USAMA MUHAMMAD

email: usamampk@yahoo.com

Contact: +974 55202405 / +974 70729991 / +92 3099511787,

I can Join Immediately as I have transferrable Visa in Qatar

Production/ Operations / Commissioning Supervisor, Coordinator

Production Planner
Seasoned Operations professional, having diversified exposure in Oil & Gas / Refinery/ Hydrocracker/ Hydrotreater / Hydrogen Plant/

Fractionation / Distillation, Natural Gas Treatment via Mole sieve operation, Acid Gas removal, Gas Dehydration removal of moisture. Air

Separation Unit (ASU) of Air Products, Cryogenic pumps, N2 Expander start up shutdown, Propane Refrigeration system for LPG Revovery, Gas

Turbine, Compressors, Operating system Mark Vi, Steam turbines, Heat Recovery steam generation (HRSG) system, Pumps, Storage Tanks

Operation and shipping, wellhead operation, Petrochemical Plant Operations aligned with Exxon, DuPont & ORYX GTL policies, standards, and procedures.

Proven expertise in Gas Plant designing (FEED), EPC, construction / erecting, Pre-commissioning, Commissioning, Start up , normal operation, Coordination,

Planning, troubleshooting, Emergency Handlings / incident commander, complimented by my experience in field, panel operations / Supervisor and

Coordinator. Received multiple awards for handling complex emergencies including Fires, preventing unsafe conditions and critical decision making. My career

goal is to become an invaluable resource for a dynamic organization which can maintains its market leadership role in Operations management

Skills / Areas of Expertise

• Production Process Coordinator, Commissioning Coordinator, Incident Commander

• Shift Supervisor, Process Operator, DCS Panel Operator.

• Oil & Gas / Refinery/ Hydrocracker/ Hydrotreater / Hydrogen production Plant/ Fractionation / Distillation, Natural Gas Treatment via Mole

sieve operation, Cold Box, Acid Gas removal, Gas Dehydration removal of moisture. Air Separation Unit (ASU) of Air Products, Cryogenic

pumps, N2 Expander start up shutdown, Propane Refrigeration system for LPG Revovery, Gas Turbine, Compressors, Operating system Mark Vi,

Steam turbines, Heat Recovery steam generation (HRSG) system, Pumps, Storage Tanks Operation and shipping, wellhead operation,

Petrochemical Plant Operations aligned with Exxon, DuPont & ORYX GTL policies, standards, and procedures. Proven expertise in Gas Plant designing (FEED),

EPC, construction / erecting, Pre-commissioning, Commissioning, Start up , normal operation, Coordination, Planning, troubleshooting, Emergency Handlings,

working side by side with EPC Contractors, RFC, AOC, HO dossiers Readiness.

• Troubleshooting, Safe Startup & Shutdown • PCC, (SOP) Procedure Development

• Expert knowledge in MS Office (Word, Excel, Outlook, etc.) and an aptitude for learning new software • SIMOPS • Punch listing •

Brownfield on-shore Project focal point for large scale projects • Catalyst Loading, replacement, Dry-out, Reduction, Oxidation, etc. • PTW / e-

PTW / CPW (RLIC PTW System) BOC systems

• PSM /Safe-Work Practices • BMS/SIS/DCS/ICS Operation • (MOC) Management of Change, PDA, PSSR

• Risk Management: HAZOP, Desktop Safety reviews, Job Safety / Hazard Analysis (JHA / JSA), HAZID

• Audits: PSSR, PSM/ Insurance audits, Permit to Work/ Safety Critical audit, MOC Audit

PROFESSIONAL EXPERIENCE & SIGNIFICANT ACHIEVEMENTS

Total Plant Operations Experience 26 years (1997 Till 2023)

ORYX GTL (Gas to Liquid) June 2005 to Present

Joined during ORYX GTL HAZOP Study Phase and established Through Refinery Plant Installation to Full capacity Operation

and capacity enhancement by working side by side with Contractors like Worley Parsons, Technip, Sasol, Clarient, Haldor

Topsoe, etc.

Projects / Achievements

• Refinery Plant installation (Greenfield) including WAX Treatment System, Pressure Leaf Filtration (PLF) System, Hydrocracker, Hydrotreater, Hydrogen

Generation Plant, Pressure Swing Adsorption (PSA) system, Compressors, punch listing, pre-commissioning, and Commissioning activities with Contractor

involvement.

• ORYX Operations Brownfield projects focal point, coordinating all brownfield projects related activities from designing to execution and lining up with system.

• HAZOP Study activities for Refinery Processes designing for all streams.

• Plant SIS / Programmable Interlock Logic control development, Testing, improvement, and Implementation.

• LPG / Hydrotreater brownfield Project designing, Installation, Punch Listing, Pre-commissioning, commissioning. Achieved 10% Profits increase.

