Khalid Mahmood

-Worked in the capacity of Process Lead and Design Engineer
-Subject matter expert for process engineering & result-proven process engineer
-Lead process engineering and design, process configuration and optimization studies
-Concept Selection / Feasibility Study/FEED Preparation & Verification/Process Simulation/Heat & Material Balance
-Execute and review Feasibility Studies / Conceptual Design / Feed verification/ Process Studies/ Detail Engineering Design
-Process Engineering for OSBL /ISBL/ MOC/ revamp projects/ new projects
-Perform Process simulations, prepare Process/Utility Flow Diagrams, Heat and Material Balance, Utility Balance
-Performing Process simulation using Hysys, PRO/II, Flarenet, Pipenet, Korf & fluid flow
-Development of Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs)
-Prepare Process equipment datasheets, instrument datasheets
-Be part of critical review teams e.g. Design (30%/60%/90%), PHA / HAZOP, P&IDs, Flow Diagrams, Data Sheets, Procurement Requisitions, Vendor Data.
-Perform relief and blowdown studies, relief load scenario analysis and flare network calculations (API-RP 521, API-RP 520)
-Perform process calculations for equipment sizing and line hydraulics
-Development of Heat & Material Balance(Process Simulation using Aspen HYSYS & Aspen Plus and preparation of Simulation Report).
-Safety and risk engineering/RISK ASSESSMENT (HAZOP, SIL, FMEA, RCM, JSA, ETC IEC 61508, 61511).
-Relief load calculations, Safety valve selection & sizing, PSV inlet line sizing
-Prepare Process design philosophies, operating guides & standard operating procedures.
-Vessel sizing like 2-phase and 3-phase separator and selection of internals
-Participates in/leads technical review meetings for MOCs, HAZOP study.
-Sets the objectives and requirements of site surveys and plant visits to determine constraints in the existing facilities systems
-A balanced multi-discipline understanding in Process Engineering, DCS/PLC Controls, Process Safety, and equipment/plant design
-Demonstrated ability to make balanced decisions weighing operability, reliability, capital costs and operating costs
-Carried out line sizing, control valve sizing and orifice designing & thermal rating of heat exchanger & air coolers.
-Equipment sizing and preparation of process data sheets of Pumps, Compressors, Vessels, Heat
-Exchangers, PSVs, Control Valves, On-off Valves, Flow Elements, RO, Miscellaneous Instrument and piping items.
-Preparation of new P&IDs of different sections of plant for modifications
-Participate in P&ID development, Operability and Hazard Reviews and define Control systems reliability, operability and availability plans.
-Develop Process Controls, Instrumentation and Analyzer Projects technical risk matrix, RAMS and Risk mitigation and project execution plan
-Attend technical meeting with Owner, Licensor, EPC Contractor and Vendors.
-Review and approve, the EPC Contractor key deliverables and other works within the Process discipline, ensuring compliance with Process design requirements and the Licensors’ PDP’s
-Ensure quality and accuracy of EPC Contractor’s Process Engineering design activities, system integration, and design selection.
-Supervises the work of junior engineers, process engineers and designers
-Provides technical advice (process) to engineers from other disciplines
-Expertise to lead and give direction to a team of engineers and designers to generate or work on discipline deliverables and drawings
-Profient user of simulation programs such as HYSYS, Aspen Plus, Unisim design, HTRI, TASC+, Aspen flare analyser, Pipe net, HAZOP Leader and promax etc.
-Dynamic attitude towards project improvements and savings.
-Ensuring compliance to company standards, procedures, policies and agreed work specifications.

-I am a UOP graduate for Naphtha Hydrotreater, Semi-regen reformer, CCR and MEROX units
-Technical services engineer for fuel refinery, Operation engineer & LP-Modeling Engineer.
-Process engineer for Process Engineering, Technical Services Division-Fuel Refinery on Crude-CDU, UOP Naphtha Hydrotreater(NHT) and UOP Platforming Units of Fuel Refinery, at National Refinery Limited (NRL), Karachi, Pakistan.
-Monitoring the UOP licensed units, platformer, naphtha hydrotreater and MEROX units & crude distillation units.
-Catalyst loading, unloading, regeneration and skimming, T&I and commisioning & start-up (C&SU)
-Unit troubleshooting and operation support, Tank inventory management
-Crude oil evaluation & Assay Management and GRM calculation
-Day to day plant performance monitoring and Economics
-Succesfully developed LP-based models using Aspen PIMS as lead PP&E engineer for GRM calculation
-Provide support services and troubleshoot any problems that arise with operations.
