Muhammad Afaq Mazher

• Developed 8 bids of turnarounds/shutdowns and EPC retrofits for Oil & Gas and fertilizer sectors worth $3.7M covering 256 vessels / static equipment and 5000 dia-inches of piping
• Achieved a bid win rate of 95% by developing highly accurate technical and commercial proposals
• Minimized budget overruns by delivering estimates with an accuracy variance of less than ±5%
• Identified and rectified 15% scope creep by thoroughly reviewing ITB, RFQ, MTO and BOQs against site conditions
• Saved 3% cost on a $3M portfolio by proposing alternate materials and optimizing manpower loading
• Negotiated with subcontractors and vendors to reduce 3P costs by 5% ensuring technical compliance
• Reduced proposal turnaround time by 20% by developing standardized estimation templates
• Streamlined the Technical Bid Evaluation (TBE) process, cutting down vendor query cycles from 5 days to 2 days
• Collaborated with the Execution team to validate estimation norms, resulting in a zero-dispute handover of the budget to the project team upon award
• Ensured 100% compliance with client HSE and QC requirements in cost estimation by accurately factoring in safety manpower, PPE, QC inspectors and training costs

Additionally:
Developed competitive and accurate proposals by integrating detailed resource loading (manpower, equipment, materials), material take-offs (MTOs), and vendor quotations.

Conducted thorough RFx analysis and technical clarifications with clients and sub-contractors to ensure compliance with specifications and industry standards.

Identified cost optimization opportunities through market testing, rate benchmarking, and alternative solutions, significantly contributing to project profitability

• Managed reliability and maintenance for critical Utility assets, including 3 Gas Turbines, HRSGs, Boilers, Cooling Towers, and the Effluent Treatment Plant
• Conducted online repair (8 TRs) on steam, water and nitric acid lines as per ASME PCC-2
• Reduced 2 hours production loss by timely rectifying leakage of Cooler Condenser at Nitric Acid Plant
• Optimized equipment performance through condition monitoring to achieve a 2% reduction in pump vibration levels
• Preserved the mechanical integrity of static equipment (Pressure Vessels, Demin/Raw Water Tanks) and piping by executing cold repair methodologies (Belzona application)
• Directed the CAPEX and Spares procurement (foreign/local) portfolio worth 120M PKR
• Streamlined OPEX procurement (15M) by processing JRs/JOs to ensure timely manpower mobilization
• Enhanced process safety by executing timely PMs of SCDs (PSVs/RVs), reducing IOW failures by 3%
• Spearheaded the site installation and commissioning of a Natural Gas Inlet Filter Separator, supervising critical path welding, radiography, and hydrotesting of 126 dia-inch piping
• Delivered critical Black Shutdown tie-ins of IFS without any rework and 100% QA/QC compliance
• Turnaround-2025: Orchestrated major scopes including 5 MOCs, Demin Train internal repairs, and complete Cooling Tower drift eliminators replacement
• Ensured 100% HSE compliance by developing JSAs/Rescue Plans and closing PSM recommendations
• Ensured 100% leak-free operations by executing maintenance on the Disposal Pumping Station
• Collaborated in 20+ weekly planning sessions to align resources and reduce WO/WR backlog by 15%
• Expedited emergency response planning by aligning key resources to minimize downtime by 2%
• Developed 15 detailed Method Statements and Work Packages by interpreting 50 equipment drawings, P&IDs, Isometrics, and OEM manuals
• Managed ~20M PKR inventory and spares management Oracle eAM maintaining 98% availability

• Enhanced MTBF of 24 pumps and gearboxes by identifying root causes and optimizing overhauling practices per OEM guidelines; developed and improvised overhauling documentation
• Improved heat exchanger pressure testing to reduce leakages by 3% using SFT and Ammonia Leak test
• Optimized practices of PSV calibration and overhauling along with pressure testing of valves
• Improvised rotor balancing to reduce vibration levels by 10% optimizing performance and cost saving

