Senior Process Engineer (2007-2008)
Responsible for daily operations, quality assurance, process control, expensed and capital projects, test runs and specialty customer order runs at the polyisoprene unit.
·Created and promoted capital budget, environmental compliance and energy conservation projects which reduced cost of operations such as surfactant injection system, maintenance overhaul of expander barrels and screws, selection and installation of improved metal detectors.
·Designed new, safer, debottlenecked and streamlined layout of the finishing building with improved material flow, fewer blind spots, better access for maintenance, improved ergonomics and personnel safety.
·Created material balance database for the finishing building. Used material balance as a design basis for the new regenerative thermal oxidizer (RTO) for finishing building emissions control.
·Adopted Aspen IP21 function on-line to improve quality control of the process and final product. Made those parameters accessible and visible to the finishing building operators. Troubleshooted process control and instrumentation in the finishing building to improve quality and first-pass prime.
·Reduced finishing building energy (steam) consumption and improved drying process through methodology of control and equipment modifications.
Senior Environmental Engineer (2005-2007)
Responsible for plant environmental compliance with federal/state air, water and waste regulations and permit requirements.
·Streamlined compliance with Title V Operating Permit through the automated system using third party (PDC) software to reduce time load of the operating personnel in complying with the requirements of the permit. Performed the analysis of compliance tasks, consolidated, streamlined and assigned them to operations and engineering personnel in the facility.
·Managed and provided technical and engineering base for the TPDES wastewater permit renewal and amendment.
·Found errors in the existing Parshall flume flow measurement instrumentation design and calculation algorithms and corrected it to comply with ISO-9826. Revised compliance procedures.
·Reduced significantly the time load for the boiler data collection, calculations and preparation of the compliance reports by applying on-line analysis using AspenTech historian IP21 in combination with “live” MS Excel worksheets for the BIF boilers compliance and compliance with HWC MACT Phase II.
·Managed waste minimization programs, elimination of landfilling, compliance with the Texas waste minimization requirements (P2 program). Through the technical analysis devised and implemented means to convert waste into reusable materials and arranged for selling those materials to outside companies.
·Created means and recordkeeping systems for analysis and minimization of hazardous and non-hazardous waste. Managed solid and hazardous waste compliance, RCRA recordkeeping, periodic audits and reporting. Issued periodic waste minimization reports. Maintained control of hazardous waste inventories and issued reports to the TCEQ for tax estimation on waste inventories.
·Eliminated inventories of waste abandoned after the sale of one of the plant operating units. Increased the percentage of recycled waste and reduced the amount of water shipped as waste. Successfully worked with two of the waste processors to implement waste recycling system in place of the incineration or landfilling.
·Conducted and submitted emissions inventory calculations for SOCMI units. Reduced annual EI reported to TCEQ by eliminating errors in the calculations and component type assignment as well as by applying correct efficiency credit factors. Reduced emissions data acquisition time by 85% through automation and advanced use of SQL systems in AspenTech IP21 platform.
·Being responsible for cooling towers (heat exchange systems) compliance, sampling and reporting, submitted numerous MOC proposals for improved cooling tower operations, control and data collection to reduceair VOC emissions and improve(MON, HON) compliance.
·Managed and improved LDAR programs by correcting the plant interpretation of the TCEQ and EPA rules, reporting systems. Reduced cost of LDAR program by consolidation of multiple programs, analysis of work schedules and by focusing the program on analysis of frequent leakers, using LeakDAS v.3.0. Reduced time and cost of collecting daily VOC samples by designing industrial-grade VOC strippers, having them approved by TCEQ and building multiple VOC (El Paso) strippers that were installed in each cooling tower cell areas. Achieved 95% reduction of paperwork by creating electronic connection between the LDAR data collecting systems and the plant compliance reporting systems.
·Prepared and submitted the SPCC (oil spills prevention, control and countermeasures) plan for the plant.
·Prepared bids for air sampling for MACT MON compliance, analyzed results and recommended path to compliance for polymerization and refinery units.
·Maintained regular superior working contact and relations with TCEQ.
·Reduced reportable emissions in the emissions inventory program by 63% through correcting errors in the original tank calculations.
·Maintained daily air compliance of the polymerization units for MACT Subp.U compliance. Prepared MACT U periodic reports for process units.
·Managed and provided technical and engineering base for the wastewater permit renewal and amendment. Corrected errors in the instrumentation design and calculation algorithms to comply with ISO-9826. This eliminated pereption of noncompliance and avoided incorrect noncompliance reports to TCEQ.
·Prepared gap analysis for compliance with HWC MACT Phase II. Reduced significantly the time load for the boiler data collection, calculations and preparation of the compliance reports.
·Managed solid and hazardous waste compliance, RCRA recordkeeping, audits and reporting. Created means and recordkeeping systems for analysis and minimization of hazardous and non-hazardous waste improving efficiency.
