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Engineer Project

Harrison, Tennessee, United States
January 29, 2018

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Frank R. Kulak, **** Dark Pond Lane, Harrison, TN 37341 423-***-**** Cell 423-***-****

Education: Bachelor of Science; Chemical Engineering; University of Pittsburgh, April 1990


PMP Certificate

Dupont Project Management

PSM OSHA 1910.119

NFPA Sprinkler/Detection Systems

Bulk Handling Systems

HPWS and Team Building

Mechanical Seals/Pumps


Steam System Design

Six Sigma Training

Summary of Qualifications

Preventive/Predictive Maintenance: CMMS; Maintenance Reliability

Led effort to develop self-directed/HPWS teams before and during startup of DuPont’s manufacturing facility in Uberaba, Brazil.

Supervised construction and startup of a large, flammable raw material storage facility at MAPEI.

Hands-On Engineer

Applied Steam Systems training to Penford plant steam systems.

Created detailed procedures for hazardous maintenance or project functions.

Created numerous bid packages and scopes for projects of varying sizes.

Worked with maintenance departments at several sites to improve maintenance reliability through redesign/replacement efforts and Preventive/Predictive maintenance programs.

Diverse experience in Construction Engineering, Project/Process Engineering, Maintenance Management and Operations Management.

Possess the ability to take charge of projects involving: fire protection, electrical distribution, and obtain the knowledge necessary to meet the project goals.

Able to lead diverse groups\teams to a common goal.

Involved with PSM in all positions

May, 2017 to Oct, 2017 Momentive, Waterford, NY

Manufacturers of silicon products and intermediates.

Project Engineer

Project engineer managing infrastructure projects

Contracted through Planet Forward

2014 to 2017 Wacker Chemical Co., Charleston, TN

Manufacturers of polysilicon used for solar panels and electronic circuitry.

Project Engineer

Managed project to upgrade and debottleneck infrastructure project

Created and administered project management training

Plant Engineer/Infrastructure

Created spare parts lists for infrastructure equipment including cooling tower, water treatment equipment, pumps, instruments and specialty equipment. Also, determined stocking and reordering points.

Setup equipment maintenance contracts for cooling towers, air compressors, filter presses, fire protection equipment, etc.

Created maintenance procedures.

2011 to 2014 Wacker Chemical Co., Adrian, MI

Manufacturers of silicon products for synthetic rubber, cosmetics and lubricants.

Project Engineer

Projects managed and successfully completed on time and under budget:

oInstalled of new 700-gallon synthetic rubber mixer – $5M

oRebuilt existing 500-gallon synthetic rubber mixer – $5M

oInstalled raw material tank farm – $5M

oInstalled intermediate holding tanks – $3M

2009 to 2011 SSOE Inc.

Engineering contractor based out of Toledo, OH.

Project Manager/Engineer

Managing Resource Conservation Projects at Quaker Oats in Cedar Rapids, IA.

Perform project studies on conservation concepts and proposals; Develop scopes/estimates; Submit for approvals; Perform risk assessments; Chair design/review meetings; Develop and implement project plans; Develop schedules, cost estimates and IRR calculations.

Projects up to $500K

Manage projects such as: Flue Gas Heat Recovery, Recycling hot air combustion chambers, Fan efficiency improvements, Dryer efficiency improvements, Compactor installations for recycling plant waste.

2007 to 2009 Penford Products Company, Cedar Rapids, IA downsizing layoff

Produces and supplies industrial, food, and specialty chemical starches for the paper and textile industries. It offers wet end products, size press products, additives, coating products, calendar stack products, and paper laminating adhesives. Headquartered in Cedar Rapids, Iowa.

Project/Process Engineer

Handled field change requests during Ethanol construction. Wrote justifications, estimated costs, wrote scopes and implemented changes. Field changes totaled $4M, or 10% of project total costs.

Engineered and implemented process improvements in Ethanol Process such as chemical addition upgrades, heat tracing/insulation, equipment redesign and equipment/process troubleshooting. Plant startup was successful and on schedule.

Created new pump seal system to replace freezing seal water lines. Heat tracing and insulation not budgeted in project ($250K). Replaced seal water system with closed seal pot systems. Eliminated need for seal water for a cost of $50K.

Project Manager for Ethanol Fire Protection system from design, construction, testing and commissioning. Created bid packages, selected contractors and managed construction. Established inspections and testing procedures and frequencies for Ethanol and revamped plant wide fire protection systems testing procedures. Ethanol Fire Protection System cost of $2M, under budget and on schedule.

Took charge of electrical distribution restoration post 2008 flood. About 45 substations, two high voltage stations and several transformers needed reconditioned or replaced. Organized project team of contractors and Penford employees, led team, developed/strategy/budget and published daily reports. Total costs $2.5M. Electrical systems back on line in 6 weeks.

Identified and revised piping specifications that were outdated or non-existent. Created specification by chemical rather than process description. Piping specifications have reduced stores inventories by standardizing valves, gaskets and piping.

