M. Shahid Karim
Safety Engineer (Safety Management & Support) @ Petro Rabigh
About
A results-driven Chemical Engineer and certified HAZOP Leader with over 17 years experience of Process Safety Management (OSHA 29 CFR 1910.119), plant operation, commissioning/startup, and operational readiness in refining and petrochemical complexes. Proven track record of improving safety culture, leading high-impact risk assessments, conducting incident investigations, inspections & audits, and ensuring compliance in high-risk, regulated environments. Experienced in both greenfield and brownfield projects across EDC/VCM, PVC, and utilities. Core strengths: • Leading HAZOPs, Analyzing & Improving Safety Culture, and Insurance Surveys • Driving PSM implementation, audits, and transition to operations in line with OSHA • KPIs development, Incident Investigation (5 Whys, Fish Bone), and COMAH • Strong knowledge of PSM/PSRM including PSI, PHA, MOC, PSSR, Emergency Response, PTW, and Integrated Management Systems (IMS) Passionate about delivering operational excellence through structured safety and performance systems in complex petrochemical environments.
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Pakistan
Chemicals
COMAH, MAH, Major Accident Hazard analysis , Bowtie, Critical activity catalogue, RCA, fish bone analysis, Management of Change (MOC), Incident Command, Pre-commissioning, Operational Readiness, Safety Culture, Risk Management, Skill Development, JQP development, Crisis Situations, Accident Investigation, Manufacturing Operations Management, People Management, Employee Engagement
Experience

Safety Engineer (Safety Management & Support)
Rabigh, Makkah, Saudi Arabia
• Led the task force for Insurance Survey 2025 for the whole complex, ensured in-depth pre-insurance survey and preparation to achieve 60% less observations than previous years • Developed and presented a safety-culture assessment plan aligned with Aramco’s Downstream Safety Transformation Model to the CEO; secured approval, designed the survey, analyzed results to identify cultural gaps, and created a targeted improvement plan for sustained performance

Operations/Production Manager - EDC/VCM & PVC Plants
Karachi Division
Jan’18 – Dec’19 | Nov’21 – Nov’22 | Dec ‘24 – Apr‘25 Managed safe, sustainable, and efficient operation of EDC/VCM plant, 3 PVC plants (MCI, TCC, JNC technology), and an associated utilities plant. • Planned and executed safe commissioning & startup of direct chlorination reactor • Led EDC/VCM plant 2025 turnaround and ensured safe execution of furnaces, decoking, HCl/VCl columns tray replacement, and OXY/OVR reactor inspection etc • Did production planning & inventory management of various grades of PVC • Implemented lean six sigma methodologies through various DBN projects and increased PVC-1,2 production capacity from 150 KT to 203 KT per annum • Led the team for seamless DCS upgrade from YAMATAKE to HW PKS R510 • Recognized with “corporate excellence award” on multiple occasions • Conducted performance appraisal and reward & reprimand of employees • Improved employee engagement from 45% to 85% within 2 years

HSE & Process Safety Manager
Karachi Division, Sindh, Pakistan
This role encompasses an integrated chlor-vinyl chemical complex consisting of EDC/VCM, PVC, ChlorAlkali, Utilities/PP, and Hydrogen Peroxide plants. • Introduced “Risk-Based Assessment” program using DuPont’s risk profiling tool comprising of a quality HAZOP, control of MAH scenarios, and bowties development • Spearheaded PSM documentation review and gap assessments across Hydrogen Peroxide and base plants, ensuring zero non-conformances during internal audits • Digitalized incident command systems, and implemented shelter-in-place concept for toxic release cases, significantly improving response time and headcounts • Member of HSE committees for PSM/PSRM, MOC, incident investigations (Tier-1/2) • Envisaged, developed, and implemented contractor skill certification program • Rationalized JSA, Work Permit procedure, and Risk Management Audit program • Aligned HSE leading & lagging indicators with API-754 and HSG-254 • Led numerous PHAs/HAZOPs and participated in FMEA, SIL/LOPA, FRA/FEHM/EERA studies, insurance survey, and IMS/PSM/EMS DuPont audits • Enhanced data analytics using “Risk Alive” & “Power Bi” for barrier management, SECE/SCD rationalization, and recommendations prioritization • Oversaw site-wide internal PSM communications, including toolbox talks, weekly safety briefings (D-level), safety flashes, lessons learned, and safety reminders • Benchmarked & aligned process isolations standard with UK HSE HSG-253 • Stewarded LOPC reduction program and reduced LOPCs by 45% in 2 years

Manager PVC Expansion
Karachi Division, Sindh, Pakistan
Led operations team as part of commissioning & operation readiness team of PVC-3 and ensured its flawless commissioning. • Hired, supervised, and coached 32 employees despite COVID-19 restrictions by embracing remote working challenge • Led commissioning readiness for greenfield PVC-3 plant, aligning systems with IMS and OSHA PSM from day one via SOPs, PSI, PHA, MOC, PSSR, ERP, training and skill certification • Coordinated cross-functional PSSR and successfully handed over plant to base plant organization with full audit compliance and no startup incidents • Collaborated with Chinese EPC (TCC) and Japanese licensor (JNC) for GTR and seamless integration of project deliverables • Identified improvements in PFD/P&ID/3D model, and DCS sequence programs • Facilitated safe construction and led safe commissioning of new VCM sphere and a utilities unit having a Boiler, Demin/Polisher, Cooling Tower, Compressors, and EDG

Lead Engineer - Operation/Production, PVC plants
Karachi Division, Sindh, Pakistan
Apr 2009 – Aug 2013 | Sep 2014 – Dec 2017 • Led PSM implementation in production dept, and its internal/external audits • Improved ERT performance as team lead and achieved >95% satisfactory drills • Worked as POC and ensured “Zero Non-compliance” in Insurance and IMS audits • Conducted RMAs (Risk Management Audit) and JCC (Job Cycle Check) • Developed safety critical defeat and emergency handling procedures • Led operations team to upgrade PVC-1 plant to “Vinnolit’s” hot water charging technology designed by “Uhde” to enhance production capacity by 6% • Implemented “Chilled Water” project and increase PVC-2 plant capacity by 30% • Did DBN study & use LSS tools to increase PVC-2 capacity by more than 20%

Training Engineer
Karachi Division, Sindh, Pakistan
• Structured operations skill certification program by developing skill syllabus and online testing mechanism. • As part of “Job Qualification Program” initiative, led the team and developed JQP modules of EDC/VCM, CA, Utility/Powerplant, and PVC plants. • Institutionalized “Departmental Training Committee” for review & stewardship of training related milestones.

Operations Shift Incharge
Dewan Salman Fibers Ltd
Hattar industrial state - Pakistan
Supervised operations team to ensure safe and sustainable operation of polyester plant.
M. Shahid Karim's Contact Information
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