Muhammad Usama

Experience

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  PepsiCo

  Jun 2015 - Jul 2015

  Intern

  - Water Treatment and Quality Control Management: Performed specific test in laboratory and understanding of process.- Prepared Flow-sheet of different sections and internship report by utilizing EDraw and Microsoft Word

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  Fauji Fertilizer Company Limited

  Jul 2015 - Aug 2015

  Intern

  - Utilities, Ammonia and Urea Unit: Learned about process flow-sheet and working environment.- Prepared internship report by utilizing Microsoft Word

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  Amal Academy

  Mar 2016 - Jan 2017

  Fellowship

  Education start-up funded by Stanford University that teaches professional skills to students and corporationsCareer-Prep Fellow: Communication: Completed a competitive written application and interview process to be selected from over 900 applicants for intensive 3-month Fellowship funded by Stanford University-Skills development: Invested 150 hours in order to develop business skills (e.g., communication, leadership, problem solving, teamwork, etc.) that will help me make a deeper impact on the job Show less

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  Engro Corp

  Jul 2016 - Nov 2021

  Worked as a Deputy Process Manager Urea Plant based on Snamprogetti Technology with a name plate production capacity of 3835 MTPD. My Responsibilities include:- Trouble Shooting - Root Cause Analysis - Product Quality Control- Quality Assurance - Daily Production Report Audit - Coverage on Start-up and Shutdown of Plant- Participation in PHA of Plant - Job Safety Analysis- Issuance of Technical Monitoring Report - Efficiency Improvement Reports- Stewardship of Leading Indicators - Modeling and Optimization of Plant - Budget Coordination- Planning of Turnarounds - DuPont PSM elements compliance - Stewardship of Incident Reporting at UnitMajor Assignments/Achievements:- Commissioning of Urea-3 Advance Process Controller on Snamprogetti technology based Plant with IPCOS team in order to optimize the process and increase the production by 1.5% Load.- CO2 Compressor simulation on ASPEN HYSYS for efficiency calculation and comparison with historical data.- Evaluated 16MW Steam Turbine efficiency and optimized the machine through adjustment of cooling water in vacuum condenser.- Identification of MAH – Major Accident Hazard at Urea Plant as per DUPONT Risk Based Methodology- Conducted Root Cause Analysis of Urea Prilling Bucket erosion issue. Show less Worked as an Assistant Production Manager at Ammonia Plant based on Topsoe technology with a name plant capacity of 2194 MeT. Responsibility includes:- Lead 40+ NMPTs Manpower- Lead 20+ Contract Manpower- Emergency Handling and Troubleshooting Skills- Product Quality Control- Production Management- Start-up and Shutdown of Plant- Perform post wise PHA of Plant- Job Safety Analysis- Steward Work Permit Unit Compliance - Six Sigma Projects- Unit Budget Coordination - Unit Management Safety Audits - Stewardship of LIs and KPIs of Unit - DuPont PSM elements complianceMajor Assignments/Achievements:- Lead 22 Days Turnaround activities for the unit which involves; Activity Planning, Critical activity resource allocation, material availability Planning, Major Machinery Overhaul Planning, Gas, Power, Steam & Fuel Balances, Handover procedure development, startup & shutdown procedure development and Safety Package development.- Start up and Shutdown of Feed Gas Enrichment Unit.- Implemented a steam saving project on Air Machine by improving steam turbine efficiency as a result of steam inlet enthalpy manipulation.- Appreciation Received from the UM and GM for the emergency handling of Fire on Syngas compressor during start up.- Conducted R&D Study on aMDEA filter and reduce the replacement frequency which resulted in 1 Million PKR Savings.- Represented Production Department as Process Safety Management Lead during 3rd Party Audit by DUPONT.