Muhammad Asif Hayat Malik

Since October 2012 I am working as Process and Production Incharge with Basic Chemical Industries group. I have been responsible to supervise all activities related to process and operation initially in Chloralkali manufacturing plant and afterwards in Sulfuric production plant.
 Supervise plant start-ups, shutdown and emergencies as per the approved established operating procedures.
 Establish effective and constructive day-to-day communication with the plant operation staff. i.e. shift engineer, DCS operators, field operators and maintenance staff.
 Good knowledge of supervising operation of Reverse Osmosis water treatment unit, Mixed bed water treatment unit, electrolysis unit, furnace, Boilers, Cooling towers, Compressors, Blowers, Brine purification unit, Repurposing of a plate and frame heat exchanger, Process steam and condensate systems and Waste water management.
 Monitor routine tests performed to keep water quality in check. (TDS, Ph, Alkalinity, Hardness, PO4, SO3). Also advise dosing of required chemicals to keep all variables in limits as advised in established procedures.
 Evaluate & troubleshoot operational concerns and implement corrective actions.
 Propose and implement projects to improve process efficiency. i.e. installation of quench air lines, Installation of drain valve on return live from absorber, Widening of Sulphur storage area, Installation of new storage tank etc.
 Coordinate with the maintenance departments (Electrical, Mechanical & Instrument) for periodic preventive maintenance of all equipment to minimize breakdowns and to avoid any trippage or unplanned shutdown causing loss of production.
 Provide training to newly hired production staff to improve and upgrade their skills.
 Access Maintenance jobs and plan hot or cold shut down accordingly. Prepare & maintain complete list of pending jobs to be executed during cold shutdown.
 Investigate incidents, accidents and injuries. Document the injuries & events leading to, during, and after the accident and finally make recommendations to fix hazards.
 Carrying out job safety analysis by making reports to ensure that the work permit system is being properly followed.
 Applying and monitoring environmental laws and regulations and waste management by coordinating with HSE department.
 Review and update SOPs, Work Instructions, Material Safety Data Sheets & Other Quality documents.
 Statistical analysis of plant parameters and preparation of reports accordingly.

Central Marketing and Distribution Company is the marketing arm of BCI Group for both manufactured and traded products. Occasionally it takes projects for chemical cleaning/chemical decontamination in different refineries & petrochemical plants. I have provided to technical support to execute these decontamination jobs in different refineries and petrochemical plants in Yanbu. Brief summary of my role as decontamination engineer is given below.
 SAMREF
 YANPET
 Ibn e Rushd
 Access quantity and type of decontamination chemical to be dosed to get the required results.
 Identify resources required to carry out the job and make sure their availability.
 Identifying points from where dosing can be made in the towers, boilers, exchangers & converters.
 Scheduling the work, accessing manpower requirement and arranging work permits required to get the job done on time.
 Identifying and following local and federal safety & environment protocols being followed by refinery/petrochemical plant.
 Checking the results with chemist after dosing whether all the coke, accumulated hydrocarbons and other hazardous material have been removed from the vessels.
 Keeping the customers satisfied about the quality and speed of the work.

Abudawood Industrial Company is one of the sister companies of “CLOROX” & Modern
Indutries Company Dammam (Procter & Gamble). They are specialized in manufacturing all
types of detergents & also HI-TECH over print varnishes. It was a batch process company and
I worked there as Technical Engineer for some period of time.
 Developed & modified products in the lab according to the market demands.
 Improved my analytical skills to take care of the quality of the detergents produced.
 Worked as assistant internal quality auditor for ISO 9001.
 Calculated amount of certain chemicals to be added to repair the batches which went out of
specification.
 Reply & log customer complaints and advise corrective and preventive actions against them.
 Set Agendas for Management review meeting and record minutes of meeting accordingly.
 QMS, EMS and ISO internal audit 07 days training in Abudawood Industrial Company.

Dawood Hercules Chemicals Sheikhupura is one of the leading industries in Pakistan producing 1350 MTPD Urea. The Plant is comprised of three sections, Ammonia, Urea & Utility. I was appointed in 815 MTPD Ammonia unit.
 Good knowledge of supervising operation of Desulphurization unit, Primary reformer, Secondary reformer, HT and LT conversion unit, CO2 absorption unit, Methanation unit and Ammonia Synthesis unit.
 Prepare a feasibility study for improved energy efficiency in ammonia plant.
 Ensure uninterrupted, safe and efficient operation of the assigned unit, responsible to handle emergencies, startups and shutdown.
 Monitor the plant operating parameters and log values of different process variables. Manage the administration of production staff assigned to shift.
 Worked to update PFD and P&ID of different plant sections as per new modifications.
 Thorough study of PFD, P&ID, Flow measurement and calculations.
 DCS & PLC System handling and monitoring.
 Ensure that all production activities are carried out in a safe & efficient manner, in line with agreed plant operating procedures and practices.
 Coordinate with services department staff (electrical, mechanical and instrument) to plan and execute routine maintenance jobs in utilities and plant area.
 Study new ideas and innovative technologies to enhance plant operation, reliability, profitability and performance.
 Part of the team to perform material and energy balance calculations in order to monitor the process efficiencies and to control losses of the product and utilities.
 Statistical analysis of plant parameters and preparation of reports accordingly as special assignments.
 Evaluate operational concerns and propose corrective actions.