-Perform optimization analysis, forecasts, economic reviews and evaluations on equipment / projects, operations and system operating strategies.
-Perform supply and demand balances and conduct investigations to determine the root cause of specific issue in the plant
-Research ways to reduce production costs, develop production goals, and create schedules and plans for individual tasks
-Supervises the work of junior engineers, process engineers and designers
-Provides technical advice (process) to engineers from other disciplines
-Participation to Review Meetings, such as P&ID review, 3D Model, HAZOP and other safety review meetings.
-Operational analysis, optimization, process control
-Dynamic simulation, operator training
-Developed Block Flow Diagrams, PFDs, P&IDs, Heat and Material balances, Hydraulic calculations, Equipment data sheets for Refinery Units, Utilities
Nitrogen, Air and Steam System.
-Process engineering experience for OSBL/ISBL, Utilities, Nitrogen, Air and steam System.
-Concept Selection / Feasibility Study/FEED Preparation & Verification/Process Simulation/Heat & Material Balance
-Process control systems, safety instrumented system and ESD system
-Field Engineering, precommissioning, commissioning, start-up support & over head corrosion control for CDU & hydroprocessing units
-Improve Asset Reliability and Performance
-Safety and risk engineering/RISK ASSESSMENT (HAZOP, SIL, FMEA, RCM, JSA, ETC IEC 61508, 61511).
-LP model development for Fuel refinery, Lube-I & Lube-II refinery as a Lead PP&E engineers
-Licensor schedule-A package review and approval
-Adequecy check/rating of all equipments for new and revamp conditions like heat exchangers, air cooler, pumps, towers & vessels
-Annual & master turn-around expereience as area lead engineer for fuel & Lube refineries.
-Participated in HAZOP studies of CDU, VDU, ISOM (PENEX), NHT, Semi-regen platformer, Diesel hydro treater hydrocracker unit, Air Separation unit, Burn-Pit etc
-HAZOP/PHA and JSA study, Exposure of HAZOP study and licensor FEED packages for the following units CDU, VDU, MEROX, NHT, Platformer, Isomerization and hydrotreating
-Monitoring of corrosion and optimization of chemical injection
-Review of EPC FEED, detailed engineering documents based on Project Specifications
-Led MOC review meetings, troubleshooting and optimization of plant
-Dynamic attitude towards project improvements and savings.
testing & commissioning of the new facilities and Turnaround and Inspection (T&I)
-Implementation of “Safety Norms” in plant area
-Selection & Installation & commissioning of recycle gas Moisture Analyzer & Oxygen for Furnaces for energy conservation
-Adequecy check/rating of all equipments for new and revamp conditions like heat exchangers, air cooler, pumps, towers & vessels
-Lead process design & optimization for projects & studies; maintain and develop process simulation (ASPEN) and hydraulic models,

-Worked as Chemical Process Engineer-MW Kellogg AMMONIA Plants of both Dawood Hercules (dh) and Pak-American (PAFL) Fertilizers.
-Optimization, Troubleshooting & debottlenecking of Ammonia plant.
-Ammonia plant day to day monitoring and troubleshooting
-Improvement & Energy Conservation projects.
-Generation of daily plant performance report to monitor the energy index of plant.
-Monitoring of process parameters of following equipments;
Hydrotreater, Desulphrizers, Reformer, HTSC, LTSC, Catacarb System, Methanator, Ammonia Converter, Air Compressor & Synthesis Gas Compressor.
-Calculation of material & energy balance of ammonia plant for trouble shooting and approach to Equilibrium Temperature of catalysts to evaluate their performance.
-Performance evaluation of cooling water heat exchangers by measuring pressure drop and rating on manual basis and by using Hysys & HTRI softwares on existing conditions.
-Preparation of pressure drop profile to monitor the performance of catalysts.
-Monitoring & adjustment of process parameters during shutdown and start-up of plant.
-Supervision of activity of loading & unloading of catalysts of different vessels alongwith accomplishment of HSE requirements.
-Monitoring of consumption of chemicals used at ammonia plant & Critical analysis of process parameters for troubleshooting.
-Calculation of efficiency of steam reformer, pumps, heat exchangers, steam turbines and steam to carbon ratio calculation for energy optimization.
-Carried out PHA and Incident Investigation of ammonia plant as Du Pont team member.
-Review P&IDs for BMR and involvement in technical correspondence.
-Carried out line sizing, control valve sizing and orifice designing.
-Preparation of new P&IDs of different sections of plant for modifications.
