Resume - Experienced Refractory Project Manager / Construction Manager / Consutant

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Resume #84822

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Work History Résumé.

November 2006 to July 2009. Petro-Tech Contract Services Pty.Ltd.
(Sydney Australia)

Projects:
GLOW Energy, Rayong Thailand; Refractory Consultant new FW 110MW CFB Power Plant.
TRU Energy: Yallorn W Power Plant. Refractory Inspection contract.
Shell Clyde Oil Refinery FCCU revamp & Shutdown, CDU Shutdowns, Boiler Shutdowns.
Shell Geelong Refinery FCCU Shutdown.
ExxonMobil Altona Refinery FCCU Shutdowns.
Caltex Kurnell Oil Refinery: FCCU Shutdowns, Boiler, CDU, DHTU, SRU & Furnace repairs.
Caltex Lubricating Oil Refinery Shutdowns
Caltex Lytton Refinery; Furnace repairs CDU, DHTU
BP Oil Refinery Bulwer Is.: FCCU Shutdown

CURRENT CONTRACTS:
1) Caltex Kurnell Refinery: Independent Refractory Consultant.
2) Palmer Tech Group: Independent Refractory Consultant
3) Alstom Power: Independent Refractory Consultant.
4) Andreco Hurll Refractory Services pty.Ltd. Projects Manager, Petro-Chem & Power.
5) TRU Energy: Yallorn W Power Plant. Refractory Consultant
6) GLOW SUEZ: GLOW Energy Public Co. Thailand, Refractory Consultant.
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June 2006 to October 2006. ALSTOM Power Inc.
(Lampung, Sumatra - Indonesia) Global Refractory Operations
Windsor, CT., USA.
POSITION & DUTIES:
Site Refractory Construction Consultant.
Site Project Refractory Consultant responsible for all construction activities on Tarahan 2 x 100MW CFB Power Plant project. The Project included Alstom Power, Marubeni Corp. and PT Alstom Power Energy Systems, Indonesia, providing the state electricity company, PLN with two circulating fluidized bed (CFB) boilers, Tarahan 3 and Tarahan 4 power plants. Employment was on a Contract Basis through my company, PETRO-TECH Contract Services Pty.Ltd.
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June 2005 to June 2006. ALSTOM Power Inc.
(New Hampshire - USA) Global Refractory Operations
Windsor, CT., USA.
POSITION & DUTIES:
Project Manager - Refractory Construction.
Site Project Manager responsible for all design, construction, quality, commercial and commissioning activities of a new Schiller 50MW FiCirc Power Plant for The Public Service New Hampshire Utility Power Company. The plant is the largest renewable energy power project in the USA. The Plant was successfully commissioned and is now in commercial operation.
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May 2003 to May 2005. ALSTOM Power Inc.
(USA) Global Refractory Operations
Windsor, CT., USA.
POSITION & DUTIES:
Consulting Engineer: Project Manager Refractory Construction.
Part of the Global Refractory Operations group in Windsor Connecticut, responsible for all
ALSTOM Power Circulating Fluidized Bed (CFB) & FiCirc Power Plant refractory projects for execution centres in Windsor, (USA); Stuttgart, (Germany) and Velizy, (France).
Duties included the preparation of specifications, design reviews, control of all commercial aspects & quality of refractory installation activities and repairs on various new and existing CFB
Projects; design, analyse and evaluate refractory systems; study and select refractory materials;
estimate costs of materials and installation services.
Value of individual project responsibilities varied from US$ 3.5 Million to US$ 17.5 Million

PROJECT RESPONSABILITIES (Including extended periods On Site)
AES (Puerto Rico) - 2 x 250MW CFB's;
East Kentucky Power, (U.S.A.) - 2 x 350MW CFB's;
ENEL Power (Sardinia Italy) - 1 x 220MW CFB;
Akrimota (India) - 2 x 125MW CFB's;
Baima (China) - 1 x 300MW CFB &
Cao Ngan (Vietnam), - 2 x 300MW CFB's.
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March 2003 to April 2003. REDBANK POWER.
Redbank FiCirc. Power Plant,
Hunter Valley, NSW Australia
ASSIGNMENTS & DUTIES:
Awarded the contract to supply Third Party Independent Refractory Engineering Consulting
Services (through PETRO-TECH Contract Services) directly to Redbank Power for the March
2003 Outage.

