Process Engineering Design

Stephen H. Maytag

ENGINEERING EXPERTISE:

Highly motivated project/process engineering professional with varied industrial design, operation, and construction experience which includes chemical, metallurgical, equipment, instrumentation, electrical, mechanical, and quality engineering services.

Experience extends laboratory and pilot plant investigations through estimating and

presentation of AFE requests through detailed design, construction, and commissioning.

Proficient in process design including: Instrumentation and Controls, Piping and Instrumentation Diagram; layouts; specification and selection of controls and instrumentation. Developed ISO 9000 quality control systems. Standardized design to improve engineering and fabrication productivity.

Skilled in application of National Codes and Standards including ASME B16, B31.1,

B31.3, Section VIII, AWWA Piping Codes, ASMT testing standards, ANSI pump and equipment standards, and DEC Area Hazard Classifications.

Extensive experience in both supervision and hands-on analyses, commissioning, and

maintenance of equipment and control systems and application of: reliability programs, statistical analysis, detailed design, installation, and commissioning of chemical processes including: biochemical conversion, specialty chemical production, water and wastewater treatment systems, HVAC, heat and mass transfer, size reduction, material handling, liquid and gas transfer, solids-liquid separation, combustion, refrigeration, piping, ductwork, conveyors, and metering systems.

Demonstrated skills in Failure Mode and Root Cause Analysis, PLC programming,

Microsoft Project, Excel, Access, Word, Maximo, AutoCAD, and FoxPro.

PROJECT WORK EXPERIENCE:

Franklin Energy LLC- Pittsburgh

Energy Engineer II

Reviewed Electrical Saving calculations for to confirm energy reductions and provide bases for Customized Rebates.

AE Resources – Pittsburgh

Process Engineer (part Time)

Revised design of demonstration Biodiesel production plant to provide operable package plant.

PavCon LLC – Pittsburgh

Reliability Engineer (part time) 2019-2020

Developed and made presentations on aircraft equipment and components to employees to help them understand the information collected for development of a new Condition Based Maintenance program for the United States Air Force.

United States Steel Corp – Pittsburgh 2015-2018

Reliability Engineer

Developed equipment hierarchies for multiple plant operations through walk-downs to provide a basis for Reliability Centered Maintenance programs

Worked with Planners to use the hierarchies to properly record work and material usage

for equipment maintenance.

Prepared detailed rebuild specifications for worn or damaged equipment.

Wood Group Mustang, Inc. – Contractor 2014 – 2015

Mechanical Engineer

Complete process and mechanical calculations and designs for gas well pad and compressor station installations. Check drawings, specifications, and calculation by others for submittal to clients.

Larsen and Toubro LLC, Mumbai, Schaumburg, IL 2013 – 2014

Sr