Executive Profile

B.Tech. (Chemical Engineer) qualified professional with expertise in managing Plant Operations, Production coordination /planning and scheduling, People management, Budgets & plans, Production Management, Technical guidance, Continuous improvement, System administration and networking, Quality, Health, Safety & Environment management, Pre-commissioning, Commissioning & Maintenance with focus on profitability by ensuring optimal utilization of resources

Implemented plans & schedules for operations & annual turnarounds with key focus on optimum utilization of manpower & material; ensuring commissioning and pre-commissioning of plant for smooth operations

Recorded success in preparing plant modification for operations with skills in executing operation of DCS System like ABB, Fischer Rosemount, and Yokogawa Centum CS3000/VP

Completed training in Firefighting Extinguishers like Dry Chemical Powder, Foam, Water, CO2.All PPE like Breathing Apparatus (SCBA) and Escape Hood

Organized toolbox meeting with expertise in preparing, issuing & following up of safety permit systems for vessel entry, hot work, cold work, high elevation, excavation and electrical jobs

Participated in Weekly Table Exercises, managed safety mock drill as per contingency plan & procedures

Knowledge in LEL & HEL of various chemicals with expertise in implementing Onsite & Offsite Emergency Preparedness Plan

Broad knowledge in aspects of operational activities and latest technological advancements/regulations related to QA/QC

Key Impact Areas

Commissioning & Pre-commissioning

Production Coordination

Quality Management System

Cross-functional Collaboration

Plant Operations

Production Recording And Analysis

Continuous Process Improvement

Root Cause Failure Analysis

Soft Skills

Knowledge Purview

Equipment Functional Test Safety Management Plant Startup & Shutdown Preparation

Work Permit System DCS Operations Emergency Management

Startup/Shutdown Operation SOP’s & Critical Proc. Preparation Process Re-engineering

Instrument Loop Test and Functional Test Plant Optimization Operation Training

Education & Credentials

B.Tech. in Chemical Engineering from St Peters Engineering College (Anna University, Chennai) in 2007 with 85%

Trainings

Polyol Plant Technology at Dow Texas Operation, Texas USA (5 months training)

Dow POLYOLS Licensor Training Program Certificate Holder

Polyol - DMC Project as Commissioning Team Member in Dow Texas Operation, USA

Safety Behavior Intervention Training

Certified Lean Practioner

ABB -800XA System

Propane, Butane,Propylene, Ethylene Propylene oxide and Ethylene Oxide Emergency Management

LIMS, ODMS, MOC & OPD System

Equipment / Systems Managed:

CSTR Reactor, Vertical flat bottom, double wall, double integrity refrigerated tanks,Boil of Gas And Flash Gas Compressor System, Propane and Butane Re-Liquefaction System, Propylene/ Ethylene /Ethylene Oxide/Propylene Oxide Refrigeration, Mounded Storage System, Steam Condensate Stabilization Unit, Jetty Operation, Pipeline Scrapping and Pigging System, Vacuum Distillation, Packed Column Distillation, Waste Heat Recovery Boiler, Rotary Equipment, Analytical & Measuring Instruments, Filtration (Various Types) Centrifugal Separation & Decantation.

Notable Achievements Across the Career

At Sadara Chemical Company, Jubail, Saudi Arabia

Received extraordinary achievement award for increasing DMC Production rate by 20% over design by additional capacity of 66 KT DMC polyol Production capability @ US$7 Million.

Received extraordinary achievement award by doing Raw material Optimization via recipe changes resulted in reduction of individual raw material cost. Annual Saving @ US $ 1.5 million

Executed and implemented specific operational policies/plans like Start-up and Shutdown Plans & programmed in concert with general policies

Participate and provide high quality input in various studies like Hazop, SIL, Risk assessment, Root Cause Analysis, etc.

Act as the technical lead and lead the critical operating procedures, which includes start-up and shutdown, commissioning and testing of new equipment of the assigned plant, to provide control and coordination.

Lead the planning activities for all critical operations in collaboration with Shift Supervisors, maintenance and engineering services to prepare pre-shutdown and shutdown execution plans, status reports, and performance evaluations’ in line with approved work lists to optimize plant turnaround and startup activities. Ensure effective coordination of all aspects of plant shutdowns to meet shutdown success criteria, including strict application of HSE and quality policies and procedures.

