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Engineer Plant

Location:
Newport News, Virginia, United States
Salary:
80000.00
Posted:
November 01, 2016

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Dr. YAW MENSAH

*** ***** ******** *****, **********, VA 23322

(H): 757-***-**** • (C): 757-***-**** • acxbvt@r.postjobfree.com

SENIOR PROCESS ENGINEER

The primary role of the Senior Process Engineer with strong educational background in Thermodynamis and fluid flow is to develop, analyze and optimize the production process in order to support various plants’ operations in an efficient manner to achieve the desired production targets and quality as well as maintain the regulatory, contractual and operating goals. Principal Accountabilities are: - Troubleshooting and optimization of the process systems, Analysis and report of results within SPC standards, Design and improve existing equipment, Flow sheet and Piping and Instrumentation Diagram (P&ID) design, Collaboration in control systems development, Simulation of chemical processes, Commissioning and startup of pilot plant and manufacturing plants, Creating important working relationships with Operations Management, R&D, Engineering and Technology groups, and Vendors/Contractors. I have used Aspen HYSYS v7.3 software for Pump Simulation, Heat and Cooling Simulation, Reactor Simulation for the Superabsorbent plant.

Resourceful and dynamic Chemical Engineer, I combine Knowledge, Skills & Experience with highly academic credentials and extensive experience in equipment design, systems development, and operations for large-scale facilities in the petroleum and chemical process industries. Able to grasp the big picture, focus on critical details, and manage multiple priorities in complex environments. Self-directed leader who can work effectively with cross-functional teams and cultivate strong partnerships with key stakeholders. Committed to adding value and exceeding expectations through creative idea generation, collaborative problem solving, passion for continuous learning, and disciplined decision-making. Demonstrated knowledge of key PSM Technology elements: PHA, Process Technology, and MOC applications to process improvement and process safety standard. Trained, coached and mentored operators on standardized SOP’s, and worked in a team based environment. Demonstrated skill in leadership, team building and achieving results through influence and negotiation as senior process engineer.

PROFESSIONAL EXPERIENCE

CONSULTING WORK REKAFO GHANA LIMITED, Accra, Ghana 2014 - 2016

Lead Senior Process Engineer

Leading the Rekafo Engineering Firm as Snr Process Engineer through effective communication to the Clients in the Construction and Process Engineering projects of Petroleum and Gas Refining Plant, Chemical and Food Processing Plants

Main Projects

Review detailed drawing before construction phase

Visit customer sites for field work and review of construction work

Develop written Scopes of Work as final deliverables detailing the process requirements

Compile detailed project estimates by task and hours spent for successful project start-up.

Manage Scope, Schedule, and Budget effectively

Manage the entire design process from inception to completion. This includes: Leading Projects, Work Planning, Leading Designers, Design Reviews (both internal and with client), and checking deliverables (calculations, drawings, technical reports)

Applying various industrial codes such as ASME and API in sizing and specifying of typical process equipment including, pumps, heat exchangers, pipes, distillation towers, absorption columns, and vapor-liquid separators for processing plant.

Review equipment submittals for accuracy and validate against specifications

Develop and/or verify Mass and Energy balances around new or existing system

Prepare PFD and P&IDs for new processes or redline existing drawings for new functionality

Perform Safety Relief Device calculations as per ASME/API code

Providing Process Engineering support as needed.

Review of system design and develop system operating procedure and train operators.

Develop Preventive Mentinance system and train the maintenance department.

Process Safety review and implementation of MOC.

ARKE.MA CHEMICAL COMPANY, Franklin, VA. 2014 – 2015

Senior Process Engineer, Organic peroxide Polymer Manufacturing

Lead project teams to complete two major capital projects and several small projects in one year.

Manufacturing team leader to transform a 1970 plant into fully automated chemical plant, implementing the following changes: -

Manufacturing

1.Closed all overdue Management of Change and all action items. Updated all procedures and completed file organizations. Also, reviewed all safety critical interlock systems action items.

