Sohail Ghaffar

Highly experienced Senior DCS / Panel Operator with 18+ years of hands-on process plant operations experience at Fauji Fertilizer Company Limited (FFC), including 6+ years in DCS / control room operations. Proven expertise in continuous process plant operation, DCS panel monitoring, field operations, startup/shutdown, troubleshooting, emergency response, and process optimization. Hands-on experience in Steam reformers, steam turbine-driven compressors, gas purification systems, CO₂ removal, cryogenic systems, hydrogen recovery, nitrogen generation, ammonia synthesis loop, refrigeration systems, ammonia recovery, distillation, absorption systems, and cooling water utilities.

Strongly suited for Refinery, Petrochemical, Gas Processing, LNG, Fertilizer, Utility, and Chemical Process Plants with solid knowledge of PTW, PSM, HAZOP, PHA, JSA, LOTO, IMS, commissioning support, P&IDs, and safe plant operations.

Senior DCS / Panel Operator – Ammonia Plant - Fauji Fertilizer Company Limited (FFC) - Pakistan

18+ Years Process Plant Experience | 6+ Years DCS / Control Room Experience. Operate and monitor ammonia plant back-end process units from DCS control room and field in accordance with SOPs, operational procedures, and safety standards.

• Perform DCS panel operation using Yokogawa CENTUM VP to maintain safe, stable, and optimized plant operation.
• Monitor critical process parameters, alarms, trips, trends, interlocks, and equipment condition during normal and upset operations.
• Execute plant startup, shutdown, process line-up changes, load adjustments, and stabilization activities.
• Respond effectively to process deviations, trips, equipment abnormalities, and emergency conditions.
• Support shutdowns, turnarounds, maintenance jobs, commissioning, and pre-startup safety reviews (PSSR).
• Ensure strict compliance with PTW, PSM, IMS, HSE standards, isolation procedures, and operating discipline.
• Prevented 08 plant shutdowns, avoiding approximately 40 days of downtime through vigilant monitoring and timely operational action.
• Contributed to achieving 696 days continuous on-stream plant performance.
• Participated in 05 safe shutdown and startup operations from both field and DCS panel roles.
• Prevented 02 environmental incidents through immediate action during abnormal operating conditions and oil spill events.
• Received 08 Housekeeping Champion Awards for strong workplace discipline, safety, and operational excellence.

Diploma of Associate Engineering (DAE) - Petroleum Technology - Punjab Board of Technical Education, Lahore, Pakistan

Secondary School Certificate - Science - BISE D.G. Khan