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April 2002 to March 2003. ALSTOM Power Inc.
Global Refractory Operations
Windsor CT. USA.
POSITION & DUTIES:
Provided Refractory Consultancy services on a part time basis (through PETRO-TECH Contract Services) to the Global Refractory Organization, Alstom Power USA. Reviewing Refractory Specifications, refractory designs and installation issues.

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June 2002 to March 2003. Vopak Terminals Aust.
(PD Van Ommeron)
Bulk Chemical Storage, Port Botany
Sydney Australia.
POSITION & DUTIES:
Contracted as Maintenance & Inspection Engineer (through PETRO-TECH Contract Services) to Vopak Terminals. Responsibilities include controlling the computerized Maintenance Program, issuing work orders, updating database and controlling ongoing maintenance. Conducted tank Inspections including Acoustic Emission Testing and coordinated NDT personnel. Assisted the Engineering Manager with special projects & Inspection duties.

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February 2002 to April 2002. ALSTOM Power Inc.
Windsor CT. USA.
ASSIGNMENT & DUTIES:
Assigned by ALSTOM Power Inc. as Mechanical Superintendent to manage the first maintenance shutdown on two FiCirc Power Plant Units at Redbank Power Station. This included major refractory warranty repair work and assisting with site mechanical inspections and commissioning duties.
____________________________________________________________

January 2001 to December 2001. ALSTOM Power Inc.
(Taiwan) Windsor CT. USA.

ASSIGNMENT & DUTIES:
Refractory Construction Consultant to ALSTOM Power Inc. for the refractory installation in 2 x 150MW CFB type coke fired Boilers for Formosa Heavy Industries Corp. (FHI) at the Formosa Petrochemical Corp. complex, Mai-Liao, Taiwan.
Responsible for advising FHI on all Quality and Technical issues during the refractory construction & thermal dryout by their subcontractor, Karrena GmbH and installation company, Forter Asia.
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March 2000 to January 2001. ABB ALSTOM Power.
Combustion Engineering.
Windsor CT. USA.
ASSIGNMENT & DUTIES:
Contracted (through PETRO-TECH Contract Services) to ABB ALSTOM Power as a Refractory Inspection Consultant, responsible for the quality of all refractory construction on the Redbank Power Station Project for two new FICIRC Power Plant Boilers, Hunter Valley, Australia.
Site managed Karrena GmbH, the refractory designer / supplier and York Linings International Pty. Ltd., the refractory installer.
Additionally carried out mechanical inspections of all fabricated components including on site erection.

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September 1998 to March 2000. Shell Oil Refining Co.
Shell Services International.
Clyde Refinery, Australia.
ASSIGNMENTS & DUTIES:
Approached by Shell Services International to act as a Refractory Consultant and Project Engineering Inspector (through PETRO-TECH Contract Services) for a major FCCU Oil Refinery Revamp Project.
Responsible for all refractory issues, reporting to the Shell Head Office in The Hague, Holland. Refractory responsibilities included Design Assistance, Selection of Refractory Materials and Anchor systems, Technical Evaluation of refractory Suppliers and Installation Contractors. Supervised all refractory construction through to the Thermal Dryout of all components. Issued detailed operations Dryout Procedure for the total Plant Start-Up of FCC Unit.
Also given full responsibility for the Inspection and Expediting of all offsite fabrication of new FCCU Reactor Riser and Cyclones including their refractory lining. Carbon steel, high & low alloy process piping, large diameter 304H Stainless Steel hot wall vapour piping, Pressure Vessels, Heat Exchangers, 304H SS refractory lined FCCU Slide Valves and large flue gas ductwork. Reviewed all Welding Procedures & Refractory Procedures for approval. Witnessed & approved all welder and refractory personnel pre-qualification testing.
All Refractory Construction & Fabrication work was completed and successfully erected on site three weeks ahead of program.