2.Obtained a zero noncompliance. Worked with Mechanical Integrity (MI) Engineer to complete evaluation of all MI requirement for Organic Peroxide tanks and heat exchangers.

3.Developed a program to identify KPI’s of the manufacturing plant and obtained complete compliance for all Process Hazard Analysis work for the Organic Peroxide plant.

Financials: - Raw Material and Capacity Improvement

1.Monitored product yield and raw material efficiency (lb. of recycle/lb. of product) of a large-scale production system.

2.Managed distillation process improvement for heptane recovery and developed step by step training procedure for operators to troubleshoot column efficiency. In this approach, I converted a given ternary system into a pseudo binary system with heptane/water layer as the lightest-boiling components and organic peroxide as the heavy-boiling component.

3.Reduced waste generation by 20% (lb. of waste generated/lb. of product) of a large-scale production facility

4.Improved raw material conversion factor (lb. of raw material/ lb. of product) and reduced unit cost /lb. of product and improved raw material efficiency by 5%.

Process Improvement

1.Installed PSV’s to minimize Heptane loss and reduce air pollution.

2.Installed mass meters, level and pressure transmitters and also, replaced Teflon lined pipes with 316 stainless steel pipes to improve raw material efficiency and reduce residence time for rate increase.

3.Project team leader to install a second centrifuge system to increase plant capacity by 50%.

4.Recommended and got approval to automate reactor and evaporator steam jets that reduce steam usage by 40% and reduced plant waste by 450,000 gallons per year.

Energy

1.Automation of steam jets to reduce steam usage per lb. of product, higher plant production at 2015 at lower steam consumption below 2014 consumption level. About 40% steam usage reduction.

2.Utility usage per lb. of product, higher plant production in 2015 at lower plant air usage below 2014 Plant air usage. Save 15% compressed air consumption.

3.Number of bulbs and the number of mercury vapor lambs with CFLs replaced.

4.Reduced 2015 Cooling water consumption by 10% below 2014 Cooling water consumption level.

Instrumentation and Control

1.Completed training to provide Risk and Project Management Skills for my employers

2.Provide expertise in the functional design and implementation of process automation applications, such as process control strategies, Human-Machine-Interface design, Manufacturing Systems applications and KPI development

3.Identified and developed cost/benefit analysis for potential new projects

4.Implement overall Advanced Process Control applications, which included developing the design, performing detailed engineering activities, collaborating with various stakeholders to implement the applications as well as operator training.

5.Implemented modern process control applications by replacing old interlock systems. Analyzed and tracked systems performance. Identified and corrected processing problems. Developed and provided additional training to operators in operations and safety when required

OLD DOMINION UNIVERSITY, Norfolk, VA • 2007 – 2013

Instructor Business Economics & Engineering (While in school)

Served as instructor in Microeconomics in a year, then Project Management and Risk Management co-currently as part of graduate teaching assistantship in the engineering management department during my graduate studies. Completed Ph.D. degree in System Engineering and Engineering Management in four years.

Developed experience in Managerial Economics.

Project Management approach to planning, scheduling and controlling.

Risk Management covering OSHA 1910 application to system, process and operation changes.

Taught Business and Managerial Economics at Averett University

BASF CORPORATION, Portsmouth, VA • 1991 – 2007

BASF is a leading global chemical manufacturer with annual sales over $60 billion.

Senior Process Engineer Superabsorbent Polymer Manufacturing

Led the super absorbent business team that created business strategy for manufacturing and financial performance by meeting productivity goals to achieve $3.7 million in cost reduction and $4.2 million yearly cash flow with an annual plant production forecast of $150 million. Collaborated with plant personnel and maintenance team to increase equipment reliability and up-time availability of all processes and equipment. Identified and implemented appropriate control systems to ensure all critical process systems were under control. Responsible the front-end of the plant and wastewater system, managed and maintained the reaction, neutralization system, drying and the plant wastewater operation with 21 operators under my supervision, including three operators at the wastewater department to meet DEQ and HRSD compliance.

