RAMAPAVANKUMARANUPOJU
PLANTOPERATIONS&COMMISSIONING

PROFILE

Dedicated and skilled Plant Operations Coordinator with over 15 years of experience in plant operations management, safety compliance, and chemical inventorycontrol.Provenexpertiseincoordinatingmaintenanceactivities, wastemanagement,andensuringadherencetosafetyprotocols.Strong backgroundinmanagingutilityprocesses,improvingoperationalefficiency, and handling emergency situations.

WORKEXPERIENCE

CoromandelInternationalPrivateLimited ShiftIncharge
JUNE2020-PRESENT

Managetankfarmoperations,jettyoperations,andutilitiesplantoperations. Coordinate and supervise hazardous liquids handling.
Conduct plant start-ups, shutdowns, and manage emergency situations. Oversee safety compliance and conduct regular safety meetings and mock drills.
Act as plant’s waste coordinator, ensuring safe disposal of waste chemicals and emptydrums.
Prepareandimplementcriticaloperatingproceduresandsafetyregulations

Liquinoxgasesprivatelimited PlantOperationManager
FEB2020-MAY2020

Managedcommissioningandstart-upoperationsforcryogenicairseparation plantsandutilities.
Coordinateddailymaintenanceactivitiestoimproveplantavailability. Developedandmaintainedoperationalproceduresandstandinginstructions.

MatixFertiliserandChemicalLtd JuniorManager
SEPT2015-JAN2021

Supervisedconstructionandcommissioningofairseparationandutilityplants. Monitoredplanttechnicalperformanceandrecommendedcorrectiveactions. Coordinatedplantshutdownsandturnaroundstoensuresmoothoperations. ActedasfocalpointforcoordinationwithHSEteamforbulkstorage management and waste disposal

NagarįunaFertilizersandChemicalsLtd JuniorEngineer
APR2009-AUG2015

Conducted pigging operations, hydro tests, inspections, and PID controller changeovers at a natural gas handling station.
Managed plant operations in desulphurization, reformer, CO2 removal, methanation, syn gas loop, and ammonia refrigeration systems.
Ledstart-upandshutdownactivitiesforairseparationandutilityprocessplants, includingboilers,ammoniarefrigeration,watertreatment,coolingtowers,and heatrecoverysteamgenerators.
Participatedininspectionsofsteamturbines,compressors,distillationcolumns,
andammoniastoragetanks.
Recognized for troubleshooting, logical thinking, emergency handling, and hard work.
Handled hazardous fluids (liquid nitrogen, HCL, NaOH, liquid ammonia, sulfuric acid) and performed chemical treatments in cooling towers, boilers, and water treatment plants, adhering to safety acts and work permit systems.

EXPERTISE

Operated PLC, DCS, and SCADA panels for utilities, boilers, and process plants. Managedcompressors, pumps, chiller units, refrigeration systems, and vapor absorption systems. Monitored plant operations, maintainedparameters,and ensured safety during start- ups, shutdowns, and emergencies.
Assistedwith troubleshooting,reviewed dailyoperations,and coordinatedmaintenance activities.
Followed steam and power distributionsystems, adhered to work permit procedures, and responded to alarms promptly.

