Ali Syed

Brownfield Modification & MOC.
Valves / Safety Valves/ Control Valves Sizing & Simulation.
Pumps & Piping / Pipeline Sizing/ Simulations.
Separators/ Heat Exchangers/ Column Sizing & Simulation.
Process Equipment Adequacy Checking/ Debottlenecking.
Flow assurance studies
Bid Evaluations.

Process Engineer (Operations), Gasco Engineering (Private) Limited. Attock, Punjab -Pakistan.
 Coordinating the preparation of the As-built P&IDs, PFDs, UFDs, Layout
 Control room plant operations and review of the Early Production/Oil Handling/ Three Phase Separation,
Oil Stabilization storage and loading, AG Compression and Produced Water Treatment Facility
 Operation, control and troubleshooting of the Process Utilities.
 Troubleshooting/ Handling abnormal operations situations including that of own, upstream and
downstream processing units, and restoration of smooth operations.
 RCA of the abnormal operating scenarios.
 Turning of PID controllers for smooth/ optimized operations & control.
 Daily and monthly production data reporting.
 Daily/scheduled meetings/ telecons within the departments/ Head office and also with the client.
 Planning, and execution/ coordination/ interfacing between departments for the maintenance works/
Raising and closing the jobs.
 Process simulations and studies to suggest optimum parameters for operations.
 Operations’/ plant modifications.
 Preparation and modification of SOPs
 Ensuring the KPIs.
 Training of the junior staff.
 Ensuring onsite availability of dosing chemicals/ HSE gadgets/ inventory.
HSE/ Environmental Compliance:
 Safety toolbox talk
 JSA and Emergency response planning and role assigning.
 Raising work permits.
 Drills.
 Suggesting improvement for safe working.
 EPA/ PEQS rules and regulations

Project Process Engineer, Gasco Engineering (Pvt.) Limited. Attock, Punjab -Pakistan.
Process and project engineering:
 MOC, Reporting to the resident manager and ensuring distribution of tasks and resources, subsequent follow
up and progress reporting.
 Interfacing with vendors/ contractors and project/ site team.
 Conducting/ participating in daily/ weekly meeting for project review and planning.
 Bids / proposals review and evaluation.
 Site visits for verification of works.
 Tasks as assigned by the resident manager
Pre-commissioning/ commissioning and startup:
 Review and suggesting modification in the design documents; P&IDs, PFDs, UFDs, manuals, procedures,
checklists)
 Reviewing the DCS/ ESD systems’ specific logic checks and suggesting/ modifying control/ shutdown
philosophies/ C&E matrix.
 Recording the mechanical completion of the project as per the design documents.
 Punch listing with the help of P&IDs and Isometrics, Layout etc, and resolution/ closure of the punched items
 Test packs and hydrotesting, blowing, drying, blanketing of the equipment.
 Loop testing.
 Pre startup Safety review, closure and reporting.
 Calibration of vessels, tanks and Instruments/ Gauges and Transmitters.
 Functional testing of rotary equipment and F&G system from field as well as the DCS workstation in the
presence of vendors.
 Dosing Chemicals’ charging.
Pre-commissioning/ commissioning and startup OSBL (Process Utilities):
 OSBL equipment and systems including storage tanks, gantry, produced water treatment, Flare, Fuel gas,
firewater network, raw water/ RO system, IA/N2 package, inlet water bath heater etc.
 Startup and Performance Acceptance Test witnessed by the client in presence of the vendors.
HSE/ Environmental Compliance:
 Safety toolbox talk
 SIMOPs, JSA and Emergency response planning and role assigning.
 Raising work permits.
 Drills.
 Suggesting improvement for safe working (eg providing of access ways, walkways, eye showers, better
lighting etc).
 EPA/ PEQS rules and regulations
 Reporting.

