Rajeev R Email & Phone Number

Mangaluru, Ka, In

Mangaluru, Karnataka, India

>Responsible for achieving 4,34,000 MT/Year of budgeted Urea production.>Oversee daily operations and coordination of the Urea manufacturing facility.>Managing team of 24 dedicated professionals to ensure smooth operations.>Conducting Hazard Operability (HAZOP) study for the process plant and proposed Projects/modifications in the plants.>Ensure process compliance with MOC, Material balance, Heat balance, PFD, P&IDs, SOP, OCP Mechanical Integrity, and… Show more >Responsible for achieving 4,34,000 MT/Year of budgeted Urea production.>Oversee daily operations and coordination of the Urea manufacturing facility.>Managing team of 24 dedicated professionals to ensure smooth operations.>Conducting Hazard Operability (HAZOP) study for the process plant and proposed Projects/modifications in the plants.>Ensure process compliance with MOC, Material balance, Heat balance, PFD, P&IDs, SOP, OCP Mechanical Integrity, and PSM.>Ensuring safety of plant and employees in compliance with ISO:45001:2018, ISO;14001:2015.>Evaluating the performance of process equipment like Compressors, Pumps, Heat exchangers, high-pressure reactors, catalyst vessels, pool condensers, WHRB, absorbers, strippers Fractionation columns, flash vessels, Vaccum Evaporators, Conveyors, Prilling towers, fans and blowers.>Providing procurement assistance for the equipment by furnishing suitable specificationsand technical evaluation of the offers. >Identifying the bottlenecks of the plants and eliminating the constraints for enhancing the production.>Studying and suggesting various energy-saving projects through Techno economics reports.>Troubleshoot and resolve operational issues, using Root Cause Analysis (RCA).>Develop contingency plans for production continuity and update superiors on performance and strategic initiatives.>Implement new technologies and sustainable practices to enhance efficiency and minimize environmental impact.>Manage Annual turnaround planning, and budget preparation (CAPEX and OPEX) of the Urea plant.>Co-ordinating for the start-up and shutdown activities of plants.>Making thorough inspection of equipment and vessels during the shutdown / Major Turn Arounds, highlighting the deviations and suggesting improvements.>Maintaining legal documents of plant.>Track and monitor KPI's of Urea plant employees and foster a culture of teamwork and continuous improvement.>Spearheading and coordinating various projects across MCFL. Show less

Mangaluru, Karnataka, India

Urea Manufacturing Plant supervisor

Mangaluru, Karnataka, India

>Process Simulation: Used tools like Aspen HYSYS for evaluating, optimization, and troubleshooting

Mangaluru, Karnataka, India

DCS Panel operations and Shift supervisor

Mangaluru, Karnataka, India

>Assisted in the day-to-day operations of the Urea production plant, gaining hands-on experience in both fieldwork and Distributed Control Systems (DCS).>Optimized and monitored process parameters using Centum VP, APC>Logged process parameters frequently to ensure plant is running smoothly.>Performed history and trend analysis during to find the root cause and troubleshoot the process problem.>Performed normal start up and shut down activities in field and… Show more >Assisted in the day-to-day operations of the Urea production plant, gaining hands-on experience in both fieldwork and Distributed Control Systems (DCS).>Optimized and monitored process parameters using Centum VP, APC>Logged process parameters frequently to ensure plant is running smoothly.>Performed history and trend analysis during to find the root cause and troubleshoot the process problem.>Performed normal start up and shut down activities in field and panel.>Confidently handled emergency scenarios and emergency shutdown in field and panel operations.>Evaluated plant performance using Exa quantum, Data Historian.>Collaborated with senior engineers and shift supervisors on process optimization projects, including troubleshooting and problem-solving for equipment like Reactors, Pumps, Compressors, Strippers, Absorbers, Heat exchangers, Distillation columns, Evaporators, Separators, Scrubbers, Filtration, Conveyors.>Received comprehensive training in safety procedures, operational safety standards (OHSMS), and environment management (EMS), actively participating in plant-wide safety initiatives.>Coordinated with various departments such as maintenance, safety, and quality to ensure smooth plant operations and compliance with industry>Gained experience in updating technical documentation, including Standard Operating Procedures (SOPs) and Operational Control Procedures (OCPs). H&MB, PFD, P&ID, Control philosophy,>Participated in extensive training programs focused on process control, plant safety, and process automation, providing a strong foundation for future roles in plant management.>Reported near miss, suggestions and abnormalities to shift supervisors.>Participated in knowledge-sharing classes.>Participated in various safety competitions Show less

Mangaluru, Karnataka, India

As a Chemical Engineer Trainee in a Urea plant, focused on these key concepts to understand and operate the plant>Urea Production Process: Learnt the ammonia-CO₂ reaction, Stamicarbon CO₂ stripping process, and high-pressure systems.>Process Diagrams (PFD & P&ID): Understood the material and energy flow via Process Flow Diagrams and Piping & Instrumentation Diagrams.>Heat and Mass Transfer: Studied heat exchangers, separation techniques, and the role of… Show more As a Chemical Engineer Trainee in a Urea plant, focused on these key concepts to understand and operate the plant>Urea Production Process: Learnt the ammonia-CO₂ reaction, Stamicarbon CO₂ stripping process, and high-pressure systems.>Process Diagrams (PFD & P&ID): Understood the material and energy flow via Process Flow Diagrams and Piping & Instrumentation Diagrams.>Heat and Mass Transfer: Studied heat exchangers, separation techniques, and the role of absorbers/strippers in purification.>Process Control Systems: Familiarized with Distributed Control Systems (DCS) and automation for real-time process monitoring.>Reaction Kinetics: Understood reaction rates, catalysts, and how conditions like temperature and pressure affect production.>Safety and Compliance: Learnt safety standards (ISO 45001), risk management, and environmental impact control.>Material and Energy Balance: Calculated material inputs/outputs and minimize energy loss in plant operations.>Ammonia and Utilities Management: Understood ammonia handling, storage, and water treatment systems.>Equipment Operation: Gained experience with pumps, compressors, and preventive maintenance for plant reliability. Show less