V Raja
Chennai
Summary
V Raja, a B.Tech graduate in Chemical Engineering and MBA holder in Operations Management, has a seasoned refining professional journey. From starting as an Operation Engineer to current role as Chief Manager of Technical Services at CPCL, has extensive experience in various facets of refinery operations. My expertise includes a wide range of units, including Crude and Vacuum Distillation, Lube Processing, Hydro Treating, Product Blending, OMS, Isomerization, CCRU, GDS, SRU, HGU and more. With15 years of cross-cultural exposure in Technical Services and Refinery Operations, has consistently excelled in troubleshooting and providing technical solutions. My proficiency extends to developing Process Schemes and overseeing erection & commissioning of proposals. My capabilities extend to conceptualizing profitable projects and overseeing operations, ensuring excellence in process monitoring, procurement and quality, etc.
Overview
16
16
years of professional experience
1
1
Certification
Work History
Chief Manager- Shift Operations
Chennai Petroleum Corporation Limited, CPCL Refinery
04.2024 - Current
- Company Overview: A Government of India Enterprise & Group Company of IOCL
- Overall Refinery Operations Management including
- Process plant, power plant, water & effluent treatment operation and coordination as per RBO
- Flare, Fuel Gas, N2, water and slop management
- Product blending and despatch management
- Monsoon management
- Coordination with different crafts/departments to ensure smooth refinery operation
- Process analysis, Plant visits and data collection from all plants
- Fire and safety, security surveillance monitoring
- Refinery gate entry management and authorization
- Work permit management and authorization
- Refinery operation and maintenance Shift turnover report generation
- Refinery daily status report generation and Reporting to management CGMs and Director
- Roles in Process Engineering / Quality Assurance / Production / Operations & Maintenance with a high growth-oriented organization
Chief Manager-TS (Technical Services)
Chennai Petroleum Corporation Limited, CPCL Refinery
03.2016 - 03.2024
- Company Overview: A Government of India Enterprise & Group Company of IOCL
- Operations & Technical Services Experience: Crude distillation unit/Vacuum distillation unit, Lube units (Propane Deasphalting, NMP extraction, Lube dewaxing, wax de oiling), Biturox unit, Propane recovery, Food grade hexane unit, hydro treating (HSD, VGO, Kero, lube), WAX HIFI, Oil Movement & Storage (Offsite), Hydrogen Generation Unit, Reforming(CCRU), Naphtha hydro treating, Isomerization, Continuous Catalytic Reforming Unit, FCCU-Gasoline Desulfurization (Prime-G plus), Sulphur recovery unit
- Approval Notes: Facilitated the approval process for process schemes, catalyst chemical procurement, manpower, and services
- Budget preparations (BE, RE, etc.): Prepared and reviewed Budget Estimates (BE) and Revised Estimates (RE)
- Coordinated with finance and procurement teams to ensure alignment with budgetary constraints and requirements
- CSA (Catalyst Supply Agreements): Negotiated and finalized agreements for catalyst supply
- Ensured terms and conditions met operational and financial requirements
- Maintained records and managed compliance with contract terms
- Catalysts Chemicals procurement: Preparation of Technical Specifications, getting budgetrary offers, cost estimate approval, administrative approval, Global Tender Enquiry Approval from govt, purchase requisition, tender inputs, technical evaluation, etc
- Spent Catalyst, Platinum, Disposal activities: Handled disposal and sale activities for spent catalysts and platinum
- Chemicals & Catalysts Review: Monitored inventory levels, usage, and performance
- Analyzed trends and issues to recommend improvements
- Prepared monthly review reports for management
- Communications:
- External: Managed external communications related to queries and data sharing
- Inter-Dept: Facilitated internal communications across departments
- IOC/RHQ: Acted as the liaison between the refinery and headquarters (New Delhi)
- Provided updates, reports, and feedback
- Coordinated on strategic and operational matters
- Licensors, Vendors: Managed relationships with licensors and vendors
- Negotiated terms, resolved issues, and ensured service quality
- Coordinated procurement and supply chain activities
- Process/Technical Concept Notes: Developed and approved technical concept notes for new proposals
- Cost Audit / Refinery Material Balance: Prepared annual refinery material balance and conducted cost audits
- Crude Assays: Conducted assays to determine crude oil properties
- Collaborated with R&D for data analysis and interpretation
- Provided insights for process optimization
- Cooling Water Treatment program: Monitored and controlled the cooling water treatment program