January 1999 to February 2000. STELFORM Engineering Pty. Ltd.
Newcastle, Australia.
ASSIGNMENTS & DUTIES.
Stelform Engineering; a Heavy Engineering fabrication company for the Power Generation & Petrochemical Industries.
Approached by Stelform to provide Refractory Consulting and Inspection services (through PETRO-TECH Contract Services) to the Major Projects Division. Provided technical advice for the design, selection, installation of refractory materials & anchoring systems, including Thermal Dryout for a large FCCU Catalyst Cooler being fabricated for BP Oil Refining. Also advised on Tender Evaluation & Selection of the Refractory Installation Contractor. Refractory installation included Vibration Casting Dense Erosion Resistant materials over "Y" anchors & hand rammed Resco AA22 into Hexmesh & "S" bars.
All work was carried out to M.W.Kellogg Refractory Specifications. The vessel was successfully refractory lined, thermally Dried Out and installed.
____________________________________________________________________________

September 1998 formed PETRO-TECH Contract Services Pty.Ltd.
Providing independent Refractory & Engineering Inspection services to the Oil & Power industries.
_____________________________________________________________________________
May 1992 to June 1998. Cookson Plibrico / Vesuvius
Andreco-Hurll Refractory Services.
Bulli, N.S.W. Australia.
POSITION & DUTIES:
Employed Position: National Manager – Oil & Petrochemical Industries. Responsible for Refractory Projects in the Oil Refining & Petrochemical industries throughout Australia.
Prepared tenders, estimates, technical, contracts and QA through to award of contracts. Site Project Managed and profitably executed contracts through to completion & on time. Provided refractory technical advice to clients, helping build Andreco-Hurll's reputation as the leading Australian refractory Installation Company in this industry.

ACHIEVEMENTS.
Oct. 1996 to Jan. 1998: Project Manager on a new AU$2.6 billion Hot Bricketted Iron Project for BHP at Port Hedland, Western Australia. Responsible for the onsite refractory contract with BHP – DRI, John Holland Constr. & Eng, with Vorst-Alpine the Process Designer.
Work included the supply and installation of 6,000 tonnes of various refractories in 16 Reactors and various other Pressure Vessels, including lining of (2.6m ID) transfer piping.
Also refractory lined two large Gas Reformer Heaters for KTI, Holland to their design.
1996: Tendered for & won all 6 Refractory contracts worth AUD$ 3.5mil. for the new FCCU at Mobil Oil Refinery, Altona. Clients included Plibrico Refractories (Japan); Toyo Eng. Corp.; Mitsubishi Heavy Ind.; Aust. Submarine Corp.; CBI Constructors; John Holland Constr.& Eng.
1992 to 1996: Successfully won & profitably completed numerous Project & Shutdown contracts for Caltex, Shell, Ampol, BP, Mobil, Esso, ICI & Incitec.
1994: Assisted management in gaining Q.A. accreditation to AS3902 (ISO 9002) for Refractory Installation. The first Refractory Installation company to do so.

January 1990 to May 1992. ABB Flakt Australia Pty.Ltd.
Sydney, Australia.

Part of the A.B.B. Group designing, constructing and maintaining large industrial Fabric Filters, Electrostatic Precipitators & Fans to the Steel, Power, Mining, Aluminium, Cement and other heavy industries.
EMPLOYED POSITIONS: Commissioning & Special Projects Engineer / Contracts Administrator & Division Quality Assurance Engineer.
Responsible for Contracts, purchasing, Quality Assurance and Technical matters. Periodic secondment for special projects within the Company for Testing, Commissioning and Engineering Development.

