Manager, Operations | Bharat Petroleum Corporation Limited | Mumbai
Hydrocracker and Lube oil Production Unit, BPCL Mumbai Refinery
- Led a team of 28+ employees at BPCL Mumbai Refinery Hydrocracker and Lube oil manufacturing unit, managing operations that generated annual revenue of INR 2400Cr.
- Leading over 100 personnels, spearheaded the commissioning of DAS Unit, in partnership with DWC Innovations, USA, ensuring their delivery met our technical and operational requirements, which resulted in generating INR 100Cr in annual revenue.
- Successfully completed unit’s Pre-Commissioning Safety Audit (OISD audit) and conducted multiple training sessions for everyone in HCU complex on DAS unit.
- Led the development of the engineering design, 3D model, and HAZOP report for the INR 400Cr DAS Phase II project, managing engagements with Chevron Lummus Global, Malaysia, and Engineers India Limited to ensure alignment with the project goals.
- Optimized unit feed/product supply chain, consumable inventories, and timely material procurement using SAP, improving work order efficiency and resource allocation.
- Guided the unit through multiple internal and external statutory audits, ensuring 100% compliance with industry regulations.
- Developed an innovative Corrosion Control dashboard, leveraging digital tools to minimize leakage risks and enhance plant reliability.
- Developed an interactive digital dashboard for the HCU and Lube oil unit, enabling remote, real-time plant monitoring for senior executives.
- Successfully led complex negotiations with the worker union, fostering collaborative dialogue and aligning interests to ensure smooth operations and enhance workforce relations.
- Certified internal auditor for ISO 9001:2015 (Quality), ISO 14001:2015 (Environment) and ISO 450001:2018 (Health and Safety) Management System (QEHS).
- Spearheaded LOBS unit shutdown in May 2023 and March 2024. Worked with cross functional team for safe completion of the shutdown in a strict timeline, increasing unit throughput by 50%.
- Handled the portfolio of ‘Process safety competency’ and ‘Measurement and Matrix’ element for Process Safety Management.
- Worked in Continuous Catalytic Reformer Unit (CCR) turnaround for a month in Oct 2023.
Crude Distillation and Hydrogen Generation Unit, BPCL Mumbai Refinery
- Implemented various energy conservation schemes for driving a sustainable operation and subsequently reduced energy expenditure by over INR 12CR.
- Led process optimization initiatives that reduced costs by INR 4Cr and improved operational efficiency by minimizing energy loss in the heat exchangers network while driving greater sustainability.
- Executed INR 20Cr strategic revamp project that increased crude distillation unit yield by 10%, improving asset utilization and reducing operational bottlenecks to boost overall efficiency
- Collaborated with various departments for safe completion of the turnaround.
- Prepared CDU3 Turnaround detailed job plan and coordinated the same.
- Conducted multiple training sessions for everyone in CDU3 before the turnaround.
Assistant Manager, Operations | Bharat Petroleum Corporation Limited | Mumbai
Crude Distillation and Hydrogen Generation Unit, BPCL Mumbai Refinery
- Worked in Hydrogen Generation and Crude Distillation Unit, overseeing operations that generated an annual revenue of INR 600Cr
- Reduced crude oil testing time by over 90%, collaborating with R&D on cutting edge crude assay prediction model.
- Collaborated with Boston Consulting Group (BCG) to implement the cutting-edge digital decision support system in CDU3, delivering real-time transparency on the economic impact of key operational parameters.
- Pioneered digital solutions through advanced data analytics, such as real time product quality prediction, enabling better decision making.
- Appointed as the Process Safety Champion for the complex, where I played a pivotal role in ensuring the safe and efficient operation of the unit.
- Spearheaded the CDU3 unit’s comprehensive external HAZOP study, critically reviewing existing safeguards and recommending enhanced safety measures to further protect both plant equipment and personnel, significantly elevating safety standards.
- Led the implementation of the ‘Process Safety Information’ (PSI) portfolio as part of the Process Safety Management, ensuring seamless integration and meticulous documentation to safeguard operations.
- Represented the Mumbai refinery’s Crude Distillation Unit in high-level quarterly strategy meetings with BPCL Kochi and Bina Refineries, driving cross-refinery knowledge sharing and contributing to strategic decision-making across the organization
- Successfully handled multiple high-stakes process emergencies, including heater trips, critical pump failures, and emergency shutdowns, demonstrating exceptional crisis management skills and ensuring minimal impact on operations.
Officer, Operations | Bharat Petroleum Corporation Limited | Mumbai
Crude Distillation and Hydrogen Generation Unit, BPCL Mumbai Refinery
- Developed an advanced electronic shift log for the CDU3 complex in collaboration with the Computer Science department, streamlining communication and enhancing operational transparency across teams.
- Designed and implemented a dynamic steam balance dashboard for the CDU3 unit, enabling real-time monitoring and optimization of steam usage, significantly improving operational efficiency.