• ORYX GTL DOT (Capacity enhancement) Project, increasing Plant Overall Capacity to 08% by Design Improvements.

• Products Storage Tanks Brownfield project’ HAZOP study, Control Logic designing, installation, Pre-commissioning, commissioning and Operation with all

interfaces, Operational, and legal documentation development, and control .

• FFBL Pakistan, Ammonia Plant Installation (Greenfield) project,

• Pre-Reformer installation project (Brownfield) Achieved Ammonia Plant 10% capacity enhancement.
• Natural Gas Desulphurizer (Brownfield) Project.

• Furnace (Reformer) Reliability Enhancement Project “Brownfield” achieving Reformer safe Operation and capacity Improvement, Fuel consumption reduction.

• Natural Gas Booster Compressor Project (NGBC) “Brownfield” Project resolving

• Reformer Duct burner installation project “Brownfield”.

• Catalyst Replacement Activities including Oxidation, Reduction, Sulphiding, Activation, Dry-out, to achieve Plant total capacity stable operation

Production Supervisor Role

Achieving Production Targets, Manpower Rostering, Job Plannings.
●

● Organizing process/equipment/people for safe, efficient and quality production need.

● Handover Planning, Safety Meetings, PSSR Team Leader.

● Working with maintenance Teams for plant operation, Emergency response Team Leader, Optimizing Plant conditions to save costs, increasing profits.

● Preparing SOP for production and giving training to operators in follow up.

● Giving Instruction to Operators to meet production requirements Production report generation, shipment reports, Incident investigation (RCA)

● Operators Appraisal system (KPIs), employees’ evaluation, motivation, and promotion

● PTW / e-PTW system implementation. Job Hazard Analysis (JHA, JSA),

● ASPEN, SAP System, Field Patrolling, Manpower management Rostering.

● Liaising with relevant department heads to improve information sharing and efficiency of planning.

● Maintaining a positive shifts culture and motivating the operators.

● Maintain effective cost control and promote cost awareness in others.

● Plant Housekeeping Audits, Quality ISO9000 Audits, Environment ISO14000 audits, Closing of Audits Findings NCs,

● Participating in equipment failure analysis investigation and suggesting solutions to avoid recurrence.

● Implementing the required and out of box measures for production improvement according to ISO/CPS and company ESHA guidelines.

● Proven track record on operator leadership, problem solving, housekeeping management in past working history.

● Management of Change (MOC), SIL (Safety Integrity Level) reviews.

● participating in managing energy & resource management for green production.

● Providing Training and developing newcomer workers, ensuring all necessary safety training and technical instructions are provided to the workers.

● Assessing the competence of subordinate personnel using company competence assurance system and ensure continuous and timely progress of subordinate
personnel.

● Patrolling work area and listening for warning signals and taking corrective actions in response in case of any warning signals or emergency.

● Supervising process requirement implementation for a stable production achievement.

● Supervising the operation in plants during the shift schedule assigned and managing work assignments.

● Monitoring and improving direct production costs especially on utilities, consumables, work efficiency and product yield as required.

● Initiating and coordinating planned and emergency maintenance and repair work to meet production schedule.

● Reviewing master production schedule and work orders, establishing priorities.

● Looking after the staff attendance, scheduling, and other administrative needs.

● Manage the workload and operation of the Production and Process and Utility systems at team level through subordinate staff.

Production Planner / Process Coordinator Role

● Managing Operations coordination along with customer operating team, network coordination & other neighboring production facilities. Achieved 98% onstream
factor in last 5 yrs.

● Incident commander, Fire/Safety Emergency Response Leader, with consistent “Excellent” rating since 2018

● Development and follow-up of Production Plans, Monthly presentation to Operations management team. Achieved 100% KPIs according to 2023 plan.

● RCA Team Leader, PSSR Team Leader, SIS BOC (Bypass Override system) lead, accountable for ensuring Safe Operations during overrides.

● Diesel / Naphtha shipment effective coordination with jetty operation, resulting in Zero demurrage cost in 2022 – 2023.

● Responsible to develop “Downtime reports” for sharing reasons and their possible solutions to prevent downtime by effective planning of PMs/ Shutdowns and
Overhauls. Reduced unplanned trippings from 90% to 95% in last 5 yrs.

● Identifying emergency situations regarding the security and safety of the facility ensuring all HSE&Q instructions are strictly followed by workers in the shift?

● Accountable for the overall safe operation, equipment maintenance, environmental compliance, and production efficiency. Achieved 100% compliance to PM plans
during assigned shift.

● Responsible for preparing/modifying job plans, producing work-packs, conducting field walk-downs, setting realistic target dates for job execution, shutdown /
startup Plannings, opportunities jobs, prioritizing jobs. Manpower allocation, backlog managements.

● Developing Standing instructions for Production Supervisors regarding Emergency handling and Optimization plans to achieve Production Targets.

