MAKRAND S KULKARNI (PMP, MSC, LSSYB, FIDIC, SCRUM FUNDAMENTALS & BOSIET/HUET CERTIFICATION)
Contacts: +91-9904601444, +91-9825745313, E-mail: adimak@gmail.com, adimak@yahoo.com
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ENGINEERING & PROJECT MANAGEMENT ROLE
SNAPSHOT: Significant international working experience with renowned operating & contractor (EPC) companies across EUROPE, AFRICA, & MIDDLE EAST & ASIA and currently RUSSIA, Encompassing exposure & expertise in hydrocarbon sector, which entails some upstream & mainly downstream projects which includes refining, petrochemicals and gas projects.
• Have 23+ years of expertise in engineering & project management which includes Pre-Engineering, Estimation, Bidding, FEED/DED, Procurement, Construction/Commissioning and to achieve them pre-planning, control of schedule, budgeting as per the long-term plan of company in the market and present business opportunities.
• Highly versatile & accomplished senior level project management & engineering professional with experience in both Green field & Brown field projects mainly spanning Oil & Gas downstream.
• A strategist with demonstrative qualities to estimate & plan dynamic models with estimation & bidding teams and implement them decisively to help company achieve the business growth plans by bidding competitively.
• Hands on experience in project delivery operations of geographically concurrent projects from development cycle to final completion and smooth hand over to clients.
• Highly efficient in administering contracts, including holistic management of contractual obligations and entitlements, resolutions of contractual disputes, implementing controls on changes (MOC) & update top management especially about complex issues/conflicts and make project cost productive.
• Responsible for smooth invoicing to maintain cash flow by ensuring that all reports & mandatory forms/Licenses and formalities (technical) are fulfilled timely & act as focal point for any discrepancies & changes.
• Human Resource & training management to locals, administration, labour laws, legal/commercial procedures, marketing and business development strategies, negotiations, and brain storming.
• Identifying critical activities & risk potential while project bidding, planning and execution stages. Giving priority in resolving them to avoid bottlenecks in project delivery within schedule & budgeted cost.
• Proactive analytical professional with technical means to identify risks (Risk analysis & management) & problems in initial stages itself & help formulate tactical plans (mitigation & avoidance), initiate changes required in diverse environments & in challenging times & convert them into opportunity.
• Leadership experience in managing & controlling design & execution programs, defining project scope, WBS, schedules; project resources & logistics, initiating SCM works & construction activities with good interface.
CORE COMPETENCIES INCLUDE
• Pre-FEED Project-Planning & Estimation, bidding
• Risk management
• Corporate Strategy & Business Development • Project Monitoring & Control
• Model Reviews 30% & 60%
• Client Mgmt. & collaboration
• Planning & controls in Engineering & Execution • FEED & Detailed Engineering
• Building Performance Team
• Constructability Review
• Process Engineering & Project engineering, Site engineering
• HSSE Management
• Document Control & Mgmt.
• Contract, claims & change Mgmt.
• SCM & Procurement
• Method study & feasibility reports
• Negotiation & communication
• HAZOP, HAZID, SAFOP, ITP • Coaching & Mentoring
• Project Mgmt. & Control
• Man-hour effort estimation
• Site Management & Execution
• Budget and cost controls
• Interpersonal skill & stake holder management • Management of Change (MOC)
• Leadership & Motivating
• Quality Assurance & Controls
• Define Scope definition to team
• Acceleration, delay analysis
• Vendor & Contractor Mgmt.
• Technical Deliverables
PROJECT ENGINEERING- PRE-FEED, FEED & DED
• Lead teams for Pre-Feed teams to develop project design basis, place boundaries to constrain and define a concept, basically by defining a design outlining operating characteristics of project, followed by technical and economic feasibility of the design basis.
• Carry out Basic engineering which comprises of PFD, P&ID’s, Process simulations for diff scenarios, Heat & Mass balance for entire plant, flare loads, utility and effluent summaries, hydraulic calculations, thermal rating of H/Ex, coolers, fired heater, fin fans, primary plot plans, Eq. data sheets, adequacy checks for E&I especially if brownfield project.