-Correspondence with different companies for purchasing of new catalyst and to remove queries regarding performance of catalysts. Reviewed and compared different RFQs for suppliers selection
-Supported the due diligence for selection and ordering of different parts and equipments
-Steam Traps survey of whole Fertilizer plant and Process Design of fuel line for Energy conversation.
-Participate in process safety engineering (relief load estimation, relief system design, and relief valve sizing and selection).
-Participate in field engineering assignments
-Preparation/Analysis of safe operating procedure for different jobs such as Shutdown, Start-up, Emergency condition and other routine maintenance jobs.
-Profient user of simulation programs such as HYSYS, Aspen Plus, Unisim design, HTRI, TASC+, Aspen flare analyser, DYNSIM, PRO-II, Pipe net, HAZOP Leader and promax etc.
-Safety and risk engineering/RISK ASSESSMENT (HAZOP, SIL, FMEA, RCM, JSA, ETC IEC 61508, 61511).
-Attend HAZOP, 3-D model, What-if, FMEA and SIL reviews and close-out reports
-Monitoring of corrosion and optimization of chemical injection
-Review of EPC FEED, detailed engineering documents based on Project Specifications
-Led MOC review meetings, troubleshooting and optimization of plant
-Participate on the testing & commissioning of the new facilities and Turnaround and Inspection (T&I)
-Implementation of “Safety Norms” in plant area
-Basic engineering for DCP & Sulfuric acid plants

-Worked as Chemical Process Engineer-MW Kellogg AMMONIA Plants of both Dawood Hercules (dh) and Pak-American (PAFL) Fertilizers.
-Optimization, Troubleshooting & debottlenecking of Ammonia plant.
-Ammonia plant day to day monitoring and troubleshooting
-Improvement & Energy Conservation projects.
-Generation of daily plant performance report to monitor the energy index of plant.
-Monitoring of process parameters of following equipments;
Hydrotreater, Desulphrizers, Reformer, HTSC, LTSC, Catacarb System, Methanator, Ammonia Converter, Air Compressor & Synthesis Gas Compressor.
-Calculation of material & energy balance of ammonia plant for trouble shooting and approach to Equilibrium Temperature of catalysts to evaluate their performance.
-Performance evaluation of cooling water heat exchangers by measuring pressure drop and rating on manual basis and by using Hysys & HTRI softwares on existing conditions.
-Preparation of pressure drop profile to monitor the performance of catalysts.
-Monitoring & adjustment of process parameters during shutdown and start-up of plant.
-Supervision of activity of loading & unloading of catalysts of different vessels alongwith accomplishment of HSE requirements.
-Monitoring of consumption of chemicals used at ammonia plant & Critical analysis of process parameters for troubleshooting.
-Calculation of efficiency of steam reformer, pumps, heat exchangers, steam turbines and steam to carbon ratio calculation for energy optimization.
-Carried out PHA and Incident Investigation of ammonia plant as Du Pont team member.
-Review P&IDs for BMR and involvement in technical correspondence.
-Carried out line sizing, control valve sizing and orifice designing.
-Preparation of new P&IDs of different sections of plant for modifications.
-Correspondence with different companies for purchasing of new catalyst and to remove queries regarding performance of catalysts. Reviewed and compared different RFQs for suppliers selection
-Supported the due diligence for selection and ordering of different parts and equipments
-Steam Traps survey of whole Fertilizer plant and Process Design of fuel line for Energy conversation.
-Participate in process safety engineering (relief load estimation, relief system design, and relief valve sizing and selection).
-Participate in field engineering assignments
-Preparation/Analysis of safe operating procedure for different jobs such as Shutdown, Start-up, Emergency condition and other routine maintenance jobs.
-Profient user of simulation programs such as HYSYS, Aspen Plus, Unisim design, HTRI, TASC+, Aspen flare analyser, DYNSIM, PRO-II, Pipe net, HAZOP Leader and promax etc.
-Safety and risk engineering/RISK ASSESSMENT (HAZOP, SIL, FMEA, RCM, JSA, ETC IEC 61508, 61511).
-Attend HAZOP, 3-D model, What-if, FMEA and SIL reviews and close-out reports
-Monitoring of corrosion and optimization of chemical injection
-Review of EPC FEED, detailed engineering documents based on Project Specifications
-Led MOC review meetings, troubleshooting and optimization of plant
-Participate on the testing & commissioning of the new facilities and Turnaround and Inspection (T&I)
-Implementation of “Safety Norms” in plant area
-Basic engineering for DCP & Sulfuric acid plants