● Preparing and issuing daily production reports to higher management.

● Developed 02 Production engineers, 10 field operators as part of Qatarization efforts.

Pre-commissioning, Commissioning Supervisor Role

● Detailed Pre-commissioning, Comm. procedures, SOPs Development. Activities checking and relevant Commissioning punch list / check list preparation.
keeping records of all activities in the logbook.

● Certificates preparations, duly signed by the involved parties, and handover to certification engineer (QA/QC).

● Ensuring that Commissioning Activities like flushing/blowing, reinstatement of piping components and local instruments, leak test, motor run-in, machinery
run-in, static equipment inspections, cleaning, internals installations, box-up are duly performed in accordance with the stated procedures, in conformity with

the safety rules and as per the instructions of Commissioning Manager or Commissioning Superintendent.

● Managing and organizing Sub-Contractor following and ensuring the working and safety procedures.

● Providing Support to Vendor specialists for job execution and coordinating their actions with the Commissioning work force, as well as supervising vendors’
specialists working and ensuring their efficient utilization

Lead Panel Operator Role

● DCS ICS Panel operation, Refinery Operation. SIS Operation. Parameter Logging.

● Alarm management. Reporting to Supervisor. Emergency handling.

● Power crisis management. Giving instructions to field operators to achieve production targets, Equipment hand over for maintenance, taking over from
maintenance.

● Plant Startup / shutdowns, Hydrocracker, distillation towers, Furnaces, Hydrogen production Unit with PSA, Hydrotreater, compressors,
pumps operation, Air separation Unit (ASU), Cryogenic Oxygen pumps, Mole Sieves, Cold Box.

Diesel / Naphtha shipments Operation management, Tanks measurements, On-shore Tanks reports generation. Storage Tanks operation.
●

● Daily production reports generation. Shipment Jetty Operation. Third party surveyor product measurements and LOP (Letter of protest) issuance as necessary.
APC (Advance process control) system Operation.

● Operating control panels and system to regulate process parameters in order to ensure the required production and meet customers' demands,

● Monitoring / adjusting process parameters to ensure safe operation and product quality /reliability.
 Field Operator Role

● Area / Field inspections, Parameter Logging, logbook writing, Pumps / Compressor Startups, Shutdowns, Emergency handlings, Firefighting, Emergency
Response Team Member, Condition Monitoring. Check list / log sheet developments / filling,

● P&ID development, Punch listing, Equipment handover / Take over after maintenance, Safety Audits, PSOI Team Member,

● PTW e-PTW system compliance, SAP system compliance.

● Contribute to the identification of opportunities for the continuous improvement of systems, processes and practices in order to increase productivity and
operational efficiency.

● Ensure production targets are met while maintaining compliance with Life Critical Procedures, Tenets of Operations, Consent to Operate, plant policies and
procedures, Daily Operating Instructions, Standard Operating Procedures (SOPs) and Job Safety Analyses (JSAs).

● Perform unit start-ups, normal operation, process upsets and shutdowns as per SOP and EOP requirements.

● Monitors process conditions and makes necessary adjustments in order to optimize the process while ensuring products are within the required specifications.

● Document critical activities and abnormalities via operator’s log.

● Perform comprehensive shift turnover. Timely completion of all compliance training.

● Ability to work on-call, shifts, weekends, holidays, and overtime to support plant operations, and

● Respond to emergency situations when they arise. Monitor and log all operating parameters ensuring that all irregularities are reported to immediate
supervisor for advice and/or resolution.

● Monitors all personnel and activities on site using, but limited to, unit surveillance, regular safety walks, audits, and Observations to ensure site safety and
operational effectiveness.

● Implement all relevant Section’s policies, processes, procedures and instructions so that work is carried out in a controlled and consistent manner.

● Reactor Catalyst Reduction, dry out, Oxidation, Replacement etc. all activities,

● charge hand over / take over. OASIS Behavioral safety program and Audits.

● Performing periodic routine operations such as switch-over of filters pumps or equipment start-up and shut-down.

● Receiving shift handover from the previous Shift, receiving shift logs and information on process conditions. Reviewing such information at the start of the shift
to determine immediate or urgent work requirements .

Engro Chemical Pakistan Limited (ECPL) Dec 2000 to June 2005

Worked in Engro as Lead / Panel Operator and Field Operator for 05 Years
FFBL Ammonia Plant Year 1999 to 2000
FFBL Ammonia Plant installation / Construction, Pre-commissioning, Commissioning as Field Operator for about
02 Years
FFC Ammonia Plant Year 1997 to Year 1999
Worked in FFC ammonia as Field Operator for 02 Years

Education / Professional Developments

Program Status

Bachelors (Chem Physics, Math) Completed

Process Plant Operator Apprenticeship Diploma Completed

Project Management Diploma Completed

HSE Diploma Completed

Chemical Tech Diploma Completed