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Project Engineer/Refinery Reliability Engineer/Turnaround Coordinator

Professional Profile

Over 13 year career of both domestic and international refinery and engineering experience spanning major areas of the oil and petrochemical industry. Result-oriented and highly motivated professional with considerable hands-on field experience dealing with project engineering, pro-active reliability and maintenance strategies for fixed equipment. Ability to develop scopes of work, coordinate field personnel, track expenditures and successfully complete multi-disciplinary projects in a cost effective and efficient manner. Projects have included vacuum column revamps, fractionator revamps, coke drum repairs/inspections, heat exchanger failure analysis, piping system installations, and work on various other types of fixed equipment.

Areas of Expertise

Project Management/Engineering*
Turnaround Planning/Coordinating
Construction Planning/Scheduling
Safety, Environmental & Compliance Management
Team Building & Leadership
Fixed Equipment Development/Strategies
Root Cause Failure Analysis
Risk Based Inspection Techniques (RBI)
Vessel Procurement and Repair (ASME/API/NBIC)
Exchanger Revamp & Procurement (Tema/API
Coke Drum Inspection/Repairs
Major Tower & Vacuum Column Revamps
Hydraulic Simulation Analysis
Multidisciplinary Hazop Reviews
Haz Mat Technician
Refinery Certified Firefighter

Professional Experience

Delta Maintenance – St. Paul, MN 2003
(Subsidiary of Philip Service Company (PSC) specializing in turnaround equipment planning, execution and maintenance.)

On-Site Construction Manager/Lead Planner/Field Turnaround Engineer
Responsible for setting up, planning, and executing all Delta Maintenance work for the Fluid Catalytic Cracking (FCC) and Sulfur Recovery Unit (SRU) turnaround at Flint Hills Resources (Formerly Koch Petroleum Group) - Pine Bend Refinery.

Selected Results:
* Responsible for planning, execution, and installation of a 425,000 lb Waste Heat Steam Generator in a tightly congested sulfur unit during a 14 day turnaround window. This entailed pre-turnaround site preparation and set up of a 500 ton gantry crane and dedicated rail system in conjunction with all structural, piping, instrumentation and civil modifications.
* Also responsible for developing, managing and executing 40 other capital/expense projects involving towers, vessels and heaters during the same turnaround window in the FCC, Clarified Oil, FCC Gas Plant, Sulfur Recovery, Alkylation, Dimersol and Flare Units.

Flint Hills Resources (Formerly Koch Petroleum Group) 1994-2002
Pine Bend Refinery – St. Paul, MN
(Part of second largest privately owned company in the United States; the Pine Bend refinery processes 285,000 BPD of crude oil.)

Fixed Equipment Reliability Engineer – Heat Exchangers
Optimized equipment life cycle cost for fixed equipment by developing a plant wide mechanical integrity and reliability program with due regard to safety and the environment. Provided technical support for day-to-day operations and reliability.

Selected Results:
* First to develop RBI Software with DNV Engineering to evaluate "Risk", "Likelihood" and "Consequence" of heat exchanger bundle failures.
* First to compile a failure history of all 1,200 heat exchangers in a single database and use this information to create a bad actors list and to calculate the mean time between failures (MTBF). Information used for establishing new RBI Model by DNV Engineering.
* Performed Root Cause Failure Analysis (RCFA) on naphtha hydrotreating unit heat exchangers due to performance degradation. Evaluated and incorporated new refinery ID tube coating options and eliminated refinery bottleneck.
* Responsible for conducting RCFA on all bundle failures, ordering all replacement bundles and heat exchangers.

Fixed Equipment Reliability Engineer – Pressure Vessels
Optimized equipment life cycle cost for fixed equipment by developing a plant wide mechanical integrity and reliability program with due regard to safety and the environment. Provided technical support for day-to-day operations and reliability.

Selected Results:
* Performed detailed cost analysis, justifications and recommendations for replacing two 24 ft. diameter existing coke drum vessels. Total cost of vessel replacement was $7,000,000.
* Established a working partnership with CIA Inspections, Inc. to perform annual laser drum inspection on all six refinery coke drums to map deformation changes, identify potential future repairs, and help evaluate remaining coke drum life.
* Installed continuous monitoring strain gage on large diameter coke drums to reduce stress on the vessel during the quench cycle, increase its remaining life and improve mean time between failures.
* Procured and oversaw all major vessel replacement.
* Performed a hot tap on the FCC Spent Catalyst Standpipe to install liquid refractory in locations where the refractory system had failed. This project reduced the need for a costly shutdown and prolonged the interval between turnarounds.
* Set-up a repetitive infrared survey on the FCC Structure to locate, monitor, and identify hot spots which may cause on-line failures and unscheduled shutdowns.
* Implemented and planned all major vessel repairs and work though outside boilermaker companies. Point person and assigned field engineer for these outside boilermaker companies during turnaround.

Reliability Centered Maintenance (RCM) Initiative – Subject Matter Expert
Developed new equipment strategies for fixed equipment throughout the plant to increase equipment/
system/unit availability while improving reliability, environmental and safety performance. Performed Root Cause Failure Analysis of individual equipment failures in conjunction to Risk Based Inspection (RBI) techniques and incorporated results into equipment strategies.

