Lead – Laboratory
Document NumberNAYA-HR-LAB-JD-05Version / Revision01 / 01Date28 / Aug / 2024Prepared bySystem CoordinatorReviewed byArea ManagerApproved byHOD
AMENDMENT DETAILS
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1 20.08.2018 Old Procedure 00Revised ProcedureNAYA-HR-LAB-JD-0501.00 Organizational Change Requirement2 28.08.2024 Revised Procedure 01.00Revised ProcedureNAYA-HR-LAB-JD-0501.01 Annual Review done.
Lead & guide laboratory team for budget planning, manpower planning, development planning, accurate analysis, timely reporting, product certification, new method / technology development, innovation & improvements in lab, new product developments, trouble shooting, technical support to refinery units for his laboratory sections.
- Ensure 100% availability, operability, and accuracy of all the analytical/other instruments.
- Ensure compliance wrt safety rules and regulation, PPE uses, good practices including calibration, and training of manpower in his section.
- Provide timely and adequate analytical support to processing plants and marketing for monitoring quality of product at various stages of operation & to Provide analytical support to TS for optimisation, problem solving and parameter development.
- Coordination with CDU 1, CDU 2, DHDS, NHT/CCR, FCCU, HMU 1 & 2, Isomerisation, DHDT Marketing/despatch, PIT, PP (particularly for LPG, SKO, MTO, Gasoline, HSD, LDO, MFO, Sulphur, Polypropylene) on day to day basis for trouble shooting, special analysis, test run , sample scheduling and special activities in field.
- Responsible for safety, ERIMS, NABL, IT, LIMs, training, external audits (RIMS & NABL), internal audits, Proficiency testing
- Review of international standards viz., ASTM, IP, UOP, ISO, BIS, APHA etc. and accordingly update SOPs and its implementation.
- Handling issues related to LPG, SKO, MTO, Gasoline, HSD, LDO, MFO, Sulphur. Polypropylene
- ADP project: Support for setting up analytical facilities for PP
- ORGANISATIONAL CHART
- RESPONSIBILITIES
RESPONSIBILITIES
ACTIVITIES
QUALITY MANAGEMENT SYSTEM
Planning & Budgeting:
Annual & Facilities plan: To provide inputs and define a business plan that satisfies short and long term business goals.
- Lead the Lab team and guide for planning of budget (Opex & capex), manpower, new testing requirements, sample scheduling etc.
- Section wise inventory management for spares, consumables and chemicals and its control.
- Development of indigenous vendors for spares and consumables as a cost saving measure.
- NABL:
- Responsible for dealing with NABL authorities for periodic assessments, changes in the scope, addition of personnels, changes in resources.
- Planning conducting internal audits and MRM
- Ensuring system documents, calibration of instruments.
- Ensuring technical competency of the team and arranging periodic training and validation.
- Participating in proficiency testing program and interlaboratory correlation programs. Interpreting the outcome. Analysis of data and conducting RCA
- Support to marketing:
- Analytical support to marketing team for customer complaints
- For setting up analytical facilities at depots and terminals
- Quality Monitoring of depots/terminal product samples.
- Representation at BIS
- Presenting technical views on product specifications and test methods, Nayara business point view by participating in BIS meetings
- Reviewing Quality specifications for amendments and adequate test methods
- Conducting studies /experiments for proving technical viewpoint for amendments in specification.
- New Products
- Conducting lab trials on new products.
- Ensuring laboratory readiness for testing and certification
- Training to lab team on test parameters and specification
Team Management:
To achieve the team's objectives and continue to do so over time.
- Lead the Lab team and define the role clarity of all position reporting to him.
- Define the responsible for managing activities and resolving issues related to ATF, TBP, Crude oil, Bitumen, Petcoke, water lab.
- ADP Project PP :
- Review of test methods, sampling schedule & frequency, Identification of Laboratory equipment list for relevant test parameters, specification of equipment, manpower calculation
- Co-ordination with EPC contractor regarding analytical & infrastructure requirement
- Installation, commissioning of equipment & Validation
- Recruitment & training of manpower
- Implementation of New Analytical techniques
- Development of new test methods to support the product export marketing & refinery problems.
- Customer Support
- Investigation of customer complaints.
- CDU 1, CDU 2, DHDS, NHT/CCR, FCCU, HMU 1 & 2, Isomerization, DHDT Marketing/dispatch, PIT, PP (particularly for LPG, SKO, MTO, Gasoline, HSD, LDO, MFO, Sulphur, PP) on day to day basis for trouble shooting, special analysis, test run , sample scheduling and special activities in field.
- Responsible for safety, RIMS, NABL, IT, LIMs, training, external audits, internal audits, Proficiency testing, In-house competency monitoring.
- Review of international standards viz., ASTM, IP, UOP, ISO, BIS, APHA etc. and accordingly update SOPs and its implementation.
- Arrange vendor visit for maintenance.
- Enhance calibration systems so as to reduce paperwork in his area.
- Trouble shooting of instruments/equipment in case of analytical abnormalities or instrument breakdown.
- In house development of alternate test method.
- Handle environment and pollution related lab issues as per management requirement.
