Success Story

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Success Story of Kishor Makadia

Overview for Tata Group, Essar & Nayara Energy

1978 - 1988

Tata Chemicals, Mithapur

  • Production
  • Loss
  • Profitability
  • More Manpower
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1977 - 1992

Tata Chemicals, Mithapur

  • Tata chemicals - fertilizer UP.
  • High accidents rate, fatal accidents
  • Plant upset created safety hazards
  • Profitability eroded
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1990 - 1994

Tata Chemicals, Mithapur.

  • Delay/ poor performance loss of profitability as well as safety.
  • Project execution from conceptualization to commissioning
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1994

Tata Chemicals, Mithapur.

  • Business disturbance
  • Delay in start up after shutdown and additional expenses
  • Environment non compliance
  • 5 crRs a Day /1.5 $/barell
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2001 - 2002

Tata Chemicals, Mithapur.

  • Business disturbance
  • Delay in start up after shutdown and additional expenses
  • Environment non compliance
  • 5 crRs a Day /1.5 $/barell
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Success Story

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2003 - 2005

Tata Chemicals, Mithapur

  • Back from BHEL, GT HRSG, DM plant, boilers was not getting stabilize.
  • Loss in Profitability
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2003 - 2008

Essar Power-VPCL

  • Phase 1 CPP for refinery ( Essar Oil limited- EOL.)
  • Refinery valuation has gone high and sold at 12.9 billion $
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2008 - 2012

Essar Power-VPCL

  • Approximate 1.5 billion $ net saving from 2012 to 2022
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2018

Essar Oil-EOL

  • Approximate 1.5 billion $ net saving from 2012 to 2022
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2018 - 2019

Essar Nayara Energy

  • Approximate 1.5 billion $ net saving from 2012 to 2022
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1978 - 1988

Tata Chemicals, Mithapur

Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss prevented.

1988 - 1988

Tata Chemicals, Mithapur

Challenge Densh ash plant product failure remain for 1 year. Business Impact Loss of profit and loss of customer. Solutions implemented after RCA and study I Was transferred to plant and shouldered accountability as head accountability, RCA done and corrected in 3 month time.Outcome Stable operation, regain customer improve profit.

1977 - 1990

Tata Chemicals, Mithapur.

Challenge Soda ash manual operation Business Impact Production loss/profitability/more manpower. Solutions implemented after RCA and study Automation done- In house designed , valve manufactured, Flowmeter manufactured installed and automated control room established.Outcome Production increased 30 % better safety in operation. High profit.

1990 - 1992

Tata Chemicals, Mithapur.

Challenge Frequent tripping of power plant (Blackout) every fortnight. Business Impact Loss of profit and safety. Solutions implemented after RCA and study I was transferred to Power plant as superintendent, change O&M practice, SOP based operation, spare, repair, coal selection, preventive maintenance, improved performance (one year no trip observed).Outcome Great improvement in profitability.  Improve safety.

1990 - 1992

Tata Chemicals, Mithapur

Challenge Coal fire boiler shutdown time reduced to 6 days from 21 days.  Business Impact Loss of profit. Solutions implemented after RCA and study I was responsible for making power plant efficient and improve reliability.. Detailed planning, accountability, 24 hrs operation, skilled team, use of new tools, rewards, involve operation team, use hydro jets for cleaning. Replace instead repair on site.Outcome Better profitability. 

1992 - 1994

Tata Chemicals, Mithapur

Challenge Fertilizer project expected to get delayed by two years at UP Babrala. Business Impact Grass root Urea plant compressors 5 Units sets with entire accessory was in critical path. ( estimated delayed 2 years) loss of profit. Solutions implemented after RCA and study Transferred to fertilizer plant and deputed to BHEL hyderabad and bought all items in time with great quality. Outcome Great impact on business bottom line.

1994 - 1994

Tata Chemicals, Mithapur

Challenge Fertilizer plant CPP and utility commissioning hold ups. Business Impact Back from BHEL, GT HRSG, DM plant, bolers was not getting stabilise. Solutions implemented after RCA and study With in three month all units are stabilized with major changes made. It was nightmare, basic issue in design which was incorrected. 1- Boiler light ups, 2, naphtha supply to GT, GT hold ups due to FOG, HRSG logics, HRSG first stage flame, DM all valves wrong design. Outcome Timely commissioning of Ammonia and urea plant.

1994 - 1994

Tata Chemicals, Mithapur

Challenge Burn Instrumentation restoration after Boiler massive fire. Operation was hold. Business Impact Loss in Profitability. Solutions implemented after RCA and study I was back to mithapur in 1995 as head C&I- inhouse 4 boilers, 4 Turbine and generators instruments and plans was burns to ash, inhouse departmentally lead design, procurement, installation, commissioning and stabilisation in 5 month time. Outcome Estimated time was two years by external agency. Back to normal in 5 m0nths.

2001 - 2002

Tata Chemicals, Mithapur

Challenge Energy loss due to improper operation of this turbine and Compressor anti surge. Business Impact Fertilizer UP. Loss in profitability. Solutions implemented after RCA and study I was transferred as HOD electrical and instrumentation, worked on IGV control mode on auto as well s redefine surge line on COR compressors. This saved energy - 20 Cr/year. Outcome improvement in profitability.

2001 - 2002

Tata Chemicals, Mithapur

Challenge Turn around time and startup was a challenge. Business Impact Tata chemicals - fertilizer UP. Loss in profitability. Solutions implemented after RCA and study New SOP for Turnaround made with no over maintenance, only identified valves and transmitter to be service. Outcome Smooth start and stabilisation, better profitability.

2003 - 2005

Tata Chemicals, Mithapur

Challenge Poor safety management system and compliances. Business Impact High accidents rate, fatal accidents. Solutions implemented after RCA and study I was transferred back from Babarala, Safety culture through BSC- 5 Star processes as well due pond safety management introduce, I was owning section 2 which is implementation and achieved 5 star. Outcome Safety standard has gone high.

2003 - 2005

Tata Chemicals, Mithapur

Challenge Company has made loss- ( import and new plants expansion by competitors) Business Impact Profitability eroded. Solutions implemented after RCA and study Mckinsey service was hired- Iwas leading energy cost reduction where structured process of cost effectiveness was implemented and thus company came back on track. Outcome Profitability has gone high.

2003 - 2005

Tata Chemicals, Mithapur

Challenge PF and CFBC boilers was not reliable, frequent failure and availability was less than 70 %. Business Impact Profitability eroded. Plant upset created safety hazards. Solutions implemented after RCA and study I was back to mithapur as head power plant and started working on PF and CFBC boilers, all set right through RCA, combustion chemistry was challenged and set right with SOP of buying coal and using, Boiler availability is 100 % from 65 % since 2005 till date. For cost reduction petcoke use started in CFBC and have cost reduction in unit cost by 50 %. Outcome Great Stability, cost reduction, safety, profitability.

2005 - 2008

Essar Power-VPCL

Challenge Phase 1 CPP for refinery ( Essar Oil limited- EOL.) Business Impact Refinery commissioning - ( EOL). Solutions implemented after RCA and study Old uninstalled oil and Gas 77 MW + 230 tons of steam plant was in bad situation due to remain at sea cost for long time, challenges was divided in to small and focus approach, solution reached and worked very hard with team. ( challenges - IBR,Documents, details, etc) Outcome Refinery was commissioned in time.

2008 - 2012

Essar Power-VPCL

Challenge Project execution from conceptualization to commissioning. Business Impact delay/ poor performance loss of profitability as well as safety. Solutions implemented after RCA and study Phase 2 I was healing construction , and decision makers for selection of equipment, better quality standard and QAP with QC an force, Format process for commissioning, coal storage and management, fire protection and detection, safety and fire management, people trained. Outcome Timely commissioning of coal based power plant started giving return better then estimated as Gas cost was doubled by this time.

2008 - 2012

Essar Power- VPCL

Challenge Coal based can not work for refinery energy supply. Business Impact 1 $ to 1.5 $ per barrel process. 20 MMTPA refinery. Solutions implemented after RCA and study Design,Technology, selection of equipments, procurement, construction, commissioning was done keeping in mind reliability. Outcome 2 billion $ straight bottom line in 10 years 2012-2023 (17500) Rs Cr.

2018

Essar Power-VPCL

Challenge Sea water cooling towers cells collapse and on inspection found many more can. Business Impact Refinery to cut down production so huge loss on through puts. Solutions implemented after RCA and study RCA indicated Poor preservation and maintenance done.. However to get immediate solution interconnection was established during shutdown Outcome Saved disaster to stop refinery/ reduce output.

2010 - 2018

Essar Power- VPCL

Challenge Sea water intake line from pump house to refinery is 17 KM leaks frequently. Business Impact Frequent shutdown create unrest in villages , water shortage for cooling, time pressure. Solutions implemented after RCA and study RCA- frequent start stop gives water hammering to GRP line so joints get weak and leak.- actions SOP for start and stop pumps. Outcome No leaks since 4 years

2008 - 2012

Essar Oil-EOL

Challenge Cooling tower cells colleps and most of weak Business Impact Business disturbance. Solutions implemented after RCA and study Interconnection provided to meet business continuity. Outcome Operation continue.

2018

Essar Nayara Energy

Challenge Storm Water - pollution Business Impact Environment non compliance. Solutions implemented after RCA and study Specific area water collected in pond large pond and saved contamination of entire storm water stream. Outcome Saved Business closure.

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1978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
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21978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
Next
31978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
Next
41978 - 1988 Tata Chemicals, Mithapur.
Challenge Instrumentation frequent failure, trappings due to air line failure. Business Impact Profitability. Solutions implemented after RCA and study I took responsibility to set right Entire airline and associated like air filters etc converted to SS316 and atlas copco with MD 6 Dryer to avoid moisture in air line.Outcome No instrument failure thuse, loss preventes.
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