- Conducted MAH verification at Plant-2 which were derived from Post Process Hazard Analysis (PHA) - Conducted Inherent Safety Audit at unit in which 100 Man hours were utilized and 49 recommendations were generated.- Developed a Technical Training Module on BFW Chemistry and WHB Case Studies for the department - Launched Safety Campaign at department level to achieve 0 TRIR target.- Conducted Cost Benefit Analysis of chemical dosing at site by Buckman and NALCO and findings were represented to GM Production Show less Worked as Assistant Production Manager at (Snamprogetti) Urea and Utilities Plant. Following are the operating units under my responisibility: Urea Plant, Reverse Osmosis Unit, Demin Trains, Polisher Unit, Condensate Recovery Unit, Instrument Air Plant, Nitrogen Plant, Boiler Feed Water Unit and Cooling Towers Package.Responsibilities Include:- Contract Manpower Handling- Auditing Body- Emergency Handling and Troubleshooting Skills- Quality Assurance- Daily handling of Contract manpower- Start-up and Shutdown of Plant- Development of Plant Reliability and Vulnerability Model and its resolution- Perform post wise PHA of Plant- Job Safety Analysis- Steward Work Permit Unit Compliance- Six Sigma Projects- Unit Budget Coordination- Unit Management Safety Audits- Stewardship of Leading Inidicators and Key Performance Indicators of Unit- DuPont PSM elements complianceMajor Assignments/Achievements:- Performed Individual Startups and Shutdown of Unit.- Developed and executed the MOC for the installation of Urea Stripper Sample Valve.- Conducted Root Cause Analysis of KW Header Erosion.- Prepared 370 Million PKR budget for utilities plant for the year 2019.- Performed IP Cycle and CAPEX study on the unit level.- Managed whole manufacturing site chemical inventories during COVID19 Lockdown. - Acted as OHIH Lead for the unit and prepared the team and unit for OHIH 2nd Party Audit.- Acted as PSM Unit Lead for the 3rd Party PSM Audit.- Conducted benchmarking study for the installation of NALCO PURATE at Cooling Tower 4- Conducted the research at the laboratory scale on Cooling Water Make up to see the impact on CW Analysis with when makeup hardness is reduced through alum and lime dosing.- Handled emergency of Ammonia Leakage from P-01 (High Pressure Ammonia Pump)- Prepared the Thawing Procedure for Nitrogen Plant in order to reduce the downtime of unit.- Participated in PHA of Medium Pressure Loop of Urea-3. Show less Worked as a Production Engineer at (Snamprogetti) Urea and Utilities Plant. The Utilities Plant comprises of Offsite Facility, Demin Trains, Polisher Unit, Condensate Recovery Unit, Instrument Air Plant, Nitrogen Plant, Boiler Feed Water Unit and Cooling Towers Package.Responsibilities Include:- Emergency Handling and Troubleshooting Skills - Product Quality Control- Daily handling of Contract manpower - Start-up and Shutdown of Plant- Perform post wise PHA of Plant- Job Safety Analysis- Steward Work Permit Unit Compliance - Six Sigma Projects- Unit Budget Coordination - Unit Management Safety Audits- Stewardship of LIs and KPIs of Unit - DuPont PSM elements compliance Show less Utilities and Urea Production Unit: Worked as Trainee Engineer at URUT-III plant which comprises of Urea World Largest Single Train Plant and Utilities Plant which comprises of Demin Trains, Polisher Unit, Condensate Recovery Unit, Instrument Air Plant, Nitrogen Plant, Boiler Feed Water Unit and Cooling Towers Package.-Trained in operation fundamentals, process deviation. Effect and cause analysis, emergency handling, plant troubleshooting and root-cause analysis.- Stewarded DuPont PSM elements- Performed Management Safety Audits, LI and KPI analysis.- White Belt Six Sigma Holder Show less

  • Senior Process Engineer

    Oct 2021 - Nov 2021

  • Assistant Manager - Ammonia Plant

    Apr 2020 - Oct 2021

  • Assistant Manager - Urea & Utilities Plant

    Aug 2019 - Apr 2020

  • Production Engineer-Urea and Utilities Plant

    Jul 2017 - Aug 2019

  • Graduate Trainee Engineer

    Jul 2016 - Jul 2017
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  EmpiricAI

