USAMA MUHAMMAD

Address: Production Department, ORYX GTL PO BOX 22533,

Ras Laffan, QATAR, usamampk@yahoo.com

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

Operations Manager

Commissioning Coordinator / Supervisor, Production Planning

Seasoned Operations professional, having diversified exposure Managing Oil & Gas / Refinery/ Hydrocracker/ Hydrotreater / Hydrogen Plant/ Storage

Tanks Operation and shipping, Ammonia Plant, Petrochemical Plant Operations and managing aligned with Exxon, DuPont & ORYX GTL policies, standards, and

procedures. Proven expertise in Plant designing (FEED), EPC, construction / erecting, Pre-commissioning, Commissioning, Coordination, Planning, TIP (Tactical

Improvement Plan), Overall Equipment Effectiveness (OEE) troubleshooting, Emergency Handlings / incident commander, complimented by my experience in field,

panel operations / Managing / Supervising / Coordination. 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

Production / Operations management

Skills / Areas of Expertise

• Production Management, 5S leadership, walk the Talk, EMP Reporting, IMS, BBS, LSR, ERT (Silver), HIRA, NEA Waste Reporting, ALPS, RACI, Stand in for

Site Manager.

• Production Planning, Road Map, Long-term, Short-term, Daily Weekly Monthly KPIs, SICs, Debottlenecking, Downgraded Operation, business continuity,

• Budgeting, in view of AUM, BOM, OAM, PEM, CapEx / OpEx etc..

• HSE&S: NEA Reporting, CTO (Consent to Operate), Waste tracking & Recovery Management, Third Party and internal Auditing, NCs follow up & closure.

• Employee KPI and performance management.

• Production Process Coordinator, Incident Commander

• Oil & Gas / Refinery, Hydrocracker, Hydrotreater / Hydrogen Production / Ammonia /Granular Urea Plant, HAZOP, Installation, construction, Pre-

commissioning, commissioning, Normal Operation, Emergency Handling, Trouble shooting, working side by side with EPC Contractors, RFC, AOC, FAT, HO

dossiers Readiness.

• Operations Mgmt • Troubleshooting, Safe Startup & Shutdown

• PCC, (SOP) Procedure Development • Catalyst Loading, replacement, Dry-out, Reduction, Oxidation, etc. • PTW / e-PTW / CPW (RLIC PTW System)

BOC systems

• SIMOPS • Punch listing • PSM /Safe-Work Practices • (MOC) Management of Change • BMS/SIS/DCS/ICS Operation

• Brownfield Projects

• Technology: Ammonia, Utilities, Fractionator, Hydrotreater, LPG system, Compressors, Pumps, Reformer, Gas purification, Distillation towers, Diesel / Naphtha

/ WAX Storage Tanks operation and shipments, Jetty Operation.

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

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

PROFESSIONAL EXPERIENCE & SIGNIFICANT ACHIEVEMENTS

Total Operations Experience 26 years (1997 Till 2023)

ORYX GTL (Gas to Liquid) -QE Company 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.

ORYX GTL, QE 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”.

Operation Manager Role

• Catalyst Replacement Activities including Oxidation, Reduction, Sulphiding, Activation, Dry-out, to achieve Plant total capacity stable operation
 Safety performance management along with HSE&S Department as leading role player. Key player for all process like LSR, BBS, SAQ, safety

committee, incident investigation, ERT, safety inspections, internal/local audits, HIRA, hazard studies (HAZOP) and others as deemed necessary

by the site management for the continual improvement of site HSE&S performance. Leads hazard recognition and safety improvement for the

site. Ensuring that adequate safety norms are used by site personnel.
 Follow up and adherence on all instructions and plans by Plant Manager (Site leader).
 Set and achieve yearly production goals in line with company Policy / strategy.
 Managing, scheduling, and safely executing field operations to ensure the achievement of production targets. Operating the oil and gas fields in a prof -

itable and optimal manner.

 TIP (Tactical Improvement Plan) planning, short term, Long term, for Production Department and all relevant interfaces. Developing and monitoring the

operational expenses.
 Lead with example (walk the talk), inspiring / guiding others, seeking systematic continuous Improvement (Leads 5S). Ensure SOP adherence, issuing

work instructions regulations and guidelines.

 Provide deeper understanding of the production process, and quality management aspects, safe plant operation.
 Being the primary point of contact between the corporate head office and the operations on site and provides regular reports to the top management to

show the efficient performance of the site within the budget.

 Assists in customer complaint and non-conformance investigations.
 OEE Tracking by following up of production schedule adherence.
 Production shift’s process management including all relevant operational activities as provided by Planner / scheduler with continuous follow up with

achieving all targets.

 Driving Risk reviews, Problem troubleshooting, Bad Actors identification with maintenance, providing solutions to achieve and maintain production tar -

gets. Taking corrective actions to rectify variances.

 Take initiatives, Giving suggestions for Plant / Process modifications, MOC Process for plant improvements.
 Improving Plant reliability Factor reliability factors / standard. ensure work requested with maintenance is value added and prioritized right.
 Proper budgeting and continuous follow up to production schedule (AUM) and BOM (PEM)
 Ensure proper execution of primary processes (OAM, AUM) and the foundations (performance management, 5S, SWS) in production.
 Ensure Plant / Equipments Maintenance schedules are properly adhered by production by Timely Hand over / Take over.
 Assist in site’s new product introduction and process optimization. Developing new strategies to increase production with safe and cost-efficient methods
 Ensure that all sort of trainings is being maintained to new / old Staff as prioritized and Assist all facilitator for any new employee training.
 Experienced in putting Early Production Facilities to start production and contribute in company’s Net Income and cash flow.
 Focus on day-to-day routine field operations to ensure compliance with HSEQ / HSE&S plans and process safety standards that meet facility availability

>98% and plant efficiency >92%.

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.
 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.

Shift Supervisor Role

● Achieving Production Targets, Manpower Rostering, Job Plannings.

● 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.

● 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.

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

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

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

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

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

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

● Looking after the staff attendance, scheduling, and other administrative needs.
Lead Panel / Field 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, Hydrotreater, compressors, pumps operation.

● 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.
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.

● 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

Masters in business administration (HRM) Completed

Bachelors (Chemistry, Physics, Math) Completed

Process Plant Operator Apprenticeship Diploma (HND) Completed

Project Management Diploma Completed

HSE Diploma Completed

Chemical Tech Diploma Completed