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Resume #81016

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Aspiring to become a part of a world class HSE team at a leading process industry that provides the perpetual opportunities for growth.

Experience: Engro Chemical Pakistan limited (FORMERLY EXXON CHEMICAL) 2003 to date
"Engro Chemical Pakistan is the second largest fertilizer industry in Pakistan and currently installing the largest single train fertilizer complex in Pakistan. Engro has accomplished significant progress not only in its base urea fertilizer business but also in other diversified projects"

HSEQ
A chemical engineer with strong desire for success in the field of Health safety and environment. Thoroughly familiar with Exxon's Safe Management practices (SMPs) and DuPont's PSRM (process safety risk management) & PSM (personnel safety management)

Key Responsibilities

* OSHA CFR 1910.119 compliance in day-to-day jobs
* Incident report writing and investigation
* Process Hazard Review and consequence analysis of process sections
* Schedule and conduct training sessions on safe practices
* Pre-start up safety reviews of new facilities and modifications
* Carry out safety audits (Behavioral and Process related) and review audit information
* Stewarding and complying incident report recommendations
* Participate in the HIRA, HAZOP processes associated with work-site activities.
* Ensure that standard safety procedures are written and followed
* Review incident investigation reports
* Create and support the systems and organization that foster the safety culture
* Issue bimonthly report on leading indicators
* Member of HSE committee as B&A (Behavior and audits) coordinator

Selected Contributions
* Rolled-out 14 elements of Process Safety Risk Management (PSRM) and Personnel Safety Management (PSM) program across the Production department to achieve OSHA compliance
* Developed level-3 documents of Safety management system for field level implementation of HSE policies
* Member of Divisional Sub Safe operations committee for behaviors and audits
* Contingency & Emergency Response planning for Explosion and toxic release
* Conducted 5 PHA of Ammonia and Urea plant process sections
* Led FMEA study for Ammonia plant DCS and Natural Gas Booster compressor PLC

Safety Projects & Due Diligence:
* Hazard Management study for existing control buildings. Project cost 4.7 MUS$
* Improving inherent safety of 1967 vintage plant. Obtained approvals by accentuating relation between the unsafe conditions with unsafe behavior.
* Installation of Integrated Ammonia Vent Header at Urea plant. Project involved installation and commissioning. Project cost 2MUS$

Six Sigma
Acquainted with six sigma and lean tools and methodology (Green Belt Certified). Responsible for coordinating all production related lean and six sigma projects. Also member of two green belt projects of manufacturing division

Key Responsibilities
* Conduct Team-briefs and work out session
* Six Sigma tools embedment
* Identify lean and six sigma projects for manufacturing
* Audit and steward the project control phase
* Coordinate production department lean and six sigma projects

Six Sigma Projects:
* Achieved annual monetary savings of 0.65 Million US$ with six sigma projects.
* Water Conservation (Green Belt). ROI = 35,000US$ Effluent generated per ton of UREA reduced by 25%.
* Furnace Fuel Optimization; ROI-annualized= 0.15MUS$
* Chemical (caustic) consumption optimization. ROI-annualized = 50,000US
* Steam optimization at Urea plant; ROI-annualized = 0.1 MUS$

Operations & Process Eng
A multi-skilled Operations engineer with experience in process design simulations, PFD preparation & doing retrofits for energy conservation at chemical related facilities including Ammonia, Urea and Utilities

Leading a crew of 90 operators for alignment with corporate goals of optimized plant operation & improved HSE performance. Major areas of responsibility include:
* Ammonia, Urea & Utilities Coordination
* First Stand-in for urea plan unit manager
* Leader of Emergency Squad
* Planning and Coordination of unscheduled/breakdown activities.
* Monitoring and development of Key Performance Indicators (KPI) of Production
* Conduct Training & Need Analysis (TNA) of operation work force
* Provide safety advices HAZID, HAZOP and Risk Assessment studies coordinated by production

Projects & selected assignments:
* Migration of Bailey Infi90 to Experion Distributed Control Systems
* Ammonia Control system ( Experion) FAT at Honeywell Singapore.
* Alarm Management at Urea plant
* Feasibility study for Gas Turbines Power Augmentation
* Catalyst replacement of High Temperature Shift Converter and Pre-Reformer
* Reduce Steam to gas ratio at primary reformer inlet to increase load and improved energy index

Business & Economics
* Responsible for the economics of the management, operation, growth and profitability of manufacturing division and validation of economics associated with new engineering projects.
* Control and monitor Macro-level engineering economic trends and issues.
* Development of future production plans and key planning basis for fertilizer operation
* Monthly issuances of plant efficiency report capturing energy and cost indices.
* Prepared complete manufacturing division budget (1.6Billion US$)
* Quarterly stewardship of all cost centers
* Event oriented reconciliations for over-runs and under-runs

Accomplishments
* Obtained 5M US$ approval for new Centralized Control Room project & elimination of long pending inherent safety issues. (Selected for supervising complete end to end design & implementation)
* Recognized as best emergency squad leader in year 2004
* Awarded for the best six-sigma project on optimizing effluent generation among 27 competitors across the organization
* Ranked amongst top 3 employees in annual appraisals among a workforce of 500 employees. Recognized under employee distinction program
* Author of AIChE paper: "Engro's 16 years of experience of relocated ammonia plant"; captures 16 years past incidents and the associated key learning's

Education
Bachelors in Chemical Engineering 1999 - 2003
University of Engineering & Technology Lahore.

Professional Courses

* Safety Pro by DuPont (For Safety Professionals)
* PHA & MSA techniques
* Safety for first line supervisors by DuPont
* Six Sigma Yellow and green belt

Skills

* Team Building and leadership
* Creativity and problem solving
* Microsoft Office
* Training and people development
* Maximo and SAP acquaintance
* Bilingual fluency (English and Urdu

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