Process Engineering
 Review and vetting of existing Process design & commissioning documents of the relocated Phthalic
Anhydride plant. Updating of troubleshoot/ shutdown, control and operating philosophies and procedures of
the main processing plant.
 Review and vetting of Equipment sizing, pre-commissioning, commissioning, operation and design
documents for the new Process utilities’ design.
 Simulations using Korf and Hysys.
Project Engineering
 Meetings and interfacing all the vendors involved.
 ITB and Bids and proposal review and recommendations.
 Progress review of construction/ erection works and reporting.
 Handling change orders.
 Inventory inspection.
Pre-commissioning/ commissioning and startup:
 Verifying, and documenting the mechanical completion and witness recording in the form of Mechanical
Completion Certificates.
 Review of pre-commissioning execution plan, procedures and checklists.
 Review of test packs, Punch listing, and closure of the punch list items, ensuring proper documentation
(marked P&IDs, Isometrics)
 Flushing, cleaning. Drying, hydrotesting, N2 purging and blanketing.
 Boxing up and section wise calibration of vessels and tanks, cleaning of plant equipment, functional test of rotary equipment, and utility systems. Filling and testing of HTM circuits, Heating, Cooling (reheating) and
(molten) Salt filling/ Reactor heating, Performing checks and Vacuum test of distillation section, trial
distillation, charging of three layer catalyst supports in reactor’s upper and lower tubes and the dome.
 Catalyst pretreatment by heating the rector, Commissioning the turbo blowers, Orthoxylene (OX) charging/
loading, starting up/ functional testing of the reactor, commissioning of gas coolers and precondensers,
commissioning of desublimation section, commissioning of vacuum system and distillation section,
commissioning of PA Flaker etc.
 Checking the control & ESD logics and suggesting modification in the C&E as per the safety of equipment
and for preventing possible loss/ downtime.
 Suggesting incorporation of pages in the DCS system for efficient smooth operation and control.
Pre-commissioning/ commissioning and startup OSBL (Process Utilities):
 OSBL equipment and systems including, Cooling Tower, IA/N2 Generation Package, Demineralized Water
Unit, Plant Steam,
HSE:
 Work permit system coordination
 Toolbox talk
 JSA
 Review of the Emergency Evacuation and rescue planning.

Senior Engineer (Process Operations) Pakistan Synthetics Limited (PSL) - Hub.
 Safe Control Room operation of Polycondensation plant & utilities by maintaining the production
parameters as well as troubleshooting and RCA of the abnormal operating situations.
 Production planning
 Preparing the production and stock availability reports/ inventory management.
 Analyzing data at the workstation through historians, trends/ graphs and tuning of the PID controllers.
 Wastage minimization by Process optimization through PID control loop calibrations.
 Review and interpretation of the lab reports and recommending/ taking actions accordingly to maintain the
product specs for the required grades.
 Process improvement and modifications to ensure smooth operations.
 Equipment changeover for maintenance and cleaning.
 Plant Partial shutdown and subsequent operations.
 Diagnosing the Plant and equipment operability issues and raising the job requisitions to the concerned
maintenance section for safe maintenance and follow up.
 OSBL systems/ Process utilities’ commissioning and operation.
 Maintenance shutdown planning and the plan implementation.
 Equipment health checking, and helping in preparation and implementation of schedules for predictive and
preventive maintenance.
 Implementation of and strict observation of the Work Permits, LOTO, JSA policies and procedures.
 Safety drills.
 Training of operations team.

JD/ Responsibilities Included;
 ITB and bids review and vendor selection.
 Progress review of the construction/ erection of plant equipment and report writing.
 Meetings and interfacing.
 Reviewing the change orders prior to closure.
 Mechanical completion check prior to pre-commissioning with the marked P&IDs and
Isometrics.
 Review of PFDs, UFDs, P&IDs, C&E matrix, procedures, plans and manuals about the Pre-
commissioning, Commissioning, Startup and Operations stages.
 Review of HMB, Material Selection study, utility requirements.
 Review of the HSE protocols, Work Permit issuance and responsibilities, ER preparedness,
SIMOPs, LOTO, operation staff safety
 Updating of operation manuals, commissioning and startup procedures, control and ESD
philosophies as well as P&IDs.
 Functional testing, Loop & Instrumentation commissioning.
 HTM charging and firing of HTM furnaces.
 Introducing process fluids and raw materials.
 Emerson Process Management Delta V DCS commissioning and document review.
 Reviewing control & ESD logics at the DCS interface/ workstation, and suggesting revisions and
improvements.
 Supervision of brown field modifications, commissioning, start up.
 Preparation of SOPs for operations.
 Training and grooming of junior team members.
HSE
 Emergency response plan
 Work permit system implementation
 Walkdown for risk analysis
 Safety talks and awareness sessions participation and conduct.