ACHIEVEMENTS
Proposed nitrogen purging to seal expansionturbinebearingsintheAir SeparationPlanttopreventmoisture entry.
Recommendedmodificationsto coolingtowersresultingin3MWpower savings for energy conservation.
Implemented water-saving measures in the De-mineralized Water Treatment Plant, achieving daily savings of 1 cubic meter despite effluent treatment.
Advised cooling water line modificationstoenhanceair compressorefficiency.
Handled emergencies such as liquid ammoniaandchlorineleaks,andfiresin gasturbinecompartments.
Troubleshootedcriticaloperational issues including boiler tube and feed waterfailures,flame-outproblems, attemperationissues,andresinfouling inwatertreatmentplants.
Providedtroubleshootingsupport duringcommissioningofutilitiesand offsites.
Developed Standard Operating Procedures(SOPs)forsafeplant operations.
CORERESPOSNIBILITIES
Led commissioning efforts for air separation
(liquid nitrogen generation) and utility plants, overseeing compressor houses, Freon
refrigeration systems, boilers, cooling towers with chemical treatment, and energy conservation
modifications.
Managedcommissioningof chillerunits,vapor absorption systems, ammonia storage tanks,
ammonia refrigeration systems, effluent treatment plants, and flare stacks.
Oversaw commissioning of rotary screw type compressors, various positive and centrifugal
pumps, BFW pumps, H2 recycle gas compressors, startup N2 blowers, lean & semi-lean pumps, and dosing pumps.
Demonstrated exceptional knowledge in boiler
operations, utilities, steam turbines, high-pressure pumps, high-purity water treatment, and heat
transfermachines.
Optimized systems including boilers, cooling towers, compressors, condensate systems,
feedwater systems, process steam systems, cryogenic systems, firewater systems, and wastewater systems.
Developed and maintained positive professional relationships, coached team members, and
ensured efficient operations in manufacturing environments.
Exhibitedstrongtimemanagement,
organizational,written,and oral communication skills,effectivelyhandlingresponsibilitiesunder stressful conditions.
Playeda key role in criticalactivitiessuch as steam blowing, chemical cleaning, pipeline
flushing,lubeoilflushing,leaktesting,hydro
testing,and inspectionsduringcommissioning processes.
Prepared and implemented critical operating
proceduresand manualsto ensurecompliance with safety standards.
Managed inventory of chemicals and additives,
includingordering,storage,and requisitioningto maintain sufficient supplies.
CoordinatedHSE reporting,ensuringcompliance with safety regulations and managing waste
disposal.
Plannedand prioritizeddaily maintenance activities to optimize plant availabilityand performance, integrating commissioning
activities.
Monitored technical plantperformance,
implementedcorrectiveactions,andparticipated inreliabilityimprovementprogramsandprojects.

AMMONIAPLANTOPERATION& MANAGEMENT

AmmoniaPlantOperationandManagement
DCSOperations:Hands-onexperiencewithYOKOGAWA(CENTUMVP)panelinGasDehydration PlantandABB(AC460)panelinAmmoniaPlantoperations,demonstratingproficiencyin distributed control systems for efficient plant management.
Desulphurization: Managed feedstock preheating, hydrogenation, and H2S absorption to achieve a sulphurcontentreductionto0.01PPM.
Primary Reformer: Oversaw the operation of a side-firing reformer with 190 catalytic tubes and 360naturalgasburners,utilizinganickel-basedcatalystat35KSCand730°C.
SecondaryReformer:Supervisedairinjectionintotheauto-ignitionchamber,withanickel-based catalystoperatingat34KSCand895°C,achievingamethanecontentreductionto0.6%.
Co-Conversion: Operated high-temperature copper-promoted iron oxide and low-temperature copper,zinc,andaluminumoxidecatalystsat350°Cand196°C,respectively.
GiammarcoVetrocoke(GV)SolutionAbsorption:ManagedCO2absorptionusingleanandsemi- lean solutions, achieving a CO2 slip outlet reduction to 500 PPM. Conducted regeneration in HP andLPgenerators.
Methanation: Directed nickel-based catalyst reactor operation to convert residual CO2 and CO into CH4 at 25 KSC and 300°C.
SynthesisGasLoop:Controlledoperationsofwasteheatboilers,heatexchangers,coolers,chillers, separators,andconvertersat150KSCusingiron-basedcatalystconverters.
ProductAmmoniaandWashSection&Distillation
Product Ammonia and Wash Section: Oversaw ammonia purification in a let-down vessel at 25 KSC and subsequent distillation, including handling inerts and small ammonia vapors.
Refrigeration Unit: Managed ammonia refrigeration chillers for cooling converted gas to -12°C, operatingat1.2KSCand6KSC.
Cryogenic Section: Operated PLC-based adsorbers and cryogenic units for hydrogen recovery from purgegas,providedbyCOSTAIN.
Furnaces: Supervised natural draft and balanced draft furnaces operations for optimal combustion andenergyefficiency.
BFWTreatment:Managedde-aerationandchemicaldosingprocessesforboilerfeedwater.
Steam Turbines: Oversaw extraction and condensing type turbines for power generation and compressordrive,includingan18MWturbine(BHEL,India)andtwoturbines(9.6MWand6.5 MW, MAN GHH, Germany).
CentrifugalCompressors:
Process Air Compressor: Operated a 4-stage horizontal split casing compressor for ambient air compression to 34 KSC.
Synthesis Gas Compressor: Managed a 4-stage vertical split casing compressor for make-up and recirculatedsynthesisgas,achievingpressuresupto150KSC.
Ammonia Refrigeration Compressor: Supervised a 3-stage horizontal split casing compressor for ammoniavaporcompressionto19KSC.
CDR Unit: Directed absorption of CO2 from reformer stack flue gases using KS1 (amine-based) solution,withregenerationat0.8KSCandadditiontothemainCO2header.

