Offsite’ Emergencies - Major/Minor Process Fire, H2S/HC Leakages, Power Failure, Cooling Water Failure, HP Steam Failure etc.
Developed & implemented the schemes to reduce Fuel (RFG, Fuel Oil) imbalances & thereby reduced flare losses
Improved Refinery Profit Margin-
oBy reducing Fuel & Flare loss in the refinery complex by proactively identifying & troubleshooting the process problems
oBy reducing Slop generation by effectively modifying processes & implementing the changes in the Refinery Units
Improved the Refinery processes
oBy Identifying & Reducing Oil carry over from DCU sour water to SRU.
oBy Identifying & Reducing Feed filter backwash frequency at DHDT.
oIdentified source of Oil in OWS (From CDU Overhead system) & thereby reduced ETP Load.
oImproved reliability of CPP by optimizing the Fuel oil & Fuel gas consumption in Generator Turbines.
Played a key role in Turn Around 2017 in-
oShutdown/startup of SRU/Hydro Treaters/HGU/FCCPC
oSulphiding activity of Hydrotreaters, HGU, SRU
Maintained the Normal Refinery Operations by analyzing the situation & taking appropriate actions at appropriate time
As Assistant Manager (Day SS CDU-VDU/ FCCPC)
Ensured quality of the equipment & systems as per standards during project take over- Suggested & Implemented necessary modifications in support system, line routing & helped developing entirely new system as per requirement
Steered the team of Panel Officers & Field Engineers from Pre-commissioning, Commissioning Stage to Stabilization Stage of the Block as Shift Supervisor
Identified & troubleshot major & minor process problems by implementing innovative ideas such as
oLevel setting for WGC KOD pump start & stop changed to reduce slop generation
oRaw Oil Feed Surge Drum LTs steam tracing provided to avoid malfunctioning of LTs, thereby saved shutdown of the block
oShutdown of the block postponed by at least one year by routing leakage of GCU Primary absorber overhead to CBD & operating FCCPC without Absorber overhead cooler
Prepared necessary documents for plant requirement such as SOPS, emergency operating manuals, and different checklists for supercritical machines (WGC/MAB)
Managed Start up Circulation, Desalter Commissioning, Heater Light up, Vacuum Pulling and stabilization of the CDU-VDU Plant.
Reliance Industries Ltd., Jamnagar
as Shift-Field-Engineer (Manager) for Fluidized Catalytic Cracking Plant Apr'07 – Aug’10
Key Result Areas:
Headed the Field Team for safe partial / full shutdown & start-up of UOP FCCU (formerly known as DTA Complex)
Analyzed the P&IDS with existing set up in the Block & developed ‘As Built P&IDs’
Delivered support for PHA & HAZOP studies in the plant for different systems such as ‘New Clarified Slurry Stripper’
Modified SOPs as per the new ‘MOCs’ in the Block.
Planned & Executed routine and non-routine operations maintenance activities in the Block
Supreme Petrochem Ltd., Nagothane, Raighad
As Day Shift In Charge - Production Aug'03 – Apr’07
Growth Path
Mar’07 – Apr’07: Sr. Engineer-Production (Day Shift In Charge)
Apr’04 – Mar’07: Engineer Level (Shift In Charge)
Key Result Areas:
Managed the process control through DCS supplied by Siemens and Honeywell Company
Managed troubleshooting of the petrochemical complex; developed Standard Operating Procedures for the different activities in the petrochemical complex
Executed emergency management plan in emergency situations such as Process Fire, Power Failure, and DCS Failure
Coordinated the feasibility studies/ HAZOP of new proposal/scheme
Commissioned Swing Line of Petrochemical Complex which can produce both General Purpose Polystyrene & High Impact Polystyrene
Executed change in product/grade as per new applications.
Handled extruder & pelletizer operations & maintenance activities effectively
Effectively implemented new plant change orders to conserve energy and improve the product yield
Trainings / Workshop Attended
Completed OSHA’s ‘Process Safety Management’ course in March 2020
FCCPC Implant Training at Integrated Refinery Petrochemical Complex, Rayong Thailand in Oct 2011 (05 Days’)
Attended India FCC Catalyst Workshop by Grace Davison at Trivandrum on Dec 2010 (4 days’)
Attended Indian School of Petroleum Engineering Training Programme at Bathinda in 2014 (6 days’)
Shaw Stone and Webster Licensor Training for DCC unit at Bathinda in the year 2013 (6 days’)
Laxminarayan Institute Of Technology, Nagpur
Experience as Student at Engineering College March’02 – Apr’03
Worked on the college level laboratory project on ‘Manufacturing Of Biodiesel From Edible Oil’
Developed Biodiesel (Mono Alkyl Esters of Long Chain Fatty Acids) from Vegetable oil.
Took successful run of two wheeler by using up to 20% blend of Biodiesel.
Personal Details
Date of Birth: 6th January 1982
Languages Known: Hindi, Marathi, Kannada, & English
Address: Plot-20, Amol Nagar, Biloli, Dist- Nanded, Maharashtra
Passport Details: Z4545608 valid up to 04/03/2028
Praviin Dudle (B.Tech. - Chemical Engineer)
**********@*****.*** / *******@**********.***
Contact this candidate