Process engineering design and project management:
 Supporting the Head Process for Development of Proposals for new projects and technologies.
 Assisting in Coordinating process engineering on projects associated with oil & gas pipelines, treatment
plants, gathering and transmission systems, gas compression, crude oil storage and refining facilities.
 Assessing scope of work for required deliverables and preparation of man hour estimates for new projects’
proposals.
 Leading the team of Process design engineers during project execution within the given time frame as per
discipline Project Schedule.
 Reviewing of Process Simulations, drawings, Datasheets, sizing calculations and design reports, manuals and
procedures.
 Training and mentor the less experienced engineers.
 Providing technical direction and supervision to engineering design in the preparation of process flow
diagrams, P&ID.
 Coordination and interacting with other disciplines staff as required by the department / project manager.
 Check if all engineering work is performed as per good engineering practices and applicable Codes and
Standards.
 Participating in meeting with client and other engineering discipline members to avoid anomalies in process
design works.
 Participating in Project reviews, HAZOPs and design reviews.
 Development of conceptual design, process selection, FEED, detail design testing and commissioning.
 Technical audits of the projects at different stages of development per the design documents and on site status
of the construction.
 Review of RFQ, ITB, SOW, Project Schedule from process end / per the process department deliverables.
 Assisting in preparation of annual budget and provide inputs for any new requirement.
 Project manager for the new projects.
 Finalization of bids and proposals, estimated man hours, CAPEX and OPEX for the projects.
 Reviewing the change requests and orders during the projects.
 Coordinating with software licensor for updating/renewal of existing software in process department.
 OSBL equipment and systems/ Process Utilities Design, HMB, Equipment sizing, Cost estimation &
Vendors’ and Packages evaluation.
Site visits and Commissioning (of Process Plant and OSBL/ Process Utilities):
 Leading the pre mechanical completion check, Pre-commissioning, Commissioning and ensuring the closure
of the outstanding items, before startup.
 Interfacing with all the stakeholders across the board, ensuring proper documentation and flow of information
at every stage of progress and milestones.
 Review of reports and SOPs for operations.
 Training of Operation (field as well as the control room) staff team members, Management of Change
ensuring smooth seamless interfacing within the employees of the company as well as in between company &
its client(s) to ensure hazard free operations.
HSE
 Finalizing LOTO, JSA, SIMOPS protocols and HSE policies, roles, Emergency Response Preparedness, Work
Permit Policies and Proformas etc.
 Leading the IMS implementation; documentation and the audits as per IMS protocols and requirements.
 Final review of the HSE plan & Layouts for the projects.
 Review of the Simulating the fire scenarios and development of the firewater/ foam and F&G system
accordingly.
 Leading the HAZOP, HAZID & SIL studies from consultant side.
 Final review of the onsite JSA, SOPs, ERA plans etc.