• Lead teams for FEED which typically has simulations, thermal ratings, material selection, design basis, PFDs & PID’s, equipment lists, E &I data sheets, line lists, plot plans, preliminary 3D models, SLD, Engineering design basis & standards, Hazardous area classification, system configurations & interfacing for PLC & control systems.
• Track Basic design & control philosophies, PFD, PID’s, UEFS, Heat/Material balance & plot plans, plant & equipment layouts & foundation drawings & deliverables as per EDR or MDR.
• Know software tools viz. Primavera P6, MS Project, Auto CAD, Bentley View, Navis Work, Smart Plant, Integrated Completion & Quality Management System (ICQMS) & Micro DMS.
• Aware of engineering codes & std’s of ISO, API, ASTM, ASME, Shell DEP, Total GS, SABIC, PDO & OGC.
• Skilled in improving project performance through reviews & audits including DR, HAZOP, SAFOP, IPF, 60% & 30% model reviews, constructability reviews, SIL reviews, PHSER, QRA, SHELL HEMP, F & G study & FAT/SAT in the end which can delay project if not adequately and timely handled.
• Use master copy of P&ID’s and line list to outline & keep track of HOLD items till supporting deliverable are not made available and ready.
• Keep review meeting with area leads weekly/bi-weekly to discuss major changes and update the P&IDs. This allows everyone (all disciplines) to be prompted to communicate their changes to the P&IDs before the last day prior to freezing them for the next issue.
• Ensure that when using smart P&IDs or Line List, an electronic copy of each is sent to the data base manager for update to keep current and area leads are aware of same.
• Coordinate vendor engineering activities with engineering & construction teams & planners to meet client’s requirement as per the priority list, responsible lead, scheduled dates and forecast manhours.
• Ensure engineering deliverables are made timely & distributed to the relevant sections of the project team by DCC so construction activities are smooth & swift.
• Ask respective experts in team to prepare SOP’s and commissioning procedures for systems and unit operations as per process plant and submit same for review.
• Ensure that changes are approved, recorded & distributed to the relevant sections of the engineering & project team timely for raising V. O’s, in parallel ensure that site changes are accurate and timely.
• Follow guidelines to conduct HSE & quality audit (internal/external) in different phases of project.
PERSONAL CHARATERISTICS
• Analytical, numerical, reasoning ability helps me take result-oriented decisions with ability to balance priorities.
• Participative and leader style of management, good with teams and professionals of diverse background, personalities with different skills, educational and social backgrounds.
• Leadership & personality development skills, presentation, financial and accounting management techniques.
• Developed interpersonal skills with the ability to establish credibility & be decisive about recognizing and supporting the organizations preferences, objectives and priorities as per goals and set objectives.
• Technically & commercially astute manager, an inspirational leader and outstanding team player utilizing collaborative approach to translate goals & objectives into achievements, while showcasing strong analytical & problem-solving aptitude in decision making and business progression.
CONSTRUCTION MANAGEMENT
• Expedite & resolve issues in design deliverables (IFC) with comment such that construction work is carried out with minimum issues and hurdles.
• Astute in management of budgets, CAPEX, project milestones, L12345 schedule, commercial functions.
• Ensure TBE & TQ’s are clarified to place P. O’s, later vendor engineering deliverables & fabrication schedules are monitored & expedited & inspections including FAT/iFAT are carried out as per agreed schedule & ITP’s.
• Interface with construction team to know about the deliverables needed urgently to keep smooth and continuous flow of work on all fronts like installation, civil/construction, piping, electrical and instrumentation.
• Resolve constraints, prevent losses by engineering & business solutions & take expediting initiatives by out of box ideas and consulting with higher technical experts and consultants available via brainstorming and collaborative discussions.
• Enhance business growth & create opportunities in wider areas of large capital investment, lowering project cost & improving safety & risk management methodologies in EPC projects.
• Strong contract & project management including change management, commercial management combined with negotiation as well as arbitration skills in resolving issues and maintaining stakeholder’s interests.
PROJECT MANAGEMENT (SCM & CONTRACT)
• Procurement plays an important role in ensuring that supply of materials, product, machinery, items and services are within the planned & estimated budget or allocated budget and deliveries are on planned schedule & cost without compromising on quality and safety so the construction pace remains.
• Expedite & resolve issues in design deliverables (IFC) with comment such that construction pace remains.
• Developed business of multimillion onshore plants and gasfields, reduced project expenditures by 4-6%.
• Astute in management of budgets, OPEX, project milestones, L12345 schedule, commercial functions.
• Ensure TBE & TQ’s are clarified to place P. O, vendor engineering deliverables & fabrication schedules are monitored & expedited. Intermittent inspections, stage inspection as per ITP including final FAT/iFAT/SAT are carried out as per agreed schedule with no ambiguity in terms and conditions.
• Interface with construction team to know about the deliverables needed urgently to keep smooth and continuous flow of work on all fronts like civil/construction, installation, piping, electrical & instrumentation.
• Resolve constraints, prevent losses by engineering & business solutions & take expediting initiatives via out of box ideas, and by virtue of consulting with higher technical experts/authorities & available consultants.
• Enhance business growth & create opportunities in wider areas of capital investment, lowering project cost by proper cash flow management. And, by improving safety & risk management methodologies in EPC projects.
• Maintain interaction with client to get feedback for improvement in services & procure new business as well.
• Strong contract & project management skills including change & commercial management in combination with negotiation & arbitration skills for resolving issues and maintain stakeholder’s interests.
STRATEGIC THINKING & BUSINESS MANAGEMENT
• Develop strategies & execution plans based on SWOT analysis, brainstorming with management think tanks.
• Successful delivery also contributes to achieve new business as reputation in market rises & gives strength.
• Strategic & analytical thinking for managing the resources for entire phases of the project. Plan OPEX budgets including overhead budgets, capital budget to enhance operations in coordination with the macro plans of organization including contingency budget in the end and as per risk tolerance and appetite.
• Utilize 7-management tools and 5-Quality tools in conjunction to define, measure, analyze, improve and control technique (DMAIC) to continuously improve process and achieve customer satisfaction.
• Emphasize & use SIX SIGMA & LEAN methods to minimize variations and eliminate waste to reduce costs.
• Formulate & implement effective strategies with a view to achieve business SMART objectives & ensure profitability, foresee performance bottlenecks & take measures to mitigate in every phase of project & PMO.
• Build a value-added business partnership with the customers & stake holders. Contribute to the development and execution of the Business Solutions strategy in cooperation with top management.
• Take buy or rent decisions after analysis, study of technical data & finance details. Also perform cost benefit analysis (CBA & ROI) in all decisions required to be taken for different gates of project.
PROFESSIONAL EXPERIENCE – July’20 started as Project Engineering Head for PP/PE in Shurtan gas expansion complex with Bureau Veritas [Engineering offices are in Korea & Tashkent] for this project based in Uzbekistan.
Project is based in Uzbekistan where the expansion of Shurtan gas field is under progress to ensure diversification of polymers production & to improve performance of Chemical Complex, thus increasing the export capacity. SGCC entered into a turnkey contract with Enter engineering which is oil and gas construction company & engineering is being done in Korea-Seoul & Tashkent. Project is based on the use of the latest gas-chemical technologies from CB&I (USA) and Chevron Philips (USA). The petrochemical complex will produce 400KTA of polymer using natural gas as a feedstock & naphtha from the GTL plant. Process facilities consist of a naphtha cracking unit, a total hydrogenation unit (THU), and HDPE & PP plant. As such detailed engineering is in progress and thus PO are being placed once TBE, TQ, PS, DS are cleared & Kick off meeting is scheduled.
AWS Engineering LLC ¦ Jan 18 till March 20 (INDIA, OMAN) For Oman Gas Company project
As Head of Projects for EPC - Reporting to MD (Team managed >100 including site and head office)
AWS does EPC & De-bottlenecking for many projects ranging from 5 to 10 M OMR for that work with estimation consultants & perform surveys in market to understand the costing & other specific intricacies. Work in tandem with feasibility study consultant and prepare draft with product specification, regulatory requirements, and capacity as well as other utility requirements under Pre-Feed report. Once we get the project then concept is to partner engineering approved company (Ex. Mott Mac/Tebodin/WP etc.) to get FEED & if scope for detailed is given then perform DED. AWS does the EPC projects for both gas projects & downstream onshore projects in OMAN. For OGC, the scope was EPC. We did the engineering with Mott MacDonald, In-house team did the procurement & Construction was carried out by AWS LLC & local partners.
GTL Project (OWEL –LINKSO GROUP) Nigeria ¦ June 2014 – Aug 2017
Senior Project Manager, EPC Project - Reported to: MD, (Team managed>100)
PROJECT- Gas Plant processes 30 million standard cubic feet of Wet Gas daily. The Gas Plant Offtakes Wet Gas from the Platform Petroleum/New cross JV Flow Station to produce Liquefied Petroleum Gas (LPG), Propane, Lean Gas and Natural Gas Liquids (NGL). The Plant contributes to the supply of LPG and Propane to the domestic market. The Lean Gas and NGL are supplied to the industrial sectors.
Highlights- Successfully utilized over 90% locals in the project. Drafted the terms and conditions as required & Secured 5-year (O&M) contract for the entire facilities with manpower and catering.
SHELL DOMGAS PROJECT – MAKON EPC Ltd (METS) ¦Nigeria ¦ Aug 2011 – Oct 2013
Senior Project Manager-Engineering - Reported to Project Director, (Team managed <100)
DOMGAS project – Creation of upstream facilities to treat & process oil & gas from various well & fields. Use same gas supply to power generation industries & liquid is sold back to Client, Shell Nigeria. Highlight - Managed (7) sites namely UTOROGU AG & NAG, ALAKIRI, AGBADA, BONNY, ADIBAWA, with EPCM scope valued at USD 380 million, crossing 1/2billion USD after variations. Daily stand up meeting to know the issues of each site & hurdles pertaining to progress and EDR/MDR status & value of work (VoWD) attained as per Milestones/schedule and man hours planned. METS bid for another five projects successfully involving subsea works and feasibility studies for brownfields and upgradation facilities in FPSO.
TOTAL NIGERIA & CAMERON SUBSEA PROJECT, Point EPC ¦Nigeria ¦ Dec 2008 – Jan 2011
Engineering Project Manager- Reported to MD, (Team managed <50)
PROJECTS - OUR 42” Pipeline Phase 1 EPC Contractor: Zakum-Baywood Joint Venture Ltd
Asset Owner: Total Nigeria – Scope of Work - FEED Review, detailed engineering & construction supervision, meeting for identification of LLI’s and developing strategy for them along with clients engineering team and planners. Interaction and coordination with project and site teams from both sides (client and In-house).
HIGHLIGHT -Completed all pipeline surveys in record time as per planned schedule with local teams.
USAN Deepwater Development Project EPC Contractor: Cameron Field, By: Chevron/ExxonMobil/Total JV.
Multidisciplinary team management for engineering related to manifolds and SPS systems, tie-in skid, subsea pipelines, flow lines & associated umbilical & riser lines. FEED review with local & Cameron team from UK by visits and skype briefing for understanding of the engineering scope by both teams. As engineering manager, I was head of both teams (Nigerian & UK) as they merged & worked together on engineering deliverables in different offices. Thus, co-ordination and communication were a challenge for the progress and mitigation of issues and concerns with common consensus & outcome.
? HIGHLIGHT -Executed subsea engineering first time locally as mostly Locals were educated and trained in UK
EARLY WORK EXPERIENCE (PETROCHEMICALS)
LINDE-KCA-DRESDEN GMBH, Germany & KSA, Area Team Leader, April 07 – Oct 08,
• Technology for PP was UNIPOL as third-party technologies to harness superior polyolefin projects which polymerizes the monomer to manufacture modern plastic materials. (Jubail-SHARQ expansion project).
• Worked in the Germany office (For Detailed engineering) & on project site (KSA) for the 800 K TPA polyethylene plant in Saudi Arabia.
WORLEY PARSONS, QATAR, Senior Project Engineer, March 06 – April 07 (NFB-platform)
• To provide project services to different heads of Qatar gas including Offshore Modification Project, Enhanced Oil Recovery (EOR) project & Glycol dehydration project.
• Had to visit off shore site also in North field bravo to keep track of progress work done by contractor is matching the schedule and plan and prioritize procurement items with vendors as well to keep fast track on progress as several constraints and hurdles are posed in running operations.
TECNIMONT, MILAN ITALY, Project Engineer& Commissioning, Aug 04 – Jan06
• PKN Orlen, Plock where the technology used was SPHERIPOL & HOSTALEN based on BASELL LICENSES. It was a Petrochemical Plant Expansion project based in Poland.
• Worked in the MUMBAI AND MILAN office (For engineering and SOP) & on project site (KSA) for the commissioning and smooth hand over of 800 K TPA polyethylene plant in Saudi Arabia.
UNILUBE, KSA, Production Engineer, Oct 02 – July 04
• In the refinery using vacuum distillation and thermal cracking to produce different grades of lube oil from used oil collected and remaining water is fed to ETP and light, medium and heavy grades of lube oil & gasoline are loaded via loading station connected with tank farm.
COMERINT-ITALY, Start-up & Production Specialist, May 00 – October 02
• US-based ABB-Lummus Global is the license technology provider for the Olefin Conversion Unit. Dow Chemical Company has licensed its proprietary “UNIPOL TECHNOLOGY” for the PP plant.
• Worked at the project as pre-commissioning and commissioning and handover to client as the main scope for expansion of SABIC IBN ZAHR Polypropylene plants in KSA-JUBAIL.
RELIANCE INDUSTRIES LTD, India, Process Assistant & DCS Supervisor, PP plant (Nov 96 – May 00) & HDPE plant (Oct 93 – Nov 96)
• Uses world class technology from DU-PONT, known as “SCLAIRTECH” solution polymerization and for PP it employs SPHERIPOL TECHNOLOGY & ADIPOL TECHNOLOGY from BASELL & UNIPOL PROCESS of DOW CHEMICALS to MFD. REPOL having Homopolymer, copolymer and Impact polymers (diff grades).
• Worked on various unit operations-fluidized reactors, recovery systems by distillation, dense phase product distribution, & extrusion, followed by conveying & bagging systems, using PLC & GUS HONEYWELL DCS system.
EDUCATION
? MSc. – Project Management, University of Roehampton, UK, 2016-18 with Merit. (60%)
? Petrochemical Engineering, MS University Baroda, India, 1992-69%, Project -CATALYTIC REFORMING.
? MBA is in progress with Nottingham Trent University 2019 -2022.
CERTIFICATIONS & MEMBERSHIPS
? Project Management Professional –PMP- 2014 valid till 2023
? Lean Six Sigma Belt, 2013 (LSSYB), cleared training for green belt also in lock down.
? FIDIC (Silver and Red book)
? Professional Memberships: Project Management Institute (PMI), Society of Chemical Engineers (SCE)
? Certified for SCRUM fundamentals also during lock down.
TRAININGS
SABIC Fire Training Centre, Safe Handling of Hazardous Chemicals, Offshore Survival & Safety Training Certificate, Training program at PARC by RIL-India, Training from Process Licensors of UOP, DuPont in RIL. Training in ATM & VAC crude distillation, Indian Refinery. JHA, H2S, BOSIET, HUET, HSE and safe driving trainings for PDO/OGC.