PRAKASH. A

Address: A10, SPIC Nagar, Tuticorin, Tamil Nadu, India

Contact: +91 9789182801; E-mail: [email protected]; Skype: prakash.kalpana

Objective

Sr. MANAGER (GAS OPERATIONS/ COMMISSIONING) – OIL&GAS/PETROCHEMICAL FIELD

Seeking a challenging and rewarding opportunity with an organization of repute which recognizes and utilizes my true potential while nurturing my analytical and technical skills in production and process engineering field

PROFILE AT A GLANCE

ü  Chemical Engineer with 18+years of experience in commissioning of Oil & Gas/ Ammonia/ CO2 Recovery plants at various capacities to lead Production/Operations Engineers in trouble shooting operation issues.

ü  Currently working with M/s. Southern Petro Chemical Industries Corporation Ltd., Tuticorin as Senior Manager – Ammonia Revamp erection & commissioning.

employment summary

ü  Total Experience                              : 18 Years

ü  Oil and Gas experience                 : 10 years

ü  Commissioning experience          : 8 years

Career summary

ONGC – OIL AND NATURAL GAS CORPORATION LIMITED, Karaikal, India                                (Jul’01 – Jan’04)

Position: Assistant Superintendent.

Capacity: Gas Production – 3 MMSCMD, Oil Production – 1200 MTPD & Water – 6000 SCMD.

CAIRN ENERGY – Rajasthan Oil Field, Barmer, India                                                                                     (Jan’ 04 – Jan’ 08)

Position: Shift Superintendent.

Capacity: Gas Production – 3.92 MMSCMD, Oil Production – 21620 SCMD & Water – 99000 SCMD.

SOUTHERN PETROCHEMICAL INDUSTRIES CORPORATION LTD, Tuticorin, India                  (Jan’ 08 – Oct’ 13)

Position: Manager/ Deputy /Assistant (Production – Ammonia & LPG Storage)

Capacity: Ammonia Production – 1260MTPD & CO2 Production – 30000NM3 /Day.

MA’ADEN, Ras AlKhair, Eastern Province, SAUDI ARABIA                                                                         (Oct’ 13 – Aug’ 16)

Position: Senior Engineer – Gas Operations & Commissioning

Capacity: Gas Production – 850MMSCFD & Condensate Production – 60,000BBLSD.

SOUTHERN PETROCHEMICAL INDUSTRIES CORPORATION LTD, Tuticorin, India                  (Aug’ 16 – till date)

Position: Senior Manager – Ammonia Revamp erection & commissioning & LPG Storage.

Capacity: Ammonia Production – 1260MTPD & CO2 Production – 30000NM3 /Day.

Commissioning Experience

ü  Worked as Senior Engineer – Commissioning of Natural Gas pipe lines & Ammonia plant in World Largest Ammonia plant with 3300MTPD capacity at M/s. Maaden – Saudi Arabia.

ü  Worked as Senior Manager – Erection & Commissioning of CO2 plant with 3000NM3/Hr capacity (By optimising process parameters achieved 3800Nm3/Hr than the design valve).

ü  Responsibilities included making start up plans & Procedures, DCS Graphic Reviews, P& IDS updating updating commissioning mark ups, test packs,making the interface drawings, training of Locals, site walk downs, punch listing, checklisting & following up the site commissioning activities. Also involved in making, Dossiers, checking and writing Commissioning procedures, participating in Hazop, Hazid etc.The plant was started successfully before being shut down for the export pipe line repair job. Activities were Scheduling , Finalizing the contracts for Sub contractors for the commissioning activities, Manpower mobilizations, preparing commissioning strategies, and assigning priorities for construction completions

ü  Working as Sr. Manager & earlier as Shift In-charge also for LPG Terminal – 8500MT storage capacity & Ammonia plant in M/s. SPIC Ltd.

ü  Team Leader for Natural Gas conversion erection/commissioning & Revamp of M/s. SPIC – Ammonia plant.

ü  Appreciation Award received from M/s. Southern Petro Chemical Industries Corporation limited, India for Record production achievements with Annual additional income of 1.125 Billion USD.

ü  Successful erection & commissioning of

o    Purge gas line to ASGU Boiler

o    Off gas line to Fired Heaters

o    Synthesis loop gas to Reformer fuel firing line

ü  Expertise in Commissioning /Start up activities like

o    Completion of Punch list items

o    Lead with a team of Operations, Mech., Elect., & Inst.,

o    Guidance, Troubleshooting & support  to Operation team

o    Work permit system & strictly follow HSE standards

o    Preparing Standard Operating Procedures(SOP)

o    Lines/vessels – Nitrogen Purging, leak checking, Blowing

o    Pre commissioning activities like line flushing, Air blowing, purging

o    Pigging – Dewatering & IPS service

o    Lines/Vessels – Chemical cleaning, hydro jetting

o    Catalyst loading and unloading activities

COMMISSIONING/ OPERATIONS MANAGEMENT

ü  Good experience in Commissioning Management  & Operations  in Oil & Gas/ H2S treatment/ Sulphur plants/ Carbon di oxide plant / Utilities & Offsites / & Storage. Good knowledge about Operation philosophy for petrochemical plants, Oil and Gas & Offsites.

