KOTTI RAMA RAGHAVA KUMAR

Plant Operations | Project Management| Planning & Control | P & L Accountability

Summary

• Result-oriented Professional with over 3 decades of total experience in which, 28 years of rich experience in Fertilizers in Operation and Maintenance of Ammonia and Urea Plants with Commissioning project related to capacity enhancement, energy revamp and feedstock conversion (from Naphtha to Natural gas) in Ammonia and Urea Complex. Details of projects mentioned below.


• Bagged Appreciation Letter & Cash Award from the Director & COO for successful revamp implementation.


• Streamlined projects leading to changes in technology, process methodology and direction of quality assurance& control systems


• Experienced in general HSE Guidelines of Fertilizer Industry, FICC related matters, Fire and Safety systems, Zero Effluent/discharge facilities. Pioneered in overseeing project activities from conceptualization to execution including technical specifications, stage inspections, progress monitoring, site management, Contracting, Budgeting and Cost Control and manpower planning


• A strategic planner with expertise in planning and executing projects with a flair for adopting modern methodologies in compliance with quality standards


• Holds the distinction of executing numerous projects of large magnitude within a strict time schedule and stringent cost measures


• Identifying deviations & making relevant modifications to stabilize processes for Petrochemical & Fertilizer Projects. Handled Process Engineering of Modern Ammonia and Urea Complex, Environment Compliances, Material and Energy Balances


• Visited M/s Haldor Topsoe, Denmark office with an aim to implement HTER- HaldorTopsoe Exchanger Reformer Scheme to increase ammonia plant capacity from 1325 MTPD to 1400 MTPD (2010). Visited PDIL office and SAIPEM, Chennai office for project work


• Headed multiple projects for end-to-end activities including Proposal Management, Constructability Review, Budgeting & Cost Control, Change Management, Quality Auditing and Safety Management


• Written 12 articles / papers (about plant performance improvement, commissioning of Ammonia & Urea Plants), which were published in international and national magazines


• Team-based management style coupled with the zeal to motivate peak individual performances

Core Competencies

Project Execution & Operations
Technical Services
Resource Allocation
Process Enhancements
Quality Control & Assurance
Risk Management
Budgetary & Cost Control
Mentoring & Knowledge Sharing
Team Building & Leadership

Soft Skills

Strategic, Responsible, Futuristic, Result-Oriented, Positive attitude, communicative

Professional Experience

Indo German Petrochemicals Limited, Navi Mumbai, Feb’18– Mar’20

As Head Plant Operations/General Manager(Production):

Managing and Continuous Improvement in Operations of Phthalic Anhydride plants(3 no’s), Maleic Anhydride plants(3 no’s), Benzoic Acid plant including all off sites facilities of Auxiliary Boilers (3 no’s), Instrument Air plants, Nitrogen plants, Cooling towers, DM plants (3 streams), ETP, Zero Liquid Discharge (UF cleaning with RO plants)

Key Result Areas:

• Monitoring overall plant operations & ensuring timely completion; setting-up standards, ensuring optimum utilization & deployment of available resources to achieve organizational objectives


• Managing the preparation of yearly budget as per the existing trends & budget forecast and maintaining the information such as Historical Performance, Expenses, Overhead, Working Capital managing:


• Incident free operations, Quality control and Continuous improvement in Operations


• Resources or operations, people and performance appraisals and Implement corporate people Excellence plans


• Plans for startup/shut downs and scheduling the preventive & predictive maintenance of the plant


• Conducting the Root cause analysis for incidents and proposing the suitable corrective and preventive action plans


• Supporting capital expansions and ensuring the adherence to the regulatory & statutory compliances


• Imparting continuous on job training for accomplishing greater operational efficiency; working on succession planning of the workforce, appraising the member’s performance & providing feedback


• Fostering safe & healthy work environment by following & enforcing safety, health & environment (SHE) & regulatory measures, standards & procedures and complying with legal regulations


• Creating & sustaining a dynamic environment that fosters development opportunities by evaluating & motivating high performance amongst team members


• Upgraded to Head Plant Operations in July 2019

Previous Experience                    

M/s. Nagarjuna Fertilizers & Chemicals Ltd. (NFCL), Kakinada, Sep’89 – Jan’18

General Manager (Projects)

• Spearheaded “Energy Reduction Project” from 5.6 G.Cals to 5.41 G.cals/MT of Urea at NFCL.


• Contributed in enhancing overall production capacity by around 2 lakh MT of Urea for the complex


• Implemented many modifications in Ammonia Plants including installation of MP process condensate stripping system, installation of additional rows in mixed feed coil in reformer convection section, suction chilling for process air compressor and synthesis gas compressors, capacity enhancement in CO2 removal section, replacement of synthesis gas water cooler with higher capacity and dedicated low pressure NG line for fuel etc.


• Led implementation of many modifications in Urea Plants : Installation of MP, LP & NH3 Condensers, Pre MP Decomposer, OVHD Condenser, additional Vacuum System


• Spearheaded detail engineering, installation and commissioning of Ammonia & Urea plants revamping. Installed and commissioned of Carbon Di Oxide Removal Plant (CDR). Revamp of Ammonia & Urea Plants completed within scheduled period of 24 months, CDR project completed 2.5 months in advance of scheduled time and GTR was successful


• Coordinated between M/s PDIL & Vendors, conducted intermediate inspections, undertaken final testing erection, piping, instrumentation, electrical activities & commissioning


• Delivered presentations to Andhra Pradesh Pollution Control Board for pollution clearance


• Installed and commissioned customized fertilizer unit

Deputy General Manager
Conducted the following feasibility studies
* For capacity enhancement Project study of Ammonia Plants with M/s. KBR for implementation of Brown Purifier at NFCL. For studying of Brown Purifier experience, NFL NANGAL and KRIBHCO- Surat Plants were visited
* Complex energy reduction to approximately 5.3 G. Cals/ MT of Urea and ~15% increase in capacity with (1) M/s. HaldorTopsoe+M/s SAIPEM, (2) M/s KBR+M/s. Stamicarbon combinations
* To enhance complex production by ~ 6.5 Lakh MT/annum and reduce energy to ~5.04 G. Cals/MT of Urea with M/s. CASALE technology
* New stream of Ammonia and Urea of KBR Ammonia (2200 MTPD Capacity) & SAIPEM Urea (3860 MTPD Capacity)

Head of the Department (HOD)

* Achieved production, energy, safety and environment targets of Ammonia Plant -1 and Urea Plant-1
* Improved installation of new ammonia converter (S-300) which included detail engineering, erection, catalyst loading, commissioning and GTR. Managed parallel operation of S300+ S200, which had resulted in savings of 30,000 G. Cals/annum (2007-2008)
* Successfully managed planned turnarounds of Ammonia plant & Urea plant