Process design and project engineering:
 Supervising team of Process design engineers during project & assign engineering tasks and completion time
frame (Project Schedule).
 Assisting in ensuring engineering work completeness, safety, and fitness to for purpose of process designs
related to consultancy, FEED, and other project related objectives.
 Contributing in organization and prioritizing discipline work tasks to ensure maximum efficiency and
performance of work in accordance with scope of work.
 Site visits to facilitate design work and to gather information to resolve project related problems.
 Preparation of the core process design reports (e.g. design basis, control & ESD philosophies, Material
selection).
 Preparation of the pre-commissioning, commissioning, startup and operations manuals.
 Preparation of process simulation and models using different software packages (HYSYS, HTRI, Flarenet,
Korf, in-house excel sheets etc) for projects Perform, monitor and review deliverable documents (e.g.
Calculations, Simulations, Design reports, Manuals, PFDs and P&IDs) produced by process engineers, prior
to estimation of BOQ and BOM.
 Providing technical direction and supervision to the engineering design team, in the preparation of HMBs,
process flow diagrams and P&IDs.
 Participating in Project reviews, HAZOPs and design reviews.
 Assigning the process engineering task to process engineers.
 Development of conceptual design, process selection, FEED, detail design testing and commissioning.
 Arrangement of meetings/telecons during project in case of any hurdle with client for timely completion.
 Inter-departmental coordination to synchronize the relevant documents.
 Estimation of Man hours, CAPE, OPEX ( for different stages of project development with fine tuning the
accuracy).
 Review of Bids and Proposals.
 RFQ, ITB and SOW preparation from process department end.
 OSBL equipment and systems/ Process Utilities Design, HMB, Equipment sizing, Cost estimation &
Vendors’ and Packages evaluation.
Site visits and Commissioning (of Process Plant and OSBL/ Process Utilities):
 Site visits for data collection.
 Witnessing completion and countersigning the field pre-commissioning completion certificates and PSSR
sessions and ensuring that the items as identified in those sessions are closed.
 Commissioning stage HAZOP, prior to static and rotary equipment commissioning, Hot Loop testing of the
Instruments (BPCS & ESD systems), Functional Testing of equipment and DCS systems/ Panel, Control loops
and C&E/ ESD commissioning &, in presence of the vendors.
 Chemical charging, process fluids introduction
 Calibration of PID control loops.
 Startup and carrying out/Participating in the Performance Acceptance Test
 Reports writing, SOPs and Handover.
HSE
 Acting as the focal person from the department for IMS and carrying out the audits as per IMS protocols and
requirements.
 Review of the HSE plan & Layouts for the projects.
 Simulating the fire scenarios and development of the firewater/ foam and F&G system accordingly.
 Participate in the HAZOP, HAZID & SIL studies.
 Reviewing the onsite JSA, SOPs, ERA plans etc.

Assisting the senior process engineer with data collection and project scheduling in process design and
project engineering.
 Conducting process engineering simulations, equipment sizing, and hydraulics calculations for process and
utilities.
 Contributing to Basic Engineering Design and Conceptual Studies.
 Generating various process design reports, such as design basis, conceptual design report, control &
shutdown philosophy, etc.
 Preparation of bids or proposals.
 Creating equipment datasheets and specifications.
 Developing HMBs, and process drawings including PFDs, P&IDs, and Schematics.
 Conducting bid evaluations.
 Supervising and reviewing the work of trainee process engineers.
 Providing guidance, assigning tasks, and setting guidelines for trainee process engineers.
 Participation in HAZID & HAZOP sessions.
 Adhering to applicable and agreed upon National and International Codes and Standards (OGRA, EPA, API,
NFPA, ASME, Client preferred Design Practices
Site visit, Pre-Commissioning and Commissioning:
 Site visits for data collection (as part of the BEDD) and for verification of mechanical completion
 Coordinating pre-commissioning activities such as preparation of test packs, pressure hold up test, flushing
drying and nitrogen gas blanketing till the introduction of the process fluids, visual inspection, punch listing,
boxing up, loop testing, functional testing of rotary equipment, control valves & F&G detection/ alarm
system, chemical charging, Over pressure protection, hazard identification through compliance check and
proper closing out through certifications.
 Participating in onsite commissioning HAZOP and PSSR sessions.
 Participating in CRA and ORA
 Preparing the commissioning manual containing system wise checklist, detailed procedures and plans,
carrying out the field process commissioning activities, commissioning of the utilities and auxiliaries starting
with firewater network, nitrogen and instrument air package, raw & potable water package, the flare etc.
HSE
 Participating in Implementation of the IMS protocols and requirements.
 Development of the HSE plan & Layouts for the projects.
 Scribe in the HAZOP, HAZID, SIL studies.
 Preparing the onsite JSA, SOPs, ERA plans

