MANJUNATH S

• Responsible for safe operation of the plant as DCS Engineer in Hydrogen Generation Unit (HGU of 16.4 MT/hr) with integrated GTG (15MW), Syngas Plant (14.6 MT/hr) and Air Separation unit (10,050 Nm3/hr)
• Responsible for the day-to-day operation of the HGU, ASU and syngas plant in 8 hour shifts, including troubleshooting plant process problems, directly supervising daily plant activities
• Identified potential problems before they occurred through proactive monitoring.
• Ensured that all safety procedures were followed when issuing work permits.
• Capability to implement emergency plans or react to abnormal situations in a measured and proactive way
• Shall coordinate with the customer BPCL regarding product requirements and ensuring communication protocols during normal and plant emergencies
• Prepare Operation hazard risk assessment

Achievements

• Commissioning of Syngas Plant (H2: CO)
• NG to Naphtha feed/fuel C/O plant start-up
• Hydrogen and syngas plant start-up, shutdown and turn around jobs
• GTG Engine replacement job
• Reviewing of SWIM's and Operation JSA
• Proficient in reading and reviewing P&ID's, Equipment data sheet, cause and effect diagrams and control logic's.

• Responsible for safe operation of the plant as console supervisor in Delayed Coker Unit of 2.7 MMTPA
• Handle plant startup/shut down and emergency activities
• Trouble shooting of process
• Review LIMS data and take corrective actions
• Lead a team of technicians

Achievements

• Online spalling of Heater pass tubes
• Pigging of heater tubes
• DCU plant shut down and start up
• MF top washing to overcome the higher fractionator top differential pressure.

• As Shift Engineer in ammonia plant of 880 MTPD supervise DCS and field operations with a team of 11 members, follow daily jobs and coordinate with different department person for job completion and meeting daily targets
• Ensure safe, efficient and timely start-up/shutdown operation
• Emergency operation and restoring the plant in minimum down time and coordination with field executives.
• Issuing of Work permits like cold work permit, vessel entry permit, hot work permit, by carrying out electrical and mechanical lockout and follow-up the job
• Logging all activities carried out, abnormalities noticed during shift and activities to be carried out in next shift
• Prepare technical reports of ATA (Annual turn around) jobs
• Operating in compliance with the OHSAS-18001 and ISO-14001 standards prescribed by company.
• Operating in Naphtha based reforming section, Benfield absorption unit, centrifugal compressor and Haldor Topsoe ammonia synthesis section.
• Operating of high-pressure Compressors (200ata), Steam turbines (back pressure), and Pumps
• Carrying out troubleshooting of the process & equipment related problems to achieve optimal running conditions

Achievements

• Have handled the ammonia plant during steam super-heater upstream of HTCO tube leak
• Have undertaken backend trip to attend the syngas compressor 6th stage discharge isovalve bypass isovalve leak attending, restored the plant in 12 hours
• Have handled Total power failure trip
• Have handled reformer ID/FD fan trip and restarted plant in minimum downtime
• Have handled twice refrigeration compressor trip due to CPP DG tripping
• Have five cold start up and planned shut-down experience
• Secondary reformer Combustion zone Castable refractory replacement and dry out of refractory - ATA 2018
• Primary reformer flue gas tunnel replacement - ATA 2018
• Hydro desulphurization, Zinc oxide bed, ammonia convertor, LTCO catalyst Replacement job.
• HTCO convertor catalyst scooping in nitrogen Atmosphere.