ACHIEVEMENTS AND EXPERIENCE:
January to May 1992: Site Manager for the installation of an Exhaust Air Scrubbing System in the North Bondi Underground Sewerage Plant.
November 1990 to January 1992: Project managed Maintenance and Construction contracts on Power Stations, Cement Plants, Aluminium Smelters, Steel Works & Mining Operations.
July to October 1990: Project Engineer at Boyne Aluminium Smelters, Gladstone, and Qld. Successfully redesigned, tested and proved new technological efficiencies on their Pot Line Fume Treatment Plant resulting in the award of a $65 million upgrade contract.
January to July 1990: Site Manager, Constructing and Commissioning a new $15 million Fabric Filter on No 5 Blast Furnace at BHP Port Kembla Steel.
_____________________________________________________________________________

January 1975 to January 1990. CALTEX Refining Co. Ltd.
Kurnell Oil Refinery, Australia.
POSITION & DUTIES.
Senior Area Engineering Inspector.
Responsible for half of the operating plants, utilities and facilities in the total Refinery Complex including their Construction, Maintenance, Inspection and Repair to Company, International and Statutory Standards.
Inspection functions include Technical Control of Materials Selection, Welding Procedures, Refractory Specifications & Installation, Maintenance and Repair Procedures, Pressure Vessel Construction Inspection, Corrosion Control, Protective Coatings Selection, Insulation Specifications, Plant Shutdowns, Project Construction, N.D.T. Inspection, Failure Analysis, Metallurgical Investigations, Compile and Maintain Inspection Records, Control of Sub-Contractors and Pre-Qualification of Refractory & Welding Contract Personnel.

ACHIEVEMENTS.
1988: Promoted to Acting Senior Area Inspector based on experience, technical competence and broad experience in all aspects of Refinery Inspection, Maintenance and Operations gained over the past 15 years.
1985: Organized & participated in the Caltex International Inspection Training Course, (4 months fulltime duration)
1980: Seconded for 5 months to Major Shutdown Group as Nightshift Shutdown Construction Superintendent, responsible for the No 1 F.C.C.U. major revamp project.
1979: Participated in first Caltex International Inspection Training Program (3 months fulltime duration)
1978: Appointed Project Inspector on a major Refinery Expansion Project, constructing a new Sulphur Recovery Unit, T.S.U., ISO-SIV Unit, D.H.T.U., C.O. Boiler and No 2 F.C.C.U. revamp, Vacuum Column, Power Plant Concrete Stack, associated piping fabrication in Stainless Steel, high and low alloy carbon steel.
_____________________________________________________________________________

January 1972 to January 1975. James N. Kirby Pty. Ltd.
Sydney, Australia.
POSITION: Indentured Fitting & Machining Apprentice.
With Higher School Certificate, qualified for accelerated Apprenticeship, completing Tech and practical work in 18 months. In three years promoted to Design Office as Production Engineer.
__________________________________________________________________________

QUALIFICATIONS.

2008: American Petroleum Industry API 936 Personnel Refractory Certification
Program

1991: Quality Assurance
Internal Auditors Certificate. Standards Australia

1985: Materials Testing Certificate. Technical College.

1985: General Non Destructive Testing
Certificate. Technical College.

1984: Mechanical Engineering Certificate. Technical College.
(stage 4)
1985: Welding Technology Certificate. Technical collage.
(stage 4)

1985: Completed 4 month full time Caltex International Inspection Training Course.

1983: Ultrasonic Testing Certificate. Technical College.

1983: Radiographic Testing Certificate. Technical College.

1979: Completed 3 month full time Caltex International Inspection Training Program

1974: Fitting & Machining
(Advanced Trade Certificate.) Technical College.

1971: Higher School Certificate. Port Hacking High School.

PERSONAL DETAILS.

David Robert Johnstone.

Date of Birth: 21st September, 1953

Australian Citizen

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