Selected Results:
* Generated and developed individual equipment strategies in a multi-disciplinary framework which when fully implemented will benefit Koch upwards of $0.75/bbl ($60,000,000/yr.).
* Procured all materials, developed scopes of work, and field supervised major revamp of two separate coker fractionator columns.
* Incorporated requirements set out in the Above Ground Storage Tank (AST) Permit from the Environmental Protection Agency (EPA) and integrated these tasks and findings into all existing and new storage tank equipment strategies.
* Reviewed and wrote preventative maintenance toolbox procedures for operations to incorporate into daily rounds to increase overall refinery reliability.

Turnaround Pressure Vessel/Heater Coordinator & Planner
Maximized the value added to the refinery by managing, developing and executing all vessel and heater scopes of work for all turnarounds and shutdowns. Insured safety and environmental issues were upheld and implemented to the highest standards.

Selected Results:
* Maximized the total profit to the refinery through optimizing manpower requirements and coordination of all vessel/heater workforces during turnarounds.
* Scoped, coordinated and field supervised four complete coke drum skirt replacements.
* Performed Root Cause Failure Analysis on hydrogen reformer roof refractory failure with the Inspection and Process Groups. Implemented plan to fix failing roof refractory support system and oversaw repairs during turnaround.
* Researched various coker heater tube cleaning technologies and cost/value comparisons. Implemented relationship with Hydro Kleen for future pigging of all coker heaters during turnaround.
* Lead the turnaround and capital projects integration of vessel and heater work into turnaround to simplify the work execution process and reduce turnaround cost.
* Coordinated and facilitated the Operation/Reliability Departments inputs in developing the turnaround/shutdown work lists and scopes to eliminate unnecessary work or increase equipment reliability.

Maintenance Project Lead Engineer
Acted in the newly developed Maintenance Engineering Group as a Lead Engineer to mentor newly hired college graduates in project management and integral workings of the refinery. Developed scopes of work and supervised contractor workforces in the field on all major reliability fixed equipment projects.

Selected Results:
* Lead Project Engineer in a $2,500,000 project, which upgraded the #3 Crude Unit heat exchanger to Brown Fintube twisted tube design increasing unit load capacity.
* Managed, scoped, and field supervised the major revamp and turnaround repairs of the 19 Unit vacuum column (22 ft. dia.), which included a new Light Vacuum Gas Oil (LVGO) draw tray, new LVGO packed section, and major vessel repairs.
* Project Engineer and Field Engineer on the #2 crude tower and preflash tower revamp project during turnaround, which included installation of a new orifice draw tray, new packed bed section, new trays and two internal piping distributors.

Refinery Project Engineer
Provided piping stress analysis, Hazop reviews, and project management on small and medium size projects throughout the plant. Piping field engineer during turnarounds and shutdowns.

Selected Results:
* Participated in multi-disciplinary team unit Hazop reviews throughout the refinery and assigned tasks for resolving various safety and environmental equipment issues.
* Managed and supervised a refinery wide heater survey project conducted by Tulsa Heaters and John Zink to establish safe operating limits and maximum heater throughput.
* Project Engineer for the hot belt project which included an elaborate series of tie-ins to redirect hot oil and de-bottleneck several heat exchangers in the FCC/Alkylation units.

Stone & Webster Engineering – Saudi Arabia 1991-1994
(Leading Engineering Contractor for Saudi Aramco Projects)

Project/Lead Mechanical Engineer
Provided project management and mechanical design on all large projects for Saudi Aramco and Samarec.

Selected Results:
* Developed and updated Piping & Instrumentation Diagrams (P&IDs) for upgrading the Jeddah Refinery Fluid Catalytic Cracking unit to a new Universal Oil Process (UOP) design for increased throughput.
* Performed Computer Hydraulic Analysis for the Abqaiq Refinery firewater, utility and oily water systems using hydraulic simulation programs along with developing mechanical pump data sheets and P&IDs.
* Responsible as Project Engineer throughout proposal and detailed design stages for development and procurement of upgrade for three existing 21,000 HP sales gas compressors to 24,500 HP and installation of six new air-cooled heat exchangers.
* Lead mechanical engineer for developing mechanical data sheets, line designation list, hydraulic analysis, P&ID and PFD drawings for installing three 250,000 BBL diesel storage tanks, three new 150,000 BBL gasoline floating roof storage tanks, two offshore submarine pipelines and truck loading facility.

Education/Qualifications

Education:
Florida Institute of Technology Spring 1991
Bachelor of Science in Mechanical Engineering
Melbourne, Florida Campus

Qualifications:

* ASME Training - Pressure Vessels Section VIII
- Repairs and Alterations NBIC
- Failure Mechanism/Analysis
* Root Cause Failure Analysis Training
* Risk Based Inspection (RBI) Training
* Hazmat Technician - Dakota County Technical College
* Hazwoper Certified - Koch Refining Company
* First Responder Certified - Emergency Medial Service (EMS) State of Minnesota
* Refinery Certified Firefighter - Advanced Firefighting Course (Corpus Christi, TX)

References:

All Business and Personal References Furnished Upon Request.

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