Analyze drawings, specifications and statements of work in preparation of activity networks for shutdown resource planning and scheduling and ensure availability of resources such as personnel, materials, logistics and infrastructure services in collaboration with Head, Shift Supervisor and other functional leads.

Provide consultation and technical advice on temporary arrangements with respect to running plants/ equipment necessary during turnaround period.

Provide guidance to work team on monitoring operating conditions and give instructions on process adjustments to ensure safe and efficient process operation.

Ensure cost and production targets are met by monitoring and reporting actual versus budgeted operating costs and production quantities at regular intervals and implement corrective actions in coordination.

Lead the identification of opportunities for continuous improvement of systems, processes and practices taking into account ‘global best practices”, improvement of business processes, cost reduction and productivity improvement.

Developing improvement plans to enhance process matrices to improved production performance.

Monitoring KPI (key performance indicators) to identify areas for improvement. Analyze key performance indicator (KPI) and recommend improvements with focus on maintenance processes and executions.

Providing technical guidance in the analysis of accident / incident / near miss reports, claims and non-conformities etc. and facilitate effective resolution of process issues for operational continuity.

Coordinating planning, scheduling, preparing and executing of production activities by acting as the link among market, production and business departments.

Coordinating planning and preparation of operations production schedules to successfully met production targets.

Leading and ensure the effective cascading of Ethylene Oxide /Propylene Oxide operational strategy and plans into plant production plans and lead the effective monthly and daily scheduling of plant shift operations in line with the approved strategies and business demands.

Identifying deviations from established schedules and budgets and take corrective actions.

Preparing status reports, forecast costs, workload and material requirements and establish inventory and production goals.

At IndianOil Petronas Pvt Ltd, Chennai, India

Successfully managed pre-commissioning & commissioning activities of:

oRefrigerated Propane(26000 m3) and Butane (26000 m3) storage tank, Propane and Butane re-liquefaction systems and vaporization system, Boil of gas Compressors and Flash Gas Compressors / refrigeration system for handling ship unloading operations, Precooling Operation of Jetty lines, Propane and Butane Mounded Bullets and Condensate Storage system.

Worked on the pre-commissioning activities including motor no-load run, system leak test, air purging, water washing, air blasting, nitrogen purging of Vertical flat bottom, double wall, double integrity refrigerated tanks and utility process systems including BOG and FOG Compressors

Supervise and co-ordinate all production activities of the plant to meet approved production objectives while providing technical guidance and expertise to ensure timely resolutions of issues and recommending changes to approved production policies in light of technological developments and changing business conditions.

Lead and supervise the setting of production parameters, timely coordination of the quality processes and adjusting production conditions during operation to ensure quality and efficiency.

Liaise with maintenance sections to coordinate the development and installation of new plant and equipment, and the implementation of correct maintenance procedures for subsequent repair and servicing of facilities

Checked process loops & control valves stroke, conducted functional test (ESD, POS, MOS Permissive & Process Controlling Logics), managed calibration through ABB System, managed Propane and Butane terminal plant start-up along with shutdown activity, BOG and FOG compressor start-up, heater & boiler dry out activities.

Provide inputs and implement departmental policies, systems and procedure across the plant so that all relevant procedural/legislative requirements, fulfilled while delivering a quality, cost-effective service.

Manage all assigned procedures and processes within own domain ensuring that they are implemented so that the process of the asset is effective.

Supervise and co-ordinate according to relevant procedures activities during any emergency situation which may arise to facilitate optimum protection of Company resources in line with defined HSEQ policies and procedures.

At Manali Petrochemicals Limited, Chennai:

Successfully prepared Check List, Startup Procedure, Work Instruction Manual (WIM), Work Instruction Procedures (WIP), Functional Test of Rotary Equipment, External & Internal Inception of Column & Vessels, Production Plan & Schedules

Streamlined hazardous & flammable liquids like loading of propylene oxide and unloading of propylene, chlorine & ethylene oxide; managed pumps, fans, blowers, rotary vane gas compressor, high rate thickener and rotary vacuum dry filter.

Monitor the production planning and schedule to validate the effective administration of SAP processes within the plant and adherence to SAP guidelines in all related aspects of annual and monthly production planning, scheduling, order processing, material movement etc. in order to facilitate achievement of system/data integrity in line with defined Company standards.