2004 to 2007 Louisiana Pigment Company, Westlake, LA Titanium Dioxide Pigment

Plant Engineering Supervisor- Identify and develop process improvements. Assistance to Operations (ATO). Improve equipment reliability and extend operating life. Specialize in finding and implementing solutions to chronic equipment problems to reduce operating costs and production downtime, incorporating workable solutions for all affected departments, including Maintenance and Production. Forecast and manage maintenance spending. Maintain equipment documentation. Maintain equipment spare parts. Provide engineering assistance to Maintenance and Production.

Diagnosed ore silo restriction to flow. Removed debris and cleaned walls from ten 600-ton silos without a vessel entry. Repaired cones where thickness was low. Restored silo flow to design conditions

Developed and managed capital & major maintenance projects including, but not limited to, the creation of detailed scopes of work, start up procedures, operating procedures, PM procedures, material selection, Management of Change, Hazard Reviews, etc.

Investigated 15-year-old chlorine leakage problem at head of baghouses. Verified that seal material type was correct. Changed installation procedures to eliminate startup leaks. Trained mechanics. Reduced installation time by 50% by eliminating the use of silicon sealant and changing the method of joining the gasket rope ends. No further gasket startup leaks occurred.

Led refractory rebuild and shell repairs of 100’ x 18’ flue scrubs-producing rotary kiln. Shutdown for repairs would shutdown entire process. Selected the sand to replace scrubs. Designed and implemented system to feed process sand and remove spent sand after use. This kept process running for 2 months to repair entire kiln.

Investigated 20yr old chlorine leakage from rotary valve packing causing shutdowns. Replaced packing with specially designed, nitrogen purged mechanical seals. Chlorine leakage and shutdown eliminated. Each chlorine leak caused 4 hours downtime. Leaks occurred 3-4 times a month. Project cost $70K.

Frank R. Kulak, 735 Hampshire Dr, Marion, IA 52302 319-***-**** Cell 319-***-****

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2000 to 2004 BASF Corporation, Batavia, IL Industrial Coatings - Plant Closed

Engineering/Maintenance Manager - Managed maintenance department of five mechanics and one clerk. Managed technical purchasing. Responsible for the development and management of capital budget. Managed projects up to $1M. Led implementation of SAP/TSP. SAP leader and site resource of TSP including Maintenance, Capital Projects and Technical Purchasing. Mentored new engineers.

In charge of SAP implementation for maintenance, capital projects and technical purchasing. Attended SAP training, rolled out program, replaced the use of old systems with SAP, trained personnel and remained a SAP resource for the site. Site succeeded with new systems.

Plant lead for design and installation of portable process tanks. Responsible for installing solvent vessel spray cleaners, construction of building addition, commissioning and startup. New equipment replaced the need for manual vessel washing and associated hazards.

1998 to 2000 MAPEI Corporation, West Chicago, IL Polymers and Adhesives

Senior Corporate Engineer -Provided engineering guidance on all major projects to all Western Hemisphere plants. Major project: Design, construction, installation and startup of Polymer Reactor Unit.

Led expansion project for latex storage. Designed double compartment vertical tanks. Created procedures for installing tanks in low overhead area. Storage capacity was successfully doubled.

Initiated and led process improvements, capital projects, project systems development, equipment feasibility assessments and support of daily operations and maintenance at the West Chicago plant.

Deigned, installed and commissioned heating system for resin storage to replace aging in-tank electric heaters. Installed used steam heat exchanger with simple thermostatic valve. Project completed with minimal cost.

1990 to 1998 E. I. DuPont de Nemours, Inc., New Johnsonville, TN

Titanium Dioxide Pigments

Maintenance Engineering Resource (1997-98)

Led problem solving and solution implementation of maintenance problems.

Led root cause analysis efforts. Dealt with many bulk-handling systems.

Attacked poor bulk conveying reliability of ore system. Changed material of constructions, replaced bolts and fasteners to more durable types and redesigned bearing seals to reduce equipment downtime by 40%.

Project Engineer (1996-97) - Managed projects up to $6,000,000. Projects included process improvements/additions, infrastructure (utilities, civil and waste treatment), D&R (conventional and alternative demolition methods) and general piping/pumping. Used DuPont project guidelines and processes. Managed project to demolish 4-boiler steam plant and install 2-mile steam line from TVA. Involved asbestos abatement and stack demolition with explosives. Project was under $6M dollar budget with no injuries, plant damage or production downtime.

Production Area Manager (1991-96) - $70 million environmental processing plant project from conception through piloting, front-end loading, design, construction and startup. Supervised four shifts of production and one shift of maintenance for 2 years after plant startup. Five direct FLS reports and maintenance supervisor. Total 50 people. Worked with R&D and engineering group to improve processes to reliably support the main TiO2 plant processes.

R&D Engineer/ATO (1990-91) - Product quality improvements, waste minimization, new product development and equipment reliability. Focused on process improvements of unit operations. Specific projects included liquid solid separation, fluid energy mills, bulk handling and filtration unit operations.

Selected as team member to startup Brazilian plant. Focused on the design, commissioning and startup of wastewater treatment processes.

Improved recovery of product from waste streams by 20% at Tennessee plant.

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