ENCON - Ammonia Plant: (Column Revamp - Turnaround 2023)
- Energy Conservation and Process Efficiency Enhancement: Led column retrofit as part of ~10M USD value project saving 0.5 Gcal/Ton energy comprising of Furnace & CO2 Stripper revamp with following key aspects:
CO2 Stripper:
• Apprehended revamp scope by studying 103 drawings, design datasheets, ITP, weld mapping, ASME AI approved WPS/PQR and revamp package
• Performed FEED, Detailed Engineering and procurement of foreign LLIs from European origin
• Prevented 10% potential budget overrun by identifying scope creep early in the engineering phase and raising timely commercial variation claims
• Led the complete conversion of tray tower into packed tower by replacement of 44 trays with 4 IMTP Random Packing Beds, 11 internals and 2 V-baffle diffusers
• Supervised “R” Stamp (ASME AI) job on 45 years old vessel and extensive repair as per NBIC Part 3
• Reduced project lead time by 15% through proactive expediting of LLIs by coordination with vendors
• Coordinated with ASME AI and contractor QC teams for PWHT exemption of stress relieved vessel
• Supervised Pre-TA Fabrication and installation of 8 Nozzles (24” each) with associated process piping
• Executed 5 tons structure installation including 6 platforms and 72 reinforcement ribs
• Managed a project budget of ~500 Million PKR, maintaining a CPI of 1.05 by strictly controlling variation orders and optimizing resource allocation
Furnace:
• Radiant Section: Supervised complete replacement of 378 catalyst / reformer tubes through critical rigging arrangements and accessories to reduce shutdown time by 3 days
• Spearheaded the replacement Inlet/Outlet Manifolds and 378 pigtails (1361 dia inch welding) with zero rework and strict ITP compliance through stage wise inspections
• Assisted in the execution of complete renewal of furnace refractory/Roof Arch pyroblocks
• Coordinated with execution team for replacement of transfer line through critical rigging (30 tons)
• Supervised pre-TA fabrication of sockolets installation on 9 inlet manifolds
• Convection Section: Executed In-Kind Replacement of 3 and new addition of 5 coil banks (3712 Dia Inches) in hot leg and cold leg sections including demolition, rigging and reinstallation
• Provided support in the replacement of manifold headers, Intermediate and End Tubesheets, Support brackets and guides
• Ensured 100% QA/QC compliance as per ITP through PWHT, RT and hydrotest to ensure the integrity of critical joints of piping in CS, SS and alloy materials (P11, P22)
• Supervised the pre-TA Fabrication (1194 Dia inches) of Convection section for welding of U bends on finned and bare tubes
• Delivered the project with Zero Lost Time Injuries (LTI) over 200, 000 safe man-hours, strictly enforcing Permit to Work (PTW) systems and daily JSA compliance
Turn Around 2021 at Nitric Acid Plant:
• Carried out inner shroud replacement of LaMont Boiler with Inconel metallurgy
• Reduced the turnaround delivery schedule by 3% by optimizing CPAs and implementing SIMOPS
• Nitric Acid Production Line Replacement (25 meters), piping repair and installation of 8 valves
• Cleaning, pressure testing and leakage rectification of 18 heat exchangers
• Achieved 98% schedule adherence (SPI 0.98) across all project phases through look-ahead planning
Storage Tank Major Repair Project:
- NP Buffer Tank Repair: Developed maintenance, project and timeline compliance plan for a sustainability and efficiency improvement project for replacement of Tank Roof and selected shell courses (4 Nos)

• Handled Critical Emergencies along with conducting PM & CM on Stationary and Rotary Equipment
• Enhanced MTBF and reduced vibration levels of pumps and blowers by 4% through PMs/ alignment
• Conducted online leakage rectification on discharge line of BFW pumps at Nitric Acid Plant
• Conducted corrective maintenance of 3 exchangers to reduce plant downtime by 2 hours
• Developed JSA and Rescue plans for critical jobs involving SIMOPS in turnaround 2021
• Carried out corrective maintenance of piping and valves to reduces leakages on plant by 2%
• Assisted Area Engineer in procurement process by conducting technical reviews of Quotations and developing Comparative Statements