ü   Major equipment handled are Centrifugal Compressors, Gas & Injection Compressors, Reciprocating compressors, Amine systems, Absorbers and separators,  Gas Turbines, Axial Compressors, Air heaters, Hot Oil heaters, Instrument  Air Compressors,  Sea water/cooling water system, Nitrogen packages, Fire water system, Ammonia and Ammonia storage system(Sphere& fixed roof) & Boil off gas compressors, Cryogenic system compressors, fixed roof and floating roof storage tanks , Inert Gas unit, Pressure swing Absorption systems , Flare packages, Boilers,  pipeline launchers and Receivers, Hydraulic systems etc.

ü  Major commissioning deliverables like Commissioning philosophy, Commissioning plans & Procedures, Commissioning Manuals, System/ Sub System identification, Vendor planning, Manpower estimation and recruitment, interface management.

ü  After completing the commissioning involved with   the plant Start- up and performance tests.

ü  Experience  in leading a Multi discipline team with people from all backgrounds.

Field of Experience

ü  Gas oil separation Plant (GOSP) plant Operation.

ü  De-salting and crude washing for hi salt content crude and high wax content crude.

ü  Gas dehydration operation and troubleshooting.

ü  Gas sweetening operation and troubleshooting.

ü  Crude oil pumping and metering.

ü  Gas lift compressor Commissioning, Operation and troubleshooting.

ü  Gas injection Compressor Operation and troubleshooting.

ü  Oil & Gas Field commissioning operation like commissioning of flow line, trunk lines, equipment’s and Crude Degassing stations.

ü  Handing over the equipment for OFF-stream inspection.

ü  Very good Experience in IPS pigging and normal de watering pigging operations.

ü  Trouble shooting to maintain the product quality.

ü  Hot oil Fired heater operation and Troubleshooting.

ü  Surge Tank and product tank operation.

ü  Flow suction tank (FST) operation.

ü  Oil dehydration tanks operation and troubleshooting.

ü  Produced water treatment plant operation and produced water injection operation and troubleshooting.

ü  Clear understanding and hands-on experience in all functional aspects of Process Engineering for Conceptual, Basic & Detailed Engineering design of Oil & Gas facilities.

ü  Experience in providing field Operation Technical Support, Process Plant Optimization, Facility Up gradations and Modifications etc.

ü  Experience in commissioning and start-up of Oil & Gas processing facilities.

ü  Experience in coordinating and leading a team of multi discipline engineers includes Chemical, Mech., Elec., &Inst.,

ü  Technical bid evaluation with vendors.

ü  Production & Budget Planning, KPI’s, Cost Control, CAPEX, Review & approve all OPEX items.

ü  Preparation of reports for Review meetings with top management & conducting plant meetings.

ü  Monitor performance of the Plant, Boilers on daily basis to meet specified energy consumption, identify problems associated with normal operation, trouble shoot problems and carry out rectification measures.

ü  Planning, execution of Startup/Shutdown of plant with utilities like 106k fuel oil fired boilers, Instrument air system, Cooling water system and Inert gas generation unit as per the yearly planned shutdown.

ü  Experience in handling plant emergencies. Instruction to SIC’s and Engineers on day by day.

ü  Study and implement modifications, carry out HAZOP, devise Standard Operating Procedure for new modifications.

ü  Receiving reports from SIC’s & Engineers on shift & daily basis and reporting to GM, COO&WTD.

ü  Leading a group of 112 members from all departments including SIC’s, Engineers, operators and technicians.

ü  Successful completion of CO2 erection and commissioning, CO2 plant was completed with my leadership by leading a team of Engineers, Operators & technicians in coordination with process licensor.

ü  Preparation & Implementation SOP’s, EOP’s, Log sheets and modification/ updates of P&ID’s.

ü  Planning, execution of Startup/Shutdown of CO2 plant with utilities like Coal fired boilers, Instrument air system, Cooling water system and Solvent generation unit.

ü  Stabilization and adjustment of operating conditions. Preparing technical performance report of plant equipment’s.

ü  Start up and Shutdown of ammonia plant from DCS as well as from field.

ü  Ensuring that all production operations are executed in a safe and efficient manner in accordance with the (SHEMS) Safety Health Environment Management System and in compliance with the production target set.

ü  Performs a variety of process engineering duties in the plant. Includes monitoring performance of plants and facilities, preparing daily performance summary and recommending corrective actions to deal with abnormalities.

ü  Estimation, Planning, Purchase Requisition and procurement of Raw Materials & chemicals.

ü  Prepares annual budget, production plan, variable cost, daily and monthly production reports.

ü  Optimization of plant operating conditions and utilities consumption.

ü  KPI Preparation, implementation and monitoring.

ü  Prepares instructions and plans for defined operations and maintenance activities.

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

ü  Playing a central role in Capital project and plant improvement

ü  Troubleshooting and preparing investigation reports for plant shutdown or any process upset.

ü  Necessary production related instruction on daily basis to the shift crew.

