About the Candidate
Over 13 years of hands-on experience in maintenance, ensuring timely execution and adherence to safety and quality standards targeting challenging roles to leverage experience and contribute to a dynamic organization.
· Proficient in maintenance and troubleshooting of static equipment such as pressure vessels, heat exchangers, reactors and fired heaters ensuring optimal operational efficiency and longevity.
· Demonstrated ability to overhaul and refurbish rotary equipment including pumps, compressors, and extruders minimizing downtime and improving reliability.
· Proven track record of implementation and management of comprehensive PM and CM programs, reducing equipment failures and enhancing plant reliability.
· Successfully led multiple shutdowns and major turnaround projects, coordinating resources, planning schedules, & executing maintenance activities within budget & timeline constraints.
· Proficiency in spare inventory management, ensuring the availability of critical spare parts while optimizing inventory costs and supporting uninterrupted plant operations.
· Played a key role in the commissioning of new plant equipment and systems, overseeing testing, validation, & operational readiness to meet project milestones & operational targets.
· Experienced in IMS implementation and compliance, leveraging SAP PM module for efficient maintenance planning, execution, and tracking.
Expertise in managing Management of Changes (MOCs) to ensure regulatory compliance and continuous improvement
· Successfully upgraded Polypropylene Reactor’s NDE side lip seals to dry gas seals in a Petrochemical plant, including redesigning the flush system which resulted in eliminating production losses caused by frequent seal failures and flush system issues.
· Implemented the replacement of conventional chain drive rotary feeders with chunk cutting type close-coupled rotary feeders in Powder Transfer Lines of the Polypropylene unit at a Petrochemical plant. Improved reliability and prevented production downtime.
· Engineered specialized tools for the installation and removal of a 14″ Polypropylene reactor mechanical seal, enhancing maintenance efficiency in a Petrochemical plant.
· Led planning, scheduling, and execution of major shutdown projects for the PP plant, focusing on critical modifications and overhaul of rotary equipment during MTA-2022.
· Held additional responsibilities as a Plant Safety Representative (PSR) for one year in a Petrochemical plant, ensuring adherence to safety protocols and standards.
· Meticulous planning and execution of Vacuum heater coil replacement while plant in operation considering extremely difficult welding position and stringent WPS compliance.
· Recognized with awards including I-GEM for CDU heater anchor welding, V-GEM for timely completion of TA’22, and for in-house emergency overhaul of L Kero pump.
· Responded to an emergency situation with the recycle gas compressor, preventing breakdown and throughput loss by implementing timely corrective actions.
· Implemented venting measures in the seal line of seal plan 11, preventing mechanical seal failure in the caustic circulation pump of NHT/CCR in a Petrochemical plant.
· Developed an innovative cleaning and lapping arrangement for reciprocating compressor suction and discharge valves, reducing cleaning time and improving valve seat lapping quality in a refinery.
· Identified critical spare parts for CCR Reactor and Regenerator in warehouse inventory, saving up to INR 50 lakhs from potential procurement costs post-commissioning.
· Completed licenser training in Unipol Technology for Polypropylene at W R Grace in Columbia, Maryland, USA, augmenting technical expertise in Petrochemical processes.
Education
Experience
• Managed maintenance operations for Crude and Vacuum heaters during the Refinery Mega Turnaround in November 2022, maintaining a flawless safety record without any Lost Time Incidents (LTI).
• Oversaw the replacement of vacuum heater flue gas duct ,Preheater bottom cone and Crude heater coil replacement jobs during the October 2022 Mega Turnaround, ensuring strict adherence to safety protocols.
• Completed the replacement of Crude Heaters Air Preheater modules ahead of schedule while the plant was operational.
• Monitored and maintained critical rotary equipment through thorough LLF field rounds, performance trend analysis, and Root Cause Analysis (RCA), implementing proactive measures.
• Expert in troubleshooting Mechanical seals, dry gas seals, and various seal flush plans (plan 11, 13, 21, 23, 31, 32, 52, 53B, 54).
• Conducted maintenance and inspections on diverse shell & tube heat exchangers including fixed tube type, floating head type, kettle type, and plate type heat exchangers.
• Initiated, planned materials/spares, and executed Management of Change (MOC) initiatives.
• Ensured compliance with statutory requirements for Pressure vessels, Pressure Safety Valves (PSVs), and Equipment Overhaul Times (EOTs) in alignment with regulatory standards.
• Proficient in SAP operations including Codification of spares, Equipment Bill of Materials (BOM), Notifications, Orders, and maintaining detailed equipment history.
• Demonstrated proficiency in spares and consumables planning and management.
• Evaluated technical bids for services and spares, developed scopes of work, and established bid evaluation criteria.
• Contributed to commissioning and start-up of a 340KTPA Polypropylene unit.
• Managed maintenance and overhauling of:
o Vertical Reciprocating Compressors (Burckhardt, 1450 kW & 825 kW)
o Horizontal Reciprocating Compressors (Dresser-Rand, 37 kW)
o Centrifugal Compressors (FIMA Maschinenbau GmbH, 280 kW)
o Wet and Dry Screw Compressors (Aerzen/ Grasso, 650 kW/ 630 kW)
o Tri-lobe Rotary Blowers (Swam Pneumatics, 355 kW & 200 kW)
o 50 MT electrical hoists (Armsel)
o Large gearboxes (JSW, Mixer G/R -11.1 MW, Gear pump G/R – 1.8 MW)
o Reactor agitator gearboxes (Siemens, 750 kW)
o Various pumps: centrifugal, progressive cavity, diaphragm, gear, screw pumps
o Rotary and screw feeders for powder, additives, pellets conveying systems
o Extruder (CMP335) package equipment: underwater pelletizer, pellet dryer, pellet classifier, etc.
o Mechanical Seal (Flowserve, Bore: 14”), Bearing (Bore: 280 mm), and agitators (39 MT weight, 20 meters length) replacement for PP reactors
o Performed Extruder package tasks: mixer screws inspection, cutter hubs replacement, screen packs replacement, universal joints inspection, rotary joints replacement, die plate replacement
• Managed mechanical maintenance at Essar Oil Ltd.’s Jamnagar Refinery, including Naphtha Hydro-treater, Continuous Catalyst Regeneration Unit (NHT/CCR), and two 1,30,000 Nm3/hr Hydrogen Manufacturing Units.
• Conducted preventive and breakdown maintenance for reciprocating compressors, managed material codifications, PR/PO creation, and BOM.
• Oversaw maintenance for static equipment (Reactors, Regenerator, Heat Exchangers) and rotary equipment (centrifugal pumps, diaphragm pumps, air fin coolers).
• Experienced in commissioning a 1,30,000 Nm3/hr Hydrogen Manufacturing Unit.
• Managed Refinery Mega turnarounds in 2011 and 2015, ensuring efficient tracking and oversight of NHT/CCR plant M&I jobs.
• Facilitated commissioning activities (card board blasting, de-greasing, leak tests, steam blowing) for Hydrogen Manufacturing Unit.
• Reviewed piping isometrics and contributed to plant model reviews from a maintenance perspective.
• Oversaw emergency maintenance for the refinery’s 16 plants during silent hours in the Central Shift.
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