Process Engineer

CURRICULUM VITAE

Vijay Pundlikrao Mohod E-mail:******@*****.*** Mobile: +966*********

A self motivated and innovative Chemical Engineer, having hand on experience from training modules development; SHEMS development & implementation and energy conservation skills, and 28 years process/safety management experience in refinery and petrochemical industries, seeks assignment, preferably in Refinery and Petrochemical to meet the challenges involved in the process/safety management.

Career Profile

A Chemical Engineering professional with 28 years of experience right from pre-commissioning, commissioning, start-up, stabilization, normal operations and troubleshooting of the units LLDPE,HDPE & BUTENE-1 in Petrochemicals and CDU,VDU,BBU,VBU,LPG,NSU&PRU in the Refineries.

Developed training modules for process operation & improvement techniques, health and safety management systems and imparted training to all categories of employees.

Acquired thorough knowledge of ISO 9001, ISO14001, OHSAS 18000 & SAP requirements and implemented the systems.

Utilized motivational, problem solving and analytical skills and successfully executed quality, process improvement projects, a team player with good communication skills.

Thorough knowledge and experience in managing unit operations in chemical engineering, Conducted PHA studies, successfully executed productivity enhancement and cost reduction projects.

Had hands on experience in Safety Health and Environment Management System development and implementation.

Professional Experience

Rabigh Refining and Petrochemical company, Rabigh, KSA Process Engineer, Butene-1 Plant 50KTA (Axenes) & HDPE 300KTA (BASELL) July2012- Present Responsibilities:

Start up, normal operations, trouble shooting and Turn Around Maintenance:

Plant Monitoring and preparation of Daily Reports such as mass balance and energy balance and making corrective actions, if any

Conduct incidents’ investigations related to Process Safety and keeping track of the recommendations implementations.

Assists the Section Head in the day-to-day functioning & enabling him to concentrate on plant trouble shooting, improvement in systems & procedures and other developmental activities.

Participates in planning and scheduling of operations, start-up and shutdown of units and process engineering, inspection and safety related work for the assigned units

Troubleshooting of operational problems.

Actively involved in the preparation of Safety Manual and SOPs of the plants

Planning and execution of modification (MOC) of plant for enhanced operations

Conducting PHA/HAZOP of the MOC with MOC committee for the proposed change.

Issue of Engineering work request based on the MOC.

Conduct Job Safety Analysis, RISK assessments for the task having high RISK.

Training and development of the subordinates fresh engineering graduates and operators Major achievements

Participated in Risk Assessment Workshops for various process activities and closely worked with the HSE department.

Conducted training sessions (200 Class room and 200 on the job) to the operators and engineers and performed their knowledge assessment and capability assessment and certification.

Prepared the document of Critical Operating Parameters and trained the operators and Engineers for the same.

Conducted JSA, Risk assessments for the critical activities such as confined space entries.

Conducted periodic QHSE Audits for the systems to continual improvements in the systems. Jindal Steel and Power Limited. Angul, Odisha, India Assist General Manager Coal Gasification Plant (Operations), Jun 2011- July 2012 Responsibilities:

Project execution, Pre-commissioning of the Coal Gasification Unit:

Plans, coordinates and endorses for Operations Managers approval the manpower requirements for the Operation Division ensuring effective implementation of the policy

Supervises the Production Divisions’ identification of training needs and the establishment of job targets for all the jobs under his supervision. Ensures the proper implementation of approved training and development programmes

Ensuring timely Review& approve Process Engineering deliverables for the project and ensure completion to the required quality standards

Ensuring scheduled completion of Process Engg. Activities

Coordination in Process Simulations

Sound knowledge of columns, heat exchangers, pumps, compressors etc·

Interaction with PMC, EPCs & Licensers in resolving process issues

Interaction with vendors during offer evaluation

Supervising vendor drawing reviews

Participates in PHA studies pertaining to proposed modifications, including identifying potential operational and safety related problems and co-coordinating appropriate solutions

Support & manage the pre-commissioning, commissioning and guarantee runs

Manning plan with deployment of resources.

PETROSKILLS CONSULTING SOLUTIONS, Bahrain

Senior Process Engineer Consultant (Training and Development), Aug 2010-March 2011 Responsibilities:

Training and Development of the Operations Staff:

Contributed a significant role in conceptualising and developing training modules for 350 KTA LDPE

(BASELL), HDPE (BASELL), PDH, Cracker plants of TASNEE Petrochemicals, K.S.A. etc while keeping abreast with latest trends and technologies.

