Plant Manager
Fatima Group
Total years of experience :22 years, 6 Months
• Mainly responsible for the plant management covering all disciplines of operation and maintenance management for 120MW Co-generation power plant project of Fatima Energy limited.
• Responsible to ensure the target availability of electrical, instrumentation and controls systems for reliable and safe plant operations.
• Strategize & develop maintenance plans to ensure target plant reliability through predictive/ on-condition maintenance of E&I equipment such as motors, generators, transformers, switchgears, power distribution networks, DCS systems, plant safety instrumented systems etc.
• Development of maintenance procedures to ensure integrity of classified electrical equipment to suit hazardous area requirements.
• Implementation of RCM2 at plant’s electrical, instrumentation and controls systems.
• Responsible for facilitating periodic reviews and audits of RCM2 analysis and implementation of its findings.
• Strategy development, effective planning for maintenance cost management in OPEX and CAPEX
• Developing plans, systems and strategies to enhance equipment/ system performance and to achieve plant reliability.
• Managing the contractors and overseeing them to ensure their compliance with specifications, standards and HSEQ regulations.
• Responsible for HSEQ area of engineering department as focal point for HSEQ.
• Leading the internal audits of work activities through documentation reviews, physical tours and interviews to ensure implementation of HSEQ Management
• Managing major turnarounds and ensuring timely and safe start-ups.
• Optimization of spares inventory in SAP Materials Module in accordance with the needs of the departments.
• Suggesting and recommending proposals for the replacement of obsolete equipment, changes in Maintenance Program and control the budgets.
• Project Management covering feasibility study, design and EPC phases for revamps and expansion projects with respect to E&I systems of PRL.
In my current position of Manager Instruments & Controls in Pakistan Refinery Limited I am mainly :
• Responsible to manage control systems of Foxboro IA Series and Yokogawa Centum CS3000 VnetIP and APC (Advance Process Controller) installed on CDU with diversified instrumentation.
• Developing plans, systems and strategies to enhance equipment/ system performance and to achieve plant reliability through predictive, preventive and routine maintenance.
• Evaluating quotations, awarding work to contractors and overseeing them to ensure their compliance with specifications, standards and HSEQ regulations.
• Conducting internal audits of work activities through documentation reviews, physical tours and interviews to ensure implementation of HSEQ Management
• Developing plans for major turnarounds and monitoring their execution
• Managing spares inventory in SAP Materials Module in accordance with the needs of the department.
• Suggesting and recommending proposals for the replacement of obsolete equipment, changes in Maintenance Program and prepare budgets & technical specifications.
• Co-coordinating Project Management activities covering feasibility study, design and EPC phases for revamps and expansion projects with respect to I&C system.
• Leading the Q-Team for Integrity and Information for Flawless Start-up Initiative for Refinery Upgrade Project.
• Responsible for hiring, training and career development of I&C team including engineers, technicians and apprentices.
• Responsible to ensure integrity of the control systems including IA series DCS, Yokogawa DCS, Siemens and Alen Bradley PLCs, stay healthy, through the effective system management
• Strategize & development of maintenance plans to ensure 100% plant availability through predictive maintenance and condition monitoring of field instruments.
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• Development and implementation of comprehensive calibration plans for analyzers, flow meters and other field instruments to ensure their accuracy and performance remains up to the mark through out the plant TA Cycle.
• Development of maintenance procedures for the maintenance team to ensure compliance of HSEQ standards and to ensure best performance of Instruments and controls system.
• Responsible to execute the approved plant changes, plant expansions and new projects.
• Responsible to provide I&C support the project team in FEED and EPC of Refinery Upgrade Project.
• Strategy development, effective planning for maintenance cost management in OPEX and CAPEX
• Responsible to ensure that electrical power system stays healthy, through the system and equipment maintenance including MV and LV switchgear and power distribution, electrical rotating equipment etc.
• Strategize & development of maintenance plans to ensure plant availability through predictive maintenance.
• Development of maintenance procedures to ensure integrity of classified electrical equipment to suit hazardous area requirements.
• Responsible for condition monitoring of electrical equipment and system for predictive maintenance including troubleshooting and proposing solutions for electrical equipment problems.
• Strategy development, effective planning for maintenance cost management in OPEX and CAPEX
• Team management for maintenance support to the refinery plant operations on 24/7 basis.
• Managing contractors and sub-contractors for routine and preventive maintenance
• Managing the on-job-training of the junior engineers and technicians.
• Completed 2 year extensive training in HSEQ, Fire Fighting, Electrical, Instrumentation and Controls sections.
• Thoroughly studied the electrical system in refinery and proposed an up gradation plan for the protection system of HT motors.
• Comprehensively audited the lighting and power distribution system in the refinery against NFPA 70B standards and recommended the revamp of the system to fulfill Hazardous area requirements for electrical system.
Completed MBA degree programme from institute of business management Karachi with 3.35 CGPA. with majors in marketing and management subjects.
Graduated in Electrical Engineering with 86% marks from NED University with distinction in the electrical controls and protection systems.