  Dec 2021 - Nov 2022

  Senior Process Engineer

  Worked in the capacity of Digitization Project Lead in order to provide subject matter expertise to cloud based industrial internet applications that are focused on monitoring and optimization of plant individual asset and overall performance in collaboration with software engineering and data science team. I've led 02 projects related to Sea Water Reverse Osmosis Desalination Plant situated in Bahrain (Aldur-2) and Saudia (Shuqaiq) with a name plate capacity of 50 Million Imperial Gallon in collaboration with GE and NOMAC.My primary responsibilities include:- Site Survey and Assessment - Process and Performance Management- Act as SME for the assigned project- Designing of Thermal Process Models- Analytical Assessment of Operating Data - Efficiency & Performance Reports- Project Management- Analysis and proposition of KPIs- Lead QA and QC of dynamic models - Issuance of Technical ReportMajor Assignments/Achievements:- Developed Desalination Unit physics based models on Ebsilon for performance evaluation.- Developed correlations of Reverse Osmosis chemical dosing for Chemical Advisors application.- Simulated Sea Water Reverse Osmosis on TORAY DS2 for Membrane KPIs evaluation.- Evaluated efficiency of energy recovery device (Pressure Exchanger) and its impact on the specific energy index of plant Show less

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  Engro Corp

  Dec 2022 - now

  - Lead the implementation of DuPont’s Risk-Based Model, including Major Accident Hazards (MAHs) revalidation, barrier effectiveness assessment, and hazard management.- Performed Baseline HAZOP and LOPA studies for ammonia plants, ensuring alignment with Process Safety Management (PSM) standards.- Performed SIL Study (Assessment & Validation) for Ammonia Plant.- Performed Transient State PHA of Ammonia Plant.- Developed Bowties for identified Major Accident Scenarios (C4 & C5 Consequences)- Aligned the Safety Critical System Assurance through Performance Standard development through the utilization of Bowties- Provide support in incident investigations using root cause analysis techniques such as Fishbone, 5-Whys, and Fault Tree Analysis (FTA).- Collaborate with first-line supervisors on critical Health, Safety, and Environment (HSE) activities, overseeing Management of Change (MOC), Pre-Startup Safety Reviews (PSSR), Permit to Work (PTW), and Emergency Response Planning (ERPG).- Drive and track HSE performance through Key Performance Indicators (KPIs), utilizing both leading and lagging indicators.- Train site personnel, including contractual staff, on safety protocols to ensure consistent and thorough implementation.- Participated in multiple national and international platform on behalf of Engro Fertilizer HSE Department and have won the following achievements: (a) IFA Green Leaf Award - Winner (b) RoSPA Gold Award - Winner (c) British Safety Council - International Safety Award - Winner Show less - Developed 2022 Sustainability Report for Engro Fertilizer as per GRI guidelines. - Calculated the overall site Carbon Footprint, Water Footprint, Solid Footprint and NOx Footprint intensity numbers.- Led the site team for the developed of Bowties (Barrier Management Tool) as a part of HSE transformational journey from Cultural based to Risk based. - Identified Safety Critical Systems additional assets as a part of Bowtie Development Exercise.- Led the site Process Safety Management Team for the 2nd Party Audit. - Prepared a corrective action plan (CAP) & follow-up on the NCs, CARs, PARs.- Ensured compliance on (a) ISO 14001/18001/9001 implementation (b) Sindh Environment Quality Standards (SEQS) (c) Works for the protection of environment and conservation of natural resources (d) Pollution prevention through Ammonia, Urea Dust Monitoring, Noise, Illumination, Effluent monitoring, Soil, Sub-soil and Potable water quality monitoring surveys, as per yearly plans.- Aligned the group company documents with the corporate level documents.- Conducted Risk Based Assessments and identified High Consequences Items along with their recommendations- Carried out the feasibility of Environmental footprint reduction projects.- Led the Budgeting & IP exercise for the HSE Department- Participated in multiple national and international platform on behalf of Engro Fertilizer HSE Department and have won the following achievements: (a) RoSPA Gold Award (b) EHS Daily Advisor -Runner Up Award (c) EFP- OSHW - 1st Prize Show less

  • Senior Process Safety Engineer

    Jan 2024 - now

  • Senior HSE & Sustainability Engineer

    Dec 2022 - Dec 2023