ü  Plan and assign jobs to workmen and follow up with minimum response time. Decide upon required measures for job execution.

ü  Facilitate Internal/External & IMS Audits includes ISO9001, ISO14001, OSHAS 18001 & ISO50001.

ü  Production report generation; Focal for Management of Change “MOC”, responsibility starts with Proposal For Change (PFC), Request for Change (RFC) till MOC Completion & Execution.

ü  To provide technical support for the department and cover for technical positions within Production.

ü  Team Leader & Member in (RCA) Root Cause Analysis studies.

ü  Strong techno-commercial acumen with the ability in participating in commercial and legal discussions, finalizing requirements, costs estimates, contract documents; evaluating & executing contracting works as well as handling vendor negotiation, award and review of contracts as per deal agreement.

ü  Involved in the planning, prioritizing, execution and monitoring of engineering activities / projects, reporting work progress, problem analysis & trouble shooting, predictive maintenance and problem anticipation.

ü  Participate in studies investigations and projects, maintain contact with process licensors / equipment manufacturers, provide specifications with regard to procurement, contract coordination and bid evaluation.

ü  Superlative leadership qualities with excellent analytical skills with demonstrated capability to effectively use manpower and motivate professionals to maximize levels of productivity

ü  Having good knowledge in P&ID’s,PFD’s, material &energy balance & commissioning of process equipments

education

B. Tech-Chemical Engineering 1997 – 2001: Graduated with first class from Bharathidasan University, Trichy,

Tamil Nadu, India

Trainings and Certifications

Course Title
Training Centre
Basic first Aid & CPR
SPIC, Tuticorin, Tamil Nadu, India
H2S, Escape & BA Set (Level I and II)
MA’ADEN Training Centre, Saudi Arabia
Fire Fighting Essentials
MA’ADEN Training Centre, Saudi Arabia
ASME process piping, Valves, flanges and fittings Standard.
MA’ADEN, Gas Operations, Saudi Arabia
HAZOP STUDY LEADERSHIP
ISRECO, MA’ADEN, Saudi Arabia
YOKOGAMA – PIMS User Certification
Yokagama Services Saudi Arbia
Aspen plus Modelling Simulation Workshop – Certificate of Achievement
Aspen Tech, MA’ADEN Training Centre, Saudi Arabia
E-Systems Training  (Audit, QIR and Suggestion)
MA’ADEN Training Centre, Saudi Arabia
Gas Production and Processing Facilities
MA’ADEN, Gas Operations, Saudi Arabia
Confined Space Entry – Competency certificate
Director Industrial Safety & Health, Chennai, India
Leadership Development Program
Thomas International, Bangaluru, India
 

Projects and achievements

ü  Letter of Appreciation Award received from M/s. Southern Petro Chemical Industries Corporation limited, India for Record production achievements with Annual additional income of 1.125 Billion USD.

ü  Team Leader in decommissioning and commissioning of Naphtha tanks (8700KL), Fuel oil tanks (3000KL).

ü  Team Leader in decommissioning of Ammonia Storage vessel Horton Sphere (3000MT).

ü  Team Leader Reformer ID/FD fan modification to improve plant reliability & down time nil.

ü  Team Leader for ASGU Boiler Tail gas lining up from PGHRU for energy saving by reducing the Spec. and increase the boiler efficiency. Spec reduced from 0.069 to 0.0575.

ü  Team Leader in Commissioning and maintenance of Cold Box and plate type heat exchanger units

ü  Team Leader for installation of VFD along with MFCV in BFWP to avoid failure & eliminate plant downtime.

ü  Operation coordinator in Hooking up of off gas to process air fired heater for firing, there by reduction in naphtha consumption by 0.2 tph.

ü  Operation Coordinator for off gas firing in 1433 Fired Heater to reduce the Naphtha Spec. and increase the fired heater efficiency.

ü  CO2 Plant production capacity was increased more than the design value by fine tuning the parameters.

ü  Comply monthly pigging of trunk lines.

skills & proficiencies

v Pre commissioning and Commissioning Experience vPlant performance monitoring & Control vTrouble shooting vP&ID, PFD & Data Sheet Review v HAZOP vJSAvRCAvPSSRvHazardous Chemicals handling and Disposal v HAZID & SIL v Risk Assessment v CAPEX vOPEXv Budget & Planningv ISO Standardsv Trip and Interlock v Cost ControlvPlant KPI’s  v Chemical and Inventory controlv SHEM and its elements  v Plant & Equipment’s performance v Emergency Preparedness plan vSOP & EOP vESDvFailure analysis report v Start up and shutdown experiences.

personal details

Permanent Address        : 38, East street, Selliampalayam, Attur (TK), Salem (Dt)-Pin: 636108.

Computer Proficiency     : SAP, MS Office, Oracle, PIMS, Optimat, Fincube, Finacle, Hyperion, Aspen Plus.

Marital Status                     : Married.

Date of Birth                       : 10th December 1977

Languages known           : English, Tamil & Hindi.

Passport No                      : J0472485/   DOI 19/08/11/ DOE 18/08/21.

(PRAKASH.A)