·Reduced reported annual EI. Automated manual tasks reducing emissions data acquisition time by 85%.
·Maintained, corrected errors and improved plant overall energy (steam, electricity, natural gas) and utilities (nitrogen, air, water) balance. Reported monthly data to Accounting and to Corporate Energy Group. Reconciled data from energy and utilities suppliers (Kinder-Morgan, Entergy).
Senior Process/HSE Engineer (2002 - 2005)
Responsible for maintaining and troubleshooting PSM programs, procedures and compliance in the polymerization units.
·Created algorithms and tools in the DCS that allowed ongoing daily environmental emissions control and corrections directly by the operating personnel resulting in increased operational efficiency.
·Implemented a Six Sigma project to modify design, regeneration cycles and operation of drying beds, and the methods for reactor “boilouts”, which optimized energy and labor cost in reactor feed preparation.
·Used the Six Sigma analytical methodology to prevent unnecessary purchasing of new equipment resulting in savings of more than $200,000.
·Ran process simulation (Chem CAD) to optimize solvent recovery column and to study the feasibility of operating reactors at reduced heat exchange capacity.
·Troubleshooted product moisture detectors to discover that they were not suitable for the desired function. Discovered error in the vendor’s calculation algorithm and consulted with vendor to correct it.
·Developed an environmental management program for the three polymerization units’ conformance with ISO14001, through which the units achieved ISO14001 certification.
·Ensured the environmental air emissions compliance through engineering improvements. Created algorithms and tools in the DCS that allowed ongoing daily environmental emissions control and corrections directly by the operating personnel and through it avoid noncompliance and fines.
·Optimized cost of operations by automating plant data collection for calculations of material use and remaining inventories and then re-assigning activities such as raw materials inventory control directly to the operations personnel.
·Optimized energy and labor cost in reactor feed preparation by implementing a Six Sigma project to modify design, modify regeneration cycles and operation of drying beds, and the methods and techniques for reactor “boilouts”.
·Achieved 10,000 lbs/hr steam saving to the column reboiler through the use of process simulation tools (Chem CAD).
·Optimized energy and utilities (nitrogen) consumption as well as environmental emissions compliance in operating units by implementing change in operating practices.
Process Safety Management and Risk Management Coordinator (1994 – 2002)
Responsible for implementation, auditing and correction of the PSM program. Responsible for implementation and compliance with the EPA RMP Standard.
·Developed schedule for PHA revalidations and coordinated conduct of those revalidations by unit engineers.
·Developed and implemented an in-house system for process hazard analyses recordkeeping and re-validation eliminating the need to purchase vendor’s software thereby reducing costs.
·Created PSI and MSDS databases accessible to anyone in the plant improving data access and operational efficiency.
·Developed the PSM program for the plant, including all 14 elements systems, procedures, timelines, practices and tools. Developed and executed HAZOP studies for six operating units – polymerization and refining. Trained plant personnel in conducting Hazard Evaluations.
·Developed internal audit assessment and evaluation using the AIChE PSM ProSmart software. Assisted AIChE in testing of this software in the plant environment. Conducted PSM internal audits in the company other chemical plants.
·Developed the environmental management program for the chemical plant compliance with ISO14001.
·Conducted risk evaluation of disaster scenarios for the compliance with the RMP Rule, including the facility siting for the six operating units, propane and isobutane refrigeration systems. Wrote complete set of Risk Management Plan policies and procedures for the facility and submitted the original RMP report to EPA.
·Saved approximately $50,000 cost of purchasing vendor’s PHA software by developing and implementing an in-house system for process hazard analyses recordkeeping and re-validation.
·As the certified Internal Consultant for Behavioral Accident Prevention Process®, coordinated and facilitated implementation of BAPP®. The plant successfully implemented the system and was only one in the company who had proven longevity of the process.
·Organized, managed and maintained HAZCOM data system and the MSDS. Ensured that the MSDS for each material are filed, technically correct and up-to date. Created a system for quick retrieval and review of MSDS by anyone in the plant. Created electronic Process Safety Information (PSI) database available to anyone in the plant and filled the appropriate process information.
·Managed plant flame-retardant clothing program, a $300,000/year account. Accomplished significant savings and improved worker satisfaction by diligent recordkeeping, establishing long-term relation with the vendor and by strict asset control.
·As a member of a Six Sigma team, reduced product switch time, cost and off-spec product generation caused by the existing moisture analyzing and testing equipment that was not suitable for the required service. Using Six-sigma methodology conducted field tests and developed calculations to prove that the moisture analyzing devices were the root cause of mistakenly classifying products as off-spec. Off-spec material was reduced by 20%.
·Corrected and created existing calculations for stack compliance for VOC emissions in the emission points.
·Provided the plant comptroller and accounting organization with more accurate and automated collection and processing of operations and utility data to obtain clearer picture of the operating cost.