- Dept
- Targets: Set performance targets and deadlines for the department
- Monitored progress and made adjustments as needed
- Ensured targets aligned with overall organizational goals
- Process plant Data digitalization/documentation: Digitized documents and dashboards for process monitoring
- Energy
- Review Presentations: Developed and delivered presentations on energy performance
- Analyzed data and provided insights for energy efficiency improvements
- ENCON schemes: Developed and implemented energy conservation (ENCON) schemes
- OGCF / PAT / MEA: Provided data for various energy performance reviews
- Coordinated with statutory bodies for certifications
- Ensured compliance with regulatory requirements
- RLNG: Managed the consumption of RLNG (Re-gasified Liquefied Natural Gas)
- Implemented controls to optimize usage and reduce costs
- RPIP / Solomon / EMS: Performed studies and analyses using RPIP, Solomon, and EMS tools
- Identified opportunities for energy savings
- Developed and implemented energy conservation strategies
- Monitoring daily fuel consumption and controlling the same by monitoring Excess O2 in furnaces and stack temperature of all heaters
- Monitoring Energy target number and evaluating the same periodically
- Performing energy calculation like Solomon EII and energy index
- Performing process loss calculations and taking necessary steps to minimize process loss
- Carrying out various energy audits to minimize energy consumption like steam leak, condensate recovery, steam trap survey, Radiation loss of heaters and etc
- Monitoring equipment efficiency such as pump, compressor and its spillback, column and fired headers
- Monitoring and troubleshooting energy conservation equipment such as air pre-heaters, steam generators and etc
- Hazop study for process schemes and modifications: Conducted Hazard and Operability (Hazop) studies for process schemes and modifications
- Highlights (Annual & Quarterly): Prepared annual and quarterly refinery highlights
- Developed reports showcasing refinery successes and improvements
- ISO / TPM/ SHEQ: Implemented ISO, TPM (Total Productive Maintenance), and SHEQ (Safety, Health, Environment, and Quality) standards
- Ensured effective implementation of ISO standards and TPM practices
- Managed SHEQ compliance and improvements
- Conducted audits and provided training
- Process unit’s management Review Presentation: Developed and delivered presentations on process plant performance
- Provided insights and recommendations for improvements
- Addressed management queries and feedback
- M&I / Turn-around / Shut-down activities: Coordinated job scope preparation, procedures, and tendering
- Oversaw catalyst unloading/loading, equipment inspection, and repair activities
- Ensured safety and efficiency during shut-downs
- Total7 number of M&I s/d activities involved covering all the process units
- Maintenance and manufacturing Coordination Meeting: Facilitated meetings between maintenance and manufacturing teams
- Monitored job progress and resolved issues
- Ensured effective coordination and communication
- Non Plan Capital Budget approvals: Developed and presented non-plan capital budget proposals
- Coordinated with finance and project teams for approval
- Monitored budget execution and adjustments
- Optimization – APC (Advanced process control): Implemented APC systems to optimize process performance
- Monitored control strategies and made adjustments
- Analysed data to improve efficiency and productivity
- Optimization - PIN network / Servers / DCS / OPC: Managed and optimized network and server configurations
- Ensured effective performance of DCS and OPC systems
- Troubleshoot issues and implemented improvements
- Procurement and Material Management: - Managed Purchase Requests and Orders
- Conducted Material Inspections
- Meetings and review: - Prepared Pre-MAC Minutes and ATR (Action Taken Reports)
- Presentation prepared for Refinery Performance Review Meetings for RHQ
- Audit and Compliance: Responded to Queries from Government Audits, Internal Audits, and Parliament/RTI inquiries
- Addressed Vigilance matters
- Refinery Business Optimization- Implemented Refinery Business Optimization strategies
- Reporting and Documentation: Compiled Monthly and Annual Reports
- Developed PGTR and Test Run reports
- Created Troubleshooting and Study Reports
- Safety: Managed HiPo analysis, ESA, ISA, CSC Minutes / ATR, etc
- Technical Proficiency: - Utilized Simulation Software for process modeling and analysis
- Evaluated Technical Proposals/Offers from Licensors
- Strategic Initiatives: Participated in Strategic Initiatives and IDEA Mela (innovation events)
- Evaluated Suggestions for process and efficiency improvements
- Surveys and Equipment Assessment: Conducted Surveys related to Equipment and Utility assessments