Worked with R&D and Marketing group to modify product chemistry that improved product performance for over 30% business growth.

Led and interacted with internal and external technical resources as needed to complete projects.

Evaluated and calculated raw material consumption and production data to determine operational asset utilization, (OAU) calculations and interpretation of process conditions through Statistical Modeling.

Implemented changes in equipment design that improved plant equipment up time by 10% resulting in productivity gains of $1.2 million.

Designed and improved a key process control program, which increased process system’s efficiency and reduced raw material waste by 20%.

Led project team to replace aged reactor then installed and commissioned new reactor.

Modified control strategy that minimized residence time and improved product quality and yield.

Identified and resolved root causes of non-conformance and minimized plant waste generation by 20%.

Reduced wastewater load to HRSD by 25% and reduced suspended solids below 500 ppm that helped bring BOD and zinc levels below compliance levels.

NALCO CHEMICAL COMPANY, Chicago, IL • 1984 – 1991

World’s largest sustainability services company focused on industrial water, energy and air applications generating over $4 billion in annual sales.

Process/Project Engineer - Water Soluble Polymer Manufacturing

Project Team Leader to led a major expansion work at the Vancouver, Washington State plant to double plant capacity and warehouse space at a cost of $750,000.

Successfully commissioned four new products used in oil field drilling applications, water, and wastewater applications that helped increase annual revenue growth by 10%.

As a project team leader, led a team to develop a conceptual design of 300 gallons 316 stainless steel totes and a wash station. The one million dollar Nalco’s “Porta-feed cleaning station” at the company’s Clearing plant in Chicago was to the chemical industry for the first time. The team received bids and awarded the bid to a contractor and managed the construction work to a successful completion of the cleaning station on schedule. The Porta-feed system helped improve on-time delivery of products to customer in returnable stainless steel totes and Nalco achieved unmatched growth in revenue $2.5 million in 1990.

Worked with manufacturing teams and R&D groups to identify and evaluate improvement opportunities that led to product yield and capacity improvement as well as cost reduction projects valued $500,000.

Collected data to identify key measures using plant performance data analysis for variable cost improvement projects.

Efficiently ran distillation column to separate methylene chloride from water, by establishing the equilibrium relationship among the constituents, in a binary system approach. Ninety-five percent methylene chloride was recovered.

UNION CARBIDE CORPORATION, Charleston, WV • 1976 – 1982

Global chemical company with net sales of $10 billion.

Production Engineer Poly Urethane Polymer and Alkylbenzene Manufacturing Units

Managed energy cost reduction, waste minimization, process improvement, and raw material efficiency for both Aky benzene and Naphthalol refining units. Developed daily production schedule for the manufacturing of seven insecticide and urethane intermediate products.

Improved manufacturing reactor efficiency by 10% and distillation efficiency by 15%.

Maintained high levels of product quality year after year without customer complaints for both units.

Completed 100% of plant annual safety review and improved Plant Standard Operating Procedures (SOPs).

Trained operators resulting in significant increases plant productivity and standard practices.

Minimized asset fire-fighting problems and system control loops that yielded 5% improvement in daily operational up-time and also improved equipment reliability by 20%.

Successfully operated wastewater treatment system, revising and modifying wastewater collection and distribution systems. Conducted component analysis and developed strategy for collection and treatment to reduce wastewater effluent loads and saved the company $200,000.

EDUCATION

Ph.D. System Engineering & Engineering Management - Old Dominion University, Norfolk, VA (Dec. 2013)

Dissertation “Measuring risks of interdependencies in Enterprise Systems: An application to Ghana Salt Enterprise”.

M.A. Business and Economics Forecast - Old Dominium University, Norfolk, VA (2005)

M.S. Chemical Engineering - University of Kentucky, Lexington, KY (1984)

Thesis: “An Analysis of Dynamic Interaction in Multi-Variable Process Control in ternary systems”

B.S. Chemical Engineering - University of Kentucky, Lexington, KY (1975)



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