Panel/ DCS/ Board Operation:
 Operation and trouble shooting of the CTIEI’s five reactors Polycondensation process plant for manufacturing
of different grades of the Polyethylene terephathalate (PET); the most prevalent thermosetting polymer resin
of the polyester family, through Delta V DCS and ESD systems of Messrs Emerson Process Management
USA.
 Achieving the product specification through maintaining the raw materials MEG/DEG and PTA/IPA
as well as the process additives batches charging ratio, the residence time of reactors by means of
controlling the process parameters such as flow rate, temperature, pressure/ vacuum controlling, also
adjusting the DCS soft calculator logics as per plant operation requirement.
 Tuning of PID control loops and maintaining the process control loops on manual, automatic or the
cascade mode as per plant operation requirements.
 Managing the process shutdown (partial and planned) and resulting off spec products subsequently
taking the plant back in operation/ production.
 Raising/ suggesting raising of the work permits for maintenance jobs with the concerned departments
as per the requirement with a view to avoid possible operability issues.
 Operation manual’s and SOPs’ updation.
 Issuing the allowed level of work permits.
 Participating in/ following up with the daily morning meetings.
 Participating in the process team’s brain storming sessions about how to ensure and improve upon the
smooth and safe plant operation.
 Product Segregation as per Lot logic in coordination with the supply chain management department.
 Shift handing over and taking over.
 Coordinating the routine field operation (equipment changeover and cleaning) and maintenance activities by
managing the field operation’s team as well as interfacing with other departments, ensuring the proper
housekeeping, as per applicable SOPs and the agree-upon mechanism.
 Coordinating the process equipment condition monitoring.
 Unloading of the incoming MEG/ DEG browsers at the Tank farm and PTA bulk container unloading.
 PTW and HSE policies implementation.
 Preparation and modification of operating procedures for pumps, additive chemical batches’ preparation.
Commissioning and startup of the new process/ OSBL systems:
 Commissioning and startup of the exhaust gas - HTM heat exchanging equipment called as economizers.
 Commissioning and startup of the exhaust gas absorption chillers.
Production:
 Daily production, inventory & chemical consumption accounting & report preparation.
HSE and Operation Training
 Participating in the fire safety drills
 Participating in the sessions and taking test about the Operational Hazards safety and the Work Permit
regimes and their subsequent implementation.
 Training the junior/ newly inducted/ Internees at the process department as well as the field operation team for
smooth and safe plant operation.

Project phase: Construction/ Erection, Pre-Commissioning, Commissioning and Startup phase;
 Working under supervision of and reporting to the shift engineer.
 Reviewing and understanding of the process scheme with the help of the Operations Manuals, UFDs, PFDs,
P&IDs and C&E Matrix.
 Reviewing and understanding of the Pre-commissioning, commissioning and startup procedures and SOPs.
 Taking part in the HSE sessions and drills and adhering to PPEs, Work Permit protocols.
 Punch listing of process piping, upstream as well as downstream of the associated equipment as per P&IDs
and Isometric drawings Identifying and then assisting in resolution of the punch list items.
 Assisting the Pre - commissioning activities such as the Vessels’/ Rectification (Distillation) Column/
Reactors’ level calibration, Flushing with water and air blowing of the process piping, chemical cleaning,
Process Loop (Vessels, Piping, H/Ex, Control Valves etc.) Pressure holdup test cold & hot leak testing,
process equipment insulation and cladding etc.
 Inspection of the process equipment before boxing-up.
 Took part as scribe in the Pre-startup safety review (PSSR).
 Assisting the Functional Test of the rotary equipment such as reactor mixers and impellers, pumps, blowers,
and the process utilities packages such as the Nitrogen generation and Instrument Air/ Compressed Air
systems, Fire Water Network, Cooling Tower, Demineralized Water System, under water Pelletizer system.
 Assisting the package wise field commissioning and startup activities of the process utilities, different Process
and Control loops, ESD system, as Heat transfer Medium charging, circulation and heating, periodic followed
by continuous firing of the convective process heaters, cooling water network, chiller/ chilled network, MEG/
DEG Storage Tank Farm, N2/IA/PA systems, charging of the raw materials and additives batch formation,
under water pelletizing system including molten polymer cutters, Liquid ring Pump etc.
 Supporting updation of the operation SOPs.
 Preparation of the periodic review reports.
Operation Phase:
 Strict adherence to HSE regimes, PPEs, and Work Permit Protocols including LOTO
 Taking part in daily Moring meetings
 Changeover/ restarting of Pumps, Heat Exchangers, Process Heaters, Cooling Tower fans, Chilled water
system, under water Pelletizer units, blowers for routine maintenance, or after partial emergency shutdown, in
coordination with the control room and relevant personnel of the HSE and maintenance departments (I&C,
Electrical and Mechanical).
 Preparation of process additives’ (Blue toner, Antimony Triacetate, Blue Toner etc) batches.
 Assisting the condition monitoring of the process equipment.
 Maintaining the field log sheet.