- Tender Evaluation: Executed Technical Evaluations of Tenders for catalysts, chemicals, and equipment
- Training and Development: Provided training and mentorship to subordinates/trainees/ fresher/ external agencies to enhance team capabilities
- Investigative Reporting: Contributed to Investigation Committee Reports, ensuring thorough analysis and recommendations
- HiPo NMI review, integrated annual report committee, external safety audit committee, steam audit, Pre-commissioning safety audit committee, Risk assessment for insurance committee,42” crude pipeline commissioning and old crude line decommissioning committee, various fire incident, process incident investigation committee etc
- Daily Operations Monitoring: Maintained Process Daily Reports and Refinery Daily Process Reports to track operational efficiency
- Process study and process scheme: More than100 process studies were carried out and implemented more than70 process schemes for profitability, energy conservation, chemical and catalyst reduction, safety improvement, reliability improvement, system improvement – Details attached in Annexure-1
- CAPEX reduction: Redundant equipment utilization: Utilized25 no of redundant equipment for new process schemes which reduced CAPEX of Rs.30 Cr (2016-2023)
- ANNEXURE-2
- Managing various project activities including:
- Basic Engineering PID review
- Equipment sizing (Piping, Pumps, Vessels, Insulation)
- Conducting Hazop Study
- Preparing Instrument Data Sheets
- SOPs preparation
- Punch List Preparation
- Tie-points List Preparation
- Process Simulation using software’s like Pro – II and Hysys
- System improvement undertaken
- Online flare monitoring system
- Online e-MOC system
- Creation of Documentation centre for process engineering documents5000 no and digitization of documents
- Procedure for Process Scheme implementation
- E- Log system
- In line Crude blending system
- Technical services- Process Engineering: Roles involved (From March2016 to March2024)
Operation Engineer
Chennai Petroleum Corporation Limited, CPCL Refinery
06.2009 - 03.2016
- Company Overview: A Government of India Enterprise & Group Company of IOCL
- Looked after Crude distillation unit/Vacuum distillation unit, Lube units (Propane Deasphalting, NMP lube extraction, Lube dewaxing, wax de oiling, Propane recovery, Food grade hexane unit, hydro treating (HSD, VGO, Kero, lube)– Control room/panel operation through YBL CS3000
- Chief Responsibilities:
- Maximizing safe production with proper quality and reduction of specific consumption & effluents
- Responsible for reporting to the management regarding daily activities and problems in the plant and submitting reports accordingly
- Ensuring & practicing safe operating procedures & conditions at all sections of the plant with thorough knowledge of all systems & procedures
- Coordinating with other maintenance and functional departments
- Executing smooth & safe start-up / shutdown of the plant as per schedule and complying of all the planned jobs during shutdown / turn-around
- Planning and effecting preventive & predictive maintenance / overhauling / repair schedules of various machineries & instruments to increase machine up time and long-term equipment reliability
- Proactively identifying areas of obstruction / breakdowns and taking corrective measures / steps to rectify the equipments through application of trouble shooting tools
- Ensuring all the machineries work efficiently by conducting timely checks & measures
- Executing cost saving and energy saving techniques / measures and modifications to achieve substantial reduction in O&M Expenditures and work within the budget
- Operation Engineer (June2009- March2016)
Education
MBA - Operations Management
IGNOU
B.Tech - Chemical Engineering
Coimbatore Institute of Technology
Skills
- Process simulation – Aspen HYSIS & PRO-II, HTRI
- Windows, MS Office
- Operations management
- Troubleshooting and problem resolution
- Organizational improvement
- Strategic planning
- Operations planning
- Organizational development
- Data analytics
- Compliance management
- Customer relations
- Human resources
- Data-driven decision making
- Business performance management
- Problem-solving abilities
- Decision-making
- Managing operations and efficiency
Certification
ANNEXURE-2
Accomplishments
- MS unit Capacity enhancement by in house modifications:
- CONTINUOUS CATALYTIC REFORMING UNIT (CCRU):
- In April2004, the Catalytic Reforming Unit (CRU) was commissioned with a capacity of225TMTPA. In April2010, the unit was converted from a Semi-Regeneration type to Continuous Catalytic Reforming (CCRU) with a capacity of304TMTPA. Subsequently, the unit was operated at120% of its capacity. From2020 to2022, five in-house modifications were done to effect22% capacity increase, from120% to142%, reaching a capacity of432TMTPA.
