Mukund Kapadia

⮚ Feed and furnace Section : Feed handling section, Ethane and propane vaporizers, Furnaces (Thermal Cracking of Ethane and Propane (‘W' coil furnaces) with 105 kg/cms2(g) steam generating system), Quench Tower with DSG system, Cracked gas compressor with caustic tower (Acid Gas removal), Gas Dryers.

⮚ Cold Section : Expander compressor with max low temp up to -160 degC, Chill down train (Cold Box), De-methaniser tower, Tail end Acetylene Hydrogenation Unit, Ethylene tower and ethylene distribution, PSA unit, Hydrogen Compressor, De ethaniser tower.

⮚ Hot section : De propaniser tower, MAPD Hydrogenation, propylene tower, De butaniser, Gasoline Fractionation, Close loop C2R (Ethylene) refrigeration with HP steam turbine at low temp up to -100 deg C, Close loop C3R (Propylene) refrigeration with VHP steam turbine at low temp up to -40 deg C, Flare System.

⮚ Taking furnace for decoking and thereafter taking in line for the operation.

⮚ Handled various emergencies like power failure/utility failure/C3R trip/CG trip/C2R trip/Furnace trip/equipment failure/Gas leak/Fire.

• Accountable for safe and efficient operation of plant and maintenance activity during shift.
• Lead the shift team and conduct the shift team meeting before each shift start with Panel Officers /Engineers , Field Officers.
• Manage and execute the site production, maintenance, and production excellence activities as per business plan
• Support the service department and technical support team to meet the asset & business objectives.
• Training and development of team and identify the GAP.
• Act as Incident controller during emergency till further support is received as per crisis and continuity management procedures.
• Handling of emergency as Incident controller.
• Optimum planning of various maintenance activities for best utilization of resources and for safe execution of work as per Planning.
• Responsibility for managing safety of RIL staff & contractor staff for production related activities.
• Coordination with OSBL and Downstream plant (HDPE/EOEG/PTA/VCM) other stakeholders (if required) in the shift for any disturbance and deviation in plant.
• Ensuring upkeep of the plant –compliance with various system such as PTW, MOC, Safe isolations.
• Maintain an overview of shift operation and maintenance activities during shift.
• Lead shutdown and start-up activities of the plant.
• Lead troubleshooting for field as well as panel
• Co-ordinate and cross plant communication during any critical activity and assist to panel officers
• Ensuring competency of shift team and arrange training as per gap assessment with co-ordination of plant trainer
• Control issuance of permits as per the criticality of job and the permit load on field officers
• Screen the PTW and TBRA before releasing permits
• Maintain all operations portable equipment, gas detectors, radio, Nueman (PA system) of fields and Control room
• Ensure availability stand by equipment and safety of critical equipment to avoid any production loss
• Daily morning shift discusses learnings (LFI's) from previous incidents related to any RIL site and implement appropriate changes.
• Ensure plant operations parameters limits and alarms process are being monitored for effective implementation / monitored and the MOC process is followed for changes to alarm, trip settings and operator actions.
• Co ordination with maintenance department for routine and non routine jobs (Like dryer molecular sieve replacement, furnace radiant and convection coil replacement)
• Excellent in hand experience in work permit system and SAP system.
• To conduct Safety Training Programmers on various Safety Topics to sub ordinates like General Safety Awareness, Work Permit Systems, Risk Assessment, Safety during entry into confine space, Hot Job, Chemical hazards, Use of Gas Testing Instruments, Use and various types of Personal Protective Equipments, Safety during repair and maintenance
• Carry out Safety Inspections, Safety Audits and RESOP Audits (A behavior base audit).
• Report near miss and incidents timely.
• Conduct PSSR (Pre Start up Safety Review) after any unit /equipment startup, Technology and safety dept
• To conduct mock drills in co-ordination with our Fire services dept
• Undergone turnaround three mega shut down ( JAMNAGAR- SEZ –Sulphur and Coker, Gas Cracker )
• Collaborated with internal teams to streamline operations across materials handling, production, and shipping.
• Monitored daily and weekly key performance indicators to maintain on-track status.
• Enhanced processes by pinpointing bottlenecks and working with support team members like Panel Engineer, Senior Day Staff Manager to resolve.
• Enhanced communication between shifts during shift briefing report & further development of detailed handover reports and daily pack up reports in each shift.
• Reduced equipment downtime by establishing a proactive maintenance program for all machinery.
• Troubleshot equipment to reduce service calls and downtime.
• Prepared shift summary reports for supervisor and communicated regularly on goals and progress.
• Effectively managed shift runs with budgeted Norms with closely monitoring parameter and consumption of raw materials and chemical and taking necessary actions accordingly and maintaining optimal operational efficiency.
• Enforced company policies and regulations with employees.

EMERGENCY HANDLING

⮚ C3R trip

⮚ C2R trip

⮚ CGC trip

⮚ Expander Compressor Trip

⮚ Hydrogen Compressor Trip

⮚ Furnace Trip

• In Green field project Pre Commissioning & Commissioning Activity like Cardboard blasting of lines, P & ID Review, HAZOP Study of Plant, GA drawings review and study
• Calibration of Vessels, Hydraulic test of Equipment and vessels, Pneumatic test of distillation column & its Packing activity
• Fixed bed Catalytic Reactor (Gas phase Ammo oxidation Reaction) Commissioning
• Vertical start up plant and with Zero incidents, Zero defects, Zero Leakages
• Co-ordinate with project department for daily task and planning of work, Stabilized the plant and run according to its raw- material consumption norms
• Get the proper training of Plant shut down & start up activities and trouble shootings from Gajurala-UP based plant
• Check QC reports and take corrective action against disturbed results
• Strictly follow the schedule activity of plant to keep smooth operation In Commissioning stage co-ordination with Project & Service department regarding punch list of the plant, Hotoil (Therminol, VP-1) handling and it circulation, Safety Work Permit System in all works
• Minimize down time by timely corrective action, Handle the plant independently during power & steam interruption and failure Monitoring of critical parameter on DCS (EMERSON DELTA –V 10.3) and training provided to Panel operator.

• Commissioning of Asia's first global carbon fiber plant
• Leakages testing of lines
• Marinating DCS (SIEMENS) activity and Startup plant with zero incidents
• Managing the shift work according to its priority Functional Trainings provided to shop –floor chemists.

• To handle the shift with smooth plant operation
• To maintain the DCS operation (CENTUM CS -3000) YOKOGAWA
• To handle any emergency, break down and safe mode start up and Shut down
• Delegate work according man power
• Planning of tanker unloading activity
• Arrangement of man power
• Preparation of daily report
• Reporting to superior at end of each shift
• Reporting any abnormalities to plant HOD and Concerned Service department
• Work as coordinator in Quality -Circle.

• To handle and planned for batches
• To carry out an experiment on various conditions
• To compilation of data and compare with other experiments data
• To collect the data of experiments
• To calculate material and energy balance of each experiments
• Calculate the estimation of utility and raw material cost
• Retrofitting of pilot plant as per our process requirement
• Arrangement of man power and raw materials
• Preparation of daily report and objective status updates.