PLANTOVERVIEWANDFACILITIES

NaturalGasHandlingStation:
Receivesnaturalgasat54kscpressure,equippedwithknock-outdrum,pressurecontrol,and condensate removal systems.
CompressorHouse:
Instrument Air:
Elliotcentrifugalcompressors(2units),2200Nm3/hrat8.0kg/cm2. Centrifugalcompressors(2units),3500Nm3/hreachat9.0kg/cm2. Booster Compressors:
Reciprocatingcompressors(2units),5500Nm3/hrat40.0kg/cm2. Plant Air:
Khoslareciprocatingcompressors(2units),900Nm3/hrat7.0kg/cm2. Portable cooling water system.
LiquidNitrogenGenerationPlant(CryogenicAirSeparationPlant):
AirProducts,UK:10TPDliquidnitrogenat9.0kg/cm2,0.1ppmO2,GANandLIN-GAN modes.
MadebySuzhouXinguAirseparationplantScienceandtechnologydevelopment.Co.Ltd, with 130TPD withBoth Dual mode such as LIN- LOX mode.
Liquid Nitrogen & Oxygen Storage tanks with 150M3 &100M3 (2 no’s) capacity each.
Includesliquidnitrogenstoragetanks(2units,50MTeach),loading/unloadingsystems, vaporizing system, PLC & DCS operations.
AmmoniaRefrigerationandStorage:
Atmosphericdouble-walltanks(2units,5000MTeach)withKSBcentrifugalpumps. Refrigerationsystemwith45TRcapacityandethyleneglycol-ammoniaheating.
SteamandGasTurbines:
Includessteamturbines(SKODAandMANGHH),gasturbines(GE),andassociated compressors.
BoilersandWasteHeatRecovery:
Mitsui Engineering, Thermax boilers, and MACCHI waste heat recovery boilers.
CoolingTowersandWaterTreatment:
Parahpurcoolingtowers,Chembondwatertreatmentforcoolingwater,rawwatertreatment by Geomiller.
DemineralizationandROWaterTreatment:
Thermaxdemineralizationplantwithionexchangetechnology,UKLROwatertreatment plant.
EffluentTreatmentandFirefightingSystems:
Includesoilseparation,sewagetreatment,solubleandinsolubleimpuritytreatment,and hydro-pneumatic firefighting systems.
OtherSystems:
Includeschillerunits,flarestacks,naphthaandpropanehandling,cryogenicsystems,andRO water treatment.
Iaffirmthattheabovedetailsaretruetothebestofmyknowledgeandbelief.Ifselected,Icommittodedicating myselftomyworktothebestofmyability.

ARamaPavanKumar