Muhammad Mudassir

CHIEF ENGINEER CORPORATE HEALTH, PROCES SAFETY /OPERATIONS SAFETY & ENVIRONMENT) (Pak-Arab Refinery Limited, Multan – Pakistan; Products: MoGas, HSD, FO, JP-1, JP-8, Capacity: 120KBPD, Employees: 1500+, Annual Profit: 0.2B USD)

RISK ASSESSMENTS / PSSR:

• Development of Process Safety Management Systems Infrastructure & Guidelines.
• HAZOP of Refinery Operating Areas
• QRA - Quantitative Risk Assessment of Refinery Site.
• HAZID study of 2000 KM long pipeline handling MoGas and High Speed Diesel (HSD) along with storage tanks, transfer pumps, Tank Lorry Gantries and Transmix Processing Facility etc.
• HAZID of Entire Refinery & New MoGas operation pumps & New Oil Terminal at PQ Karachi
• Boe Tie Analysis for Identification of SC Systems, Elements & Equipment of Refinery.
• HSE Case Study of entire Refinery Site and it’s HSE systems
• OPERATIONAL RISK ANALYSIS: PENEX & Pressure Swing Absorption Units.
• PSSR of 2000 KM long MoGas & HSD Dual Operation pipeline with 20 new storage tanks.

PROJECTS:

• Safety Studies of Bottom of the Barrel Project for Refinery including HAZID, HSEIA, QRA.
• Re-evaluation of Refinery Hazard Area Classification as assurance of existing facilities.
• Replacement of CFC refrigerants in Air Conditioning systems with Non CFC coolants
• Improvisation in ERP system of the site. 
• Evaluation of Refinery Carbon Footprints as an effort to achieve Net Zero Target 

Assurance AUDITS of:

• Coordinated from Client side for Asset Integrity Management Systems Gap Analysis
• Compliance reviews of all newly developed and implemented guidelines and SOPs of Process Safety, Loss & Fire Prevention, Job Safety Analysis and Work Permit etc. 
• PSSR of new MFM MP and WOP MP lines operation on MoGas.
• Stations & Terminals on 2000 KM long pipeline as Final Check for Commissioning
• Mid Country Refinery along with Oil Gantries to address Safety related issues for Safe Operation. Also ensured OGRA and ADR compliance for vehicles.

INCIDENT INVESTIGATIONS:

• Using techniques like 5-Why, Fish boning, Fault Tree Analysis, 5-M done investigation of Fatality at Pipeline pumpingstation, Finger amputation at CCR reactor, Huge HSD spill owingto Operational malfunction & Systems failure, Instrumentation malfunction resulting in overflow & spill of MoGas tank lorries, Vehicle topple inside refinery etc.

EXPERIENCE:

• Providing Support to Organization for Process Safety, Loss Prevention & Risk Engineering for operating assets during normal plant operations, maintenance activities, shutdowns/ plant outages & brownfield projects. Developed their reports.
• Providing Support in terms of Risk Analysis and Risk Management studies for Risk-Engineering activities like HAZID, QRA (Quantitative Risk Assessment) etc responding to plant operational events, 
• For Plant Operational events, providing assistance in the development of risk-based solutions to novel or higher risk situations.
• Performed Process Components Risk Assessment in the form of HAZOP, HAZID and FMEA to identify prevailing risks along with development of Procedures & action plans for their mitigation for assurance of adequate implementation of Process Safety.
• Developed and implemented “HSE Assurance Plan” comprising of Key Performance Indicators in the form of Leading indicators to control Lagging events (alignment with API-754) for Process Safety Performance measurement along with collaboration with Operations interfaces to initiate and complete corrective actions with quality. Developed necessary reports and presentations to provide Insight analysis for KPIs improvement.
• Leading the given below activities:
  • Development, deployment and implementation of Process Safety & Risk Management, Occupational Health and Environment related Corporate Wide Objectives and corresponding action plans.
  • Development & implementation of Guidelines/Procedures & General Instructions on Process Safety Management Systems, Loss Prevention, Hazard Identification Risk Assessment & Control, Fire Prevention, Safety Critical System & Elements identification/ evaluation & control, Work Permit System, Asset Integrity Management System, Scaffolding & Ladder Safety, Incident/ Accident Reporting & Investigation, Contracts & CSM, Job Safety Analysis, & Work at Height, Environmental Impact Assessment etc.
  • Provision of Loss Prevention input and review for engineering documentations, project deliverables, interface documents to ensure relevant standards are met. 
• Participated in multiple MOC (Management of Change) Process for modifications at site both Hardware & Soft changes. In MOC process, consulted departmental interfaces & functional groups to ensure adequate Plant & its equipment integrity along with overall Safety of the Process is maintained. 
• Revamped existing Emergency Response System of Refinery to align with International best practices to improvise emergency response through quick and accurate head count, effective mustering, timely process isolation to control fire/ toxic etc.
• Coordinated for “End to End (both Construction & Operational)” EIA (Environmental Impact Analysis) / IEE (Initial Environmental Evaluation) for their timely completion with quality.  Management of water quality & emissions parameters with NEQS/PEQS limits thru adequate monitoring & supervision.
• Developed & delivered Trainings on Process Safety, Project Safety, Safety Critical Systems, HAZOP, QRA, HAZID, FERA, Fire & Gas Mapping, Asset Integrity Management System, permit to Work and Leading/ Lagging Indicators etc.
• Developed and implemented Business Continuity Plan (BCP) as per ILO guidelines covering areas of Feedstock discontinuity, Market Competitors dominance, Catastrophes at refinery and pipeline, loss of important data & major damage to equipment etc. 
• For accidents control, developed Pre-Qualification criteria for Oil Tank Lorries to enter at site along with Safety checks mandatory to ensure Tank Lorry health & Driver’s Safety Knowledge. Developed and implemented Drivers Safety Awareness program. 
• Brought Mutual Aid program to next level in PARCO through effective communication, coordination and extending help.
• As expert Process Safety & Loss Prevention Resource, Performed Loss Prevention studies and provided support to the capital projects during design, construction, commissioning, turn-over to operations, on-going operations, management of change and decommissioning of facilities including QRA, HAZID, HAZOP, 3D Model Review, SIL Review, FERA and FMEA from Client side.
• Yearly Budget development with control strategies to precisely utilize more than 90%.