- Coordinate training of team members at learning center.
- Review performance of individuals periodically.
Systems, Policies & Procedures:
To create a management framework with the capability to achieve targeted gross margin performance.
- Implementation of department RIMS objectives and to achieve the set targets.
Management:
To always ensure achievement of targeted outcomes as efficiently as possible while complying with process design standards & Statutory regulations
- Ensure release of reports and quality certificates.
- Ensure release of reports on special samples from various agencies/customers.
- Highlighting abnormality/product failure through to superiors.
MIS:
To enable timely decision making to achieve the business's targets.
- MIS report for management for critical refinery results to concerned officials.
- CDU 1, CDU 2, DHDS, NHT/CCR, FCCU, HMU 1 & 2, Isomerization, DHDT Marketing/dispatch, PIT (particularly for LPG, SKO, MTO, Gasoline, HSD, LDO, MFO, Sulphur) on day-to-day basis.
Coordination Internal & External
- Attend refinery safety coordination meetings.
- Attend refinery safety coordination meetings.
- Held internal safety meetings on monthly basis.
- Conduct CFA & SSO and coordinate CFA of lab.
ENVIRONMENT MANAGEMENT SYSTEM
Systems, Policies & Procedures:
To be accountable for implementation and improvement of the EMS systems, procedures & policies in respective functional operations.
- To ensure adherence to all health, safety, and environment systems during all lab activities
- Implementation of department RIMS objectives and to achieve the set targets.
- General awareness on Environment Management in Refinery.
- Implementation of environment management procedures like Hazardous / Non-Hazardous waste management.
- Coordinate waste disposal activity.
OHSAS
"HSEF - Care & Welfare:
To achieve any safe and healthy workplace.
Authority:
To stop any unsafe job on observation"
- Implementation of Safety Audit observations and firm up the course of actions for further improvement
- Involvement in root cause analysis of incidents & preparation of incident investigation reports
- Based on recommendations of the Safety audit reports, incident reports & root cause analysis, Initiate plant change modifications to improve safety in operations.
Energy Management Systems (EnMS) 50001:2018
Energy Management systems ISO 50001:2018
- Awareness about Energy policy, significant energy uses, Energy objectives and Energy Management System.
- Monitoring and controlling of EnPIs, variables, baseline, Objective/ Targets & Management programs (Energy action plan) and Energy performance as applicable
- KEY CHALLENGES
- Meet stringent export parameter testing for increased value realisation.
- Ensure lab readiness for increased marketing, unit expansion requirements.
- Upgradation of facility with latest technology.
- Ensure 100% reliability and zero% downtime of analytical services.
- Ensure zero% product failure at customer end.
- Bench marking lab performance with international lab (ASTM PT Program).
- Maintaining NABL accreditation of laboratory.
- KEY DECISIONS
- Made by Jobholder:
- Budget and manpower planning.
- Selection of equipment / chemicals / spares.
- Permissible deviation in finished products.
- Planning for facility improvement.
- Recommendations to superior:
- Future quality parameters of product quality.
- Possible changes with respect to quality parameters to meet the quality.
- Suggestion for new test method / instruments.
- Improvement projects and new products.
- Requirements of budget, infrastructure, and manpower.
- INTERACTIONS
- Internal Interactions:
- With Technical Services about improvement in unit parameters and other departments on quality issues.
- With Safety, Procurement, IT, Maintenance, Learning Center, LIMS issues.
- With Head Lab / TS for manpower, budget allocation.
- External Interactions:
- With vendors for evaluating their product offers, discussions etc.
- With NABL and other agencies for maintaining certifications.
- With various vendor for AMC/ maintenance of instruments.
- With ASTM for PTP
- With BIS for test methods and product specification.
- With NABL secretariat.
- DIMENSIONS
- Budget (Opex & Capex), manpower, infrastructure etc.
- Procurement/ Upgrade of analytical equipment.
- Chemical inventory management.
- Team Size: Direct Reports: 2 to 5 Indirect Reports: 25 to 35
- SKILLS & KNOWLEDGE
- Educational Qualifications & Certifications:
- Minimum M. Sc. / B. SC. with good working knowledge of Refinery / Petrochemical Laboratory
- Relevant (Functional/Level) & Total Years of Experience:
- Minimum 20 years of experience in Refinery / Petrochemical Laboratory.
- Functional Skills:
- He should have experience of coordination with various functions.
- He should have operational experience of latest sophisticated instruments/ analysers/ equipment.
- Behavioural Skills:
- Ability to lead, guide and work in team and team building.
- Customer focused, operational excellence, result oriented.
- Good learner, trainer, and managerial skill
RESPONSIBILITIES
RESPONSIBILITIES
ACTIVITIES
QUALITY MANAGEMENT SYSTEM
Planning & Budgeting:
Annual & Facilities plan: To provide inputs and define a business plan that satisfies short and long term business goals.
- Lead the Lab team and guide for planning of budget (Opex & capex), manpower, new testing requirements, sample scheduling etc.
- Section wise inventory management for spares, consumables and chemicals and its control.
- Development of indigenous vendors for spares and consumables as a cost saving measure.