- ISOMERISATION UNIT (ISOM):
- The ISOM Unit was commissioned as part of the Euro IV project in February2011. Originally designed to process156TMTPA of feed with90% recycle, the unit was subsequently operated at up to120% of its capacity. Through seven in-house modifications the ISOM unit's capacity increased by55% from120% to172%, reaching268TMTPA with25% recycle.
- The in-house modifications outlined above resulted in a significant capacity increase and led to a15% increase in MS production. This paper provides a comprehensive account of the cost-effective approach employed to de-limit MS units, ultimately maximizing the Octane barrel and MS production through a simpler and more efficient method
Others roles undertaken
- 1. Digital transformation committee- June2023
- 2.42” crude oil Pipeline commissioning and30” old crude oil decommissioning committee- Oct2018
- 3. ATF tank product off- investigation committee- Feb2023
- 4. NHDT AFC tube leak- Investigation committee- June2023
- 5. Crude- VDC- Hot-well fire incident- Investigation committee- July2019
- 6. Old pond near scrap yard- fire incident- Investigation committee- Dec2023
- 7. Task force committee for DHDT and CCR H2 rich gas recovery compressor performance improvement- Jan2022
- 8. BS VI SRU PCSA audit committee- Aug2022
- 9. Risk assessment by M/s CHUB- Insurance- Task Force – May2023
- 10. Task force committee for rerouting of old H2 block pipe rack rerouting for GDS unit construction- Oct2016
- 11. OISD ESA preparedness committee – Sep2022
- 12. Implementation of First Integrated annual report2022-23- Committee -Mar2023
- 13. Identification and root cause analysis of High potential near miss incident (HiPo NMI) committee2023-24
- 14. Internal safety Audit (ISA) committee for2021-22 and2023-24
- 15. OMS- REF II OWS pit fire incident – Investigation Committee- Oct2019
- 16. Safety Surveillance Audit(SSA) team2023
- 17. Second Integrated annual report2023-24- Committee -Mar2024
- 18. System Audit Team – Non Aviation fuel2018-19- Committee- Oct2019
- 19. System Audit Team – steam management2023-24- Committee- Jun2023
- 20. Internal Strategy Meet2020-21- Member- Profitability Improvement Strategies
- 21. Idea Mela2022 – Member
- 22. CHT- Steam Leak Survey2024- Mathura Refinery-IOCL- Jan2024- Member
- 23. Visited BPCL Mumbai refinery for Isom Operation, Panipat refinery and bitumen loading plant and port, Vizag Refinery and strategic crude storage area, Paradip refinery, Haldia Refinery and port
Planting trees, cycling
More interest in gardening, planting etc, cycling
Languages
Tamil
Bilingual or Proficient (C2)
English
Bilingual or Proficient (C2)
Hindi
Beginner (A1)
Timeline
Chief Manager- Shift Operations
Chennai Petroleum Corporation Limited, CPCL Refinery
04.2024 - Current
Chief Manager-TS (Technical Services)
Chennai Petroleum Corporation Limited, CPCL Refinery
03.2016 - 03.2024
Operation Engineer
Chennai Petroleum Corporation Limited, CPCL Refinery
06.2009 - 03.2016
B.Tech - Chemical Engineering
Coimbatore Institute of Technology
MBA - Operations Management
IGNOU
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