Develop and maintain effective business relationships with all relevant internal departments and external entities such as Petrochemical company counterparts, contractors, and service providers etc. with highest standards of business ethics, whilst promptly attending to all critical technical issues in-order to ensure the services required by the organization are delivered in the most effective manner.

Represent Company externally with customers and stakeholders in all technical meetings to handle any escalated technical matters

Reviewed operators’ sheets & laboratory results to ensure correct product specifications, participated in preparation of plant start-up, shutdown procedures, activities and in review of P&IDs and Hazop Studies.

Ensure compliance to all relevant quality, health, safety and environmental management procedures and controls within a defined area of activity to guarantee employee safety, compliance, delivery of high quality products/service and a responsible environmental attitude.

Collaborate with HSE and Quality on related issues such as process safety, continuous improvement systems, etc. to achieve and exceed target standards.

Follow and promote the best work practices related to optimum production, quality, health, safety and environmental protection. Coordinate the issue of the Incident Reports with Shift Supervisor and follow up till close out after due implementation of corrective / preventive actions.

Career Timeline

Professional Experience

Since April’2014 with Sadara Chemical Company, Jubail, Saudi Arabia as Production Engineer - POLYOLS

“The company is a unique alliance between two corporate leaders in their respective industries Saudi Aramco and The Dow Chemical Company”

Key Result Areas:

Executing plant start-up & shutdown activities, maintaining process, maintenance, quality & environment, devising new procedure for critical, non-routine and routine plant activities

Managing process design stage in P&ID Study and Hazop Identification, providing updates in Greenfield Development, working on new operation equipment, preparing punch-list & start-up checklist along with resource management

Taking time bound actions on punch points, dead-end logging, insulation damage, and sacrificial anode replacement, preparing LIMS for tracking LAB oriented updates like product certificates sampling request & event management and working on plant waste materials through SAP System

Contributing to development of vision, mission & goals and other top level strategies and tactics for achieving long & short-term aspirations of company; creating and implementing best practice, manufacturing vision, strategy, policies, processes & procedures to achieve company’s goals & ambitions

Ensuring smooth plant production, financial performance, meeting customer requirements and collaborating with Sales, Production & Purchase Department to ensure production targets are met

Performing RCI, identifying technical skill set, resource levels & systems to deliver projects, including engagement of external resources, conducting risk assessments of processes and tasks in department

Working towards mapping requirements & providing best solutions for evaluating & defining scope of project and finalizing project requirements

Previous Experience

Dec’2011 – Mar’2014 with IndianOil Petronas Pvt Ltd, Chennai, India as Operation Executive for Refrigerated Storage Tank Propane/ Butane Terminal

Growth Path: Started Carrier as an Operation Executive and promoted as a Process Engineer

Jul’2007 – Nov’2011 with Manali Petrochemicals Limited, Chennai as Executive (Operations): Propylene Oxide, Propylene Glycol and Polyol Plant

Growth Path: Initially started my carrier in Manali petro Chemical Ltd as a Management Trainee, after continuous hard work and Experienced in Polyol, Propylene Glycol and Propylene Oxide Plant, promoted as Production Engineer/ Executive.

IT Skills

Windows Environment (MS Office: Word, Excel & PowerPoint) and Internet Applications

Personal Details

Date of Birth: 9th May 1985

Languages Known: English and Tamil

Permanent Address: 9,Lakshmi Amman Koil Street, Thadaperumbakkam, Ponneri-601204, India

Passport No.: L6218258

Marital Status: Married

Nationality: India

BALAJI BOOPALAN

An established professional with 13+ years of experience; targeting assignments in Process Engineering /Plant Commissioning & Pre-commissioning / Operations, preferably in Process Industries / Oil & Gas / Petrochemical Sector with a reputed organization

Leader

Decision-making

Problem-solving

Liaison & Coordination

Change Agent

Collaborator

Adaptability

July’2007 – Nov’2011 with Manali Petrochemicals Limited, Chennai as Executive (Operations)

Since April’2014 with Sadara Chemical Company, Jubail, Saudi Arabia as Process / Production Engineer - POLYOLS

Dec’2011 – Mar’2014 with IndianOil Petronas Pvt Ltd, Chennai, India as Operation Executive-Process

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