- NABL:
- Responsible for dealing with NABL authorities for periodic assessments, changes in the scope, addition of personnels, changes in resources.
- Planning conducting internal audits and MRM
- Ensuring system documents, calibration of instruments.
- Ensuring technical competency of the team and arranging periodic training and validation.
- Participating in proficiency testing program and interlaboratory correlation programs. Interpreting the outcome. Analysis of data and conducting RCA
- Support to marketing:
- Analytical support to marketing team for customer complaints
- For setting up analytical facilities at depots and terminals
- Quality Monitoring of depots/terminal product samples.
- Representation at BIS
- Presenting technical views on product specifications and test methods, Nayara business point view by participating in BIS meetings
- Reviewing Quality specifications for amendments and adequate test methods
- Conducting studies /experiments for proving technical viewpoint for amendments in specification.
- New Products
- Conducting lab trials on new products.
- Ensuring laboratory readiness for testing and certification
- Training to lab team on test parameters and specification
Team Management:
To achieve the team's objectives and continue to do so over time.
- Lead the Lab team and define the role clarity of all position reporting to him.
- Define the responsible for managing activities and resolving issues related to ATF, TBP, Crude oil, Bitumen, Petcoke, water lab.
- ADP Project PP :
- Review of test methods, sampling schedule & frequency, Identification of Laboratory equipment list for relevant test parameters, specification of equipment, manpower calculation
- Co-ordination with EPC contractor regarding analytical & infrastructure requirement
- Installation, commissioning of equipment & Validation
- Recruitment & training of manpower
- Implementation of New Analytical techniques
- Development of new test methods to support the product export marketing & refinery problems.
- Customer Support
- Investigation of customer complaints.
- CDU 1, CDU 2, DHDS, NHT/CCR, FCCU, HMU 1 & 2, Isomerization, DHDT Marketing/dispatch, PIT, PP (particularly for LPG, SKO, MTO, Gasoline, HSD, LDO, MFO, Sulphur, PP) on day to day basis for trouble shooting, special analysis, test run , sample scheduling and special activities in field.
- Responsible for safety, RIMS, NABL, IT, LIMs, training, external audits, internal audits, Proficiency testing, In-house competency monitoring.
- Review of international standards viz., ASTM, IP, UOP, ISO, BIS, APHA etc. and accordingly update SOPs and its implementation.
- Arrange vendor visit for maintenance.
- Enhance calibration systems so as to reduce paperwork in his area.
- Trouble shooting of instruments/equipment in case of analytical abnormalities or instrument breakdown.
- In house development of alternate test method.
- Handle environment and pollution related lab issues as per management requirement.
- Coordinate training of team members at learning center.
- Review performance of individuals periodically.
Systems, Policies & Procedures:
To create a management framework with the capability to achieve targeted gross margin performance.
- Implementation of department RIMS objectives and to achieve the set targets.
Management:
To always ensure achievement of targeted outcomes as efficiently as possible while complying with process design standards & Statutory regulations
- Ensure release of reports and quality certificates.
- Ensure release of reports on special samples from various agencies/customers.
- Highlighting abnormality/product failure through to superiors.
MIS:
To enable timely decision making to achieve the business's targets.
- MIS report for management for critical refinery results to concerned officials.
- CDU 1, CDU 2, DHDS, NHT/CCR, FCCU, HMU 1 & 2, Isomerization, DHDT Marketing/dispatch, PIT (particularly for LPG, SKO, MTO, Gasoline, HSD, LDO, MFO, Sulphur) on day-to-day basis.
Coordination Internal & External
- Attend refinery safety coordination meetings.
- Attend refinery safety coordination meetings.
- Held internal safety meetings on monthly basis.
- Conduct CFA & SSO and coordinate CFA of lab.
ENVIRONMENT MANAGEMENT SYSTEM
Systems, Policies & Procedures:
To be accountable for implementation and improvement of the EMS systems, procedures & policies in respective functional operations.
- To ensure adherence to all health, safety, and environment systems during all lab activities
- Implementation of department RIMS objectives and to achieve the set targets.
- General awareness on Environment Management in Refinery.
- Implementation of environment management procedures like Hazardous / Non-Hazardous waste management.
- Coordinate waste disposal activity.
OHSAS
"HSEF - Care & Welfare:
To achieve any safe and healthy workplace.
Authority:
To stop any unsafe job on observation"
- Implementation of Safety Audit observations and firm up the course of actions for further improvement
- Involvement in root cause analysis of incidents & preparation of incident investigation reports
- Based on recommendations of the Safety audit reports, incident reports & root cause analysis, Initiate plant change modifications to improve safety in operations.
Energy Management Systems (EnMS) 50001:2018
Energy Management systems ISO 50001:2018
- Awareness about Energy policy, significant energy uses, Energy objectives and Energy Management System.
- Monitoring and controlling of EnPIs, variables, baseline, Objective/ Targets & Management programs (Energy action plan) and Energy performance as applicable
QUALIFICATIONS
- Minimum M. Sc. / B. SC. with good working knowledge of Refinery / Petrochemical Laboratory