Single handedly formulated the e-learning training modules for field and panel operation to ensure smooth execution of overall tasks of 720 KTA Polypropylene Plant (Novolene Technology) for TASNEE Petrochemicals, K.S.A; successfully facilitated the Saudi operators for their training needs during the plant operations.

Judiciously overseeing entire Middle East operations of the Canadian Company while rendering cutting edge consultancy for smoothing the Refining and Petrochemical Operations for its Clients viz. Saudi Aramco and SABIC Affiliate.

Major achievements

Hold credentials of efficiently completing the 720 KTA Polypropylene (PP) project training e-learning modules appreciated by TASNEE management for well-designed content and e-learning resources with suitable graphics.

Gains ample exposure, knowledge and database for all polymer plant running needs and improved the analyzing skills for selection of new technology for the polymer plants. SAUDI KAYAN, SABIC, Al-Jubail, Kingdom of Saudi Arabia Operations Specialist Polyethylene, Feb’ 2008 – July 2010 Responsibilities:

Pre-commissioning, Commissioning, Start up Trouble shooting:

Played lead role as Operations Specialist of HDPE Plant 400KTA licenser BASELL whilst Systemization, WEFS, Activity listing, Detail Activity listing, CSU procedures, Start-up procedures and emergencies scenarios procedures

Played Lead role in Operation Implementation Project as Core Q-Captain (Operability and Maintainability) for the execution of project.

Support Operations Manager in planning, to manage and coordinate the activities to ensure that Production targets are effectively met, the Plant is operated and maintained safely and efficiently in accordance with Company policies, objectives and quality standards

Involved in the P& ID review, Risk assessment, PHA, HAZOP Study, 3-D Model review, FAT, SAT and ISAT witness during the project phase.

Project coordination like Preparation of ITB, Field Engineering at site, Vendor selection.

Experienced in the Safety Health Environment Management System preparation and implementation in the large scale Organizations as an administrator based on the SABIC SHEM Standard

Recommends continuous improvement of Company policies, SHEM systems, processes and practices based on the audits conducted by me as an Auditor (SHEMS Element Administrator)

Worked as active Risk Based inspection (RBI) team member and fully conversant with Meridian Software Human Resource development:

Select and facilitate to appoint qualified technical staff for Polyethylene department for LDPE & HDPE Unit.

Trained Saudi Kayan Petrochemical Company Operations and maintenance staff on Safety Health and Environment management Systems (SHEMS-07.06 and SHEMS-07.08)

Guide and motivate a team of 30 Operations engineer, supervisor and Saudi engineer trainee, train them in plant operations, safety awareness and emergency procedures, quality requirements. Major achievements

Appreciated by Saudi Kayan Management for development of SHEMS and training all the operations and Maintenance Staff.

Reviewed and given major inputs in the HAZOP and SIL Report for the HDPE Project.

Task force member for DCS FAT and 3D Model Review for HDPE.

Closed HAZOP Action items in Detail Engineering phase for HDPE Project department in Saudi Kayan.

GAIL (India) Limited, Petrochemical Complex, Pata, India Manager Petrochemical (Operations), Jan 1998- February 2008 Responsibilities:

Production/process management:

Managing the day-to-day operations activities, coordinate and follow-up with different department to manage development and implementation of Operations for Plants High Density Polyethylene Plant (Mitsui Japan) 100KTA, LLDPE (Nova chemical) 160KTA and Butene-1 (Axens /IFP) 10,000MTPA

Played Lead role in Execution of Pre-Commissioning, Commissioning, Start-up & stabilization of High Density Polyethylene Plant (Mitsui Japan) 100KTA, LLDPE (Nova chemical) 160KTA and Butene-1 (IFP) 10,000MTPA

Support Operations Manager in planning, to manage and coordinate the activities to ensure that Production targets are effectively met, the Plant is operated and maintained safely and efficiently in accordance with Company policies, objectives and quality standards

Monitoring the performance with the help of direct reports from the subordinates and giving the recommendations for the areas required improvements so that the subordinates are motivated and utilizing to their full potential.

Implementation of Company policies, procedures that are to be fulfilled while operating the Plants within specified ranges of Security and Quality.

Recommend continuous improvement of Company policies, systems, process and practices based on audit recommendations.

Overall monitoring & implementation of Standard Operation Procedures (SOP) for all type of Operation.

Preparation, follow-up Start-up & Shut-down schedule and all related activities and instruction.

Overall manpower control for the units.

Maintain monthly meeting with all Supervisor to enhance the communication.

Enhance the team work in the department and shift personnel.

Evaluate the efficiency of Operation Personnel.

Solve Operation Problems and instruct the Operation Supervisor for the corrective action.

Analyze Operation Trouble Reports and make corrective action with recommendation.

Attend Plant Emergency and Operation Trouble while Start-up or Shut-down.

Attend daily meeting and give daily instruction

Follow-up with Operation Supervisor regarding the issued instruction to ensure implementation and completion of the work.

Issuing of MOC as per the requirements with follow up.

Overall control of Catalyst Optimization and the technical support and advice.

Prepare all requirements for Turnaround Maintenance (TAM).

Giving the mentioned plant Process training to all operations staff.

Follow up any recommendation regarding PHA, Projects implementation, etc.

Implementation of Process Safety management System.

Comply with GAIL(India) Limited; Safety health & Environment procedure

Execution of well defined Work Permit System & related Document Control.

Involved in the energy conservation projects in GAIL (India) Limited Human Resources development:

Managed and motivated the operations staff, of 32 engineers and operators, trained them in process operations, safety and environmental management.

Major achievement:

Competently managed the capacity expansion project LLDPE, Planned, monitored progress, procured equipments/ materials and increased plant capacity from 160 to 210 KTA.

Stabilized the production process for five grades of Polyethylene. Mangalore Refinery & Petrochemicals Limited, Mangalore, India Production Engineer, March1995 - Jan1998

Responsibilities:

Production/process management:

Played lead role as lead Engineer during project execution, pre-commissioning, commissioning, start-up, GTR, stabilization, normal operations & TAM of the units, CDU/VDU/BBU/VBU/LPG.

Actively involved in the preparation of Safety Manual and SOP are for the plants

Responsible for supervising and leading a shift team as a Shift Supervisor for the above mentioned units

Coordinating with the other department executing operations, plan, maintenance activities, assessing root cause & remedies

Meeting production targets & Product specifications with established safety procedures.

Analyzing and minimizing the downtime and off-grade production.

Manpower handling and deployment.

Shutdown and start-up planning.

Planning and execution of modification of plant for enhanced operations.

Problem solving and trouble shooting.

Developing procedures and systems for safe and sustained running of the plants.

Co-ordination with central Operation group, Fire and Safety departments, Laboratory, maintenance and other service group.

Finalised monthly production plan, managed daily production operations, reviewed daily production/ quality data, and resolved operational problems.

Coordinated with purchase department and maintained adequate inventory of raw materials, lined up imports of raw material and additives.

Resolved various process problems by modifying process parameters. Human Resources development:

Managed and motivated a team of 25 plant operators and guided them in process, safety operations.

Imparted regular training to the operating personnel of the plant.

Conducted Dynamic process simulator training to the DCS Operators Major achievement:

Acquired good knowledge of resources mobilization and use, improved Processes, quality & reduced Operating costs.

Suggested and implemented the production enhancement scheme within the existing infrastructure without any major field change.

Hindustan Petroleum Corporation Limited (Vizag Refinery) India Operation Technologist, Aug 1992 – March 1995

Responsibilities:

Production/process management:

Trained under experienced plant supervisors and studied day-to-day operations of PRU/CDU/VDU/LPG.

After successful completion of training, worked as DCS Panel In-charge, stabilized and controlled the process and achieved targeted output with desired quality

Operation of the PRU/CDU/VDU/LPG plant with optimum efficiency and productivity.

Resolving operational problems and competently handling emergencies.

Data collection, interpretation and data analysis Major achievement:

Trained young Operators in the process operations and control. Educational Qualifications

Degree in Chemical Engineering with specialization in Petrochemical Engineering from L.I.T. Nagpur University, Nagpur, 1990 with first division. India.

Degree in Science from Amravati University, Amravati, 1987.India.

One Year Advance Course in Industrial Safety form HRM Gov. Of India

NEBOSH International General Certificate in Occupational Safety and Health, UK.

NEBOSH International Diploma in Occupational Safety and Health, UK.

Certificate course in energy manager and energy auditor from BEE Minister of power Government of India.

Training

SAP PP, PM and QM User Training completed and the User Test conducted on line by SAP Team in Saudi- Kayan, SABIC, Al-Jubail.

RCE Certificate Courses from Meridian /APM Basic/Advance course /RBI course /RBI Methodology Facilitation course

Certificate course of ISO 14001 Lead Auditor Course

Training on Petroleum Refining Technology from IIP, Dehradun India.

Certificate course of corrosion prevention & control from NPC. India. Computer Proficiency

Conversant with MS Word, MS Excel, MS PowerPoint etc.

Conversant with SAP PP, PM, QM etc.

Conversant with Aspen Plus etc.

Personal Information

Date of birth: 22nd June 1966.

Passport No.P3503644, Valid up to 07.04.2027

Languages known: English, Hindi and Marathi.

Date: 16th June 2021

Place: Rabigh KSA

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