Prasanna Kumar

• Led end-to-end commissioning from Greenfield to Brownfield projects, including pre-commissioning, system turnover, and integration across static equipment, rotating machinery, DCS/SIS, and electrical systems.
• HSSE & Safety Performance: Drove improvements in site safety, achieving consistent reductions in incidents through coaching-based interventions and culture development
• Led and Accountable for Maintenance Performance cross-functional teams to achieve project goals, fostering collaboration and innovation.
• Budget & Contract Management: Managed an annual maintenance budget while meeting business targets; served as contract owner for all maintenance and services contracts.
• Leadership Team Contribution: Active member of the Site Leadership Team, contributing to strategic planning and operational excellence
• Cost & Productivity Optimization: Managed maintenance costs with disciplined execution and productivity improvements.
• Performance Improvement: Consistently enhanced Maintenance Division performance and results delivery, achieving for continuous improvements

Achievements:

• Achieved mechanical completion, pre-com & commissioning, schedule timeline and plant start-up with zero LTI, ensuring operational readiness.
• Established SAP structures (PM & MM), set up workshops and warehouse operations and setting up maintenance team and control procedures.
• Ensured compliance with NEA, SCDF, QRA, PCS, P&FM, HAZOPs, and Safety Case regulatory requirements and participated in getting approvals in permits work process with local Authority.
• Drove successful audits, securing SS651, ISO 9001, and ISO 14001 certifications
• Established Reliability and Inspection frameworks and strategies in the plants

• Managed mechanical maintenance of production units with 12 direct reports, contractors, and vendors, overseeing annual SGD 14M budget.
• Mentored engineers and technicians, enabling progression into Authorized Engineer and Next levels of roles.
• Trained new team members by relaying information on company procedures and safety requirements.
• Promoted a positive work environment by fostering teamwork, open communication, and employee recognition initiatives.
• Implemented maintenance strategies that optimized costs, resources, and schedule adherence.
• Participate in RCA, FMEA studies, Spare Managements.

Achievements:

• Recognized with multiple Shell Special Recognition Awards (2010, 2016, 2017) and Bukom Cost Hero Award (2019).
• Achieved Shell People Survey scores of 84% (People Management) and 82% (Team Leadership) in 2020.
• Delivered major turnarounds for Cogen, Boilers, Gas turbines, Multi-stage compressors, HRSG, SCOU, SRU & Hydrocracker, Ethylene cracker units with Goal Zero safety record..

• Executed maintenance for static & rotating equipment in Ethylene Cracker and Hydrocracker complexes.
• Authorized Engineer for lifting plans, confined space, method statements, and JOHAN for high-risk activities.
• Delivered complex maintenance works including hot tapping, in-situ welding in statutory pressured equipment following inspections requirements with regulatory compliance.
• Developed comprehensive documentation detailing maintenance schedules, procedures, and guidelines for reference by all personnel involved in upkeep activities.
• Enhanced equipment reliability by performing regular maintenance and addressing potential issues proactively.

Achievements:

• Shell EVP Award, April 2014:
• Performed and developed on-stream repair solutions for statutory vessels with proper engineering methods & approvals from MOM, and avoiding multi-million-dollar production losses. in shutting down entire ECC.
• Performed as a block execution lead for the rotating equipment in Ethylene Cracker year Oct 2014 & Oct 2019 and delivered the work with “Goal Zero”, Quality (non-repetitive works), within the schedule and cost.

• Year 2005: Delivered Turnaround execution activities for PODU (PU2) unit as a Mechanical Supervisor.
• Year 2006: Delivered in Turnaround execution activities for SMPO(PU1) unit as a Mechanical Supervisor.
• Supervised day-to-day maintenance of steam boilers, HRSGs, gas turbines, chillers, pumps, heat exchangers, incinerators, and compressors.

• Supervised piping fabrication, installation, hydrotesting, and commissioning (~125,000 ID).
• Delivered rerouting, tankage erection, steam/electrical tracing, and jacketing header works
• Process piping P&ID, PFD and Equipment construction works.

• Responsible as a Field Maintenance Engineer for various process equipment’s such as pumps, screw compressors, gearboxes, accumulator, heat exchangers, belt conveyors, hydraulic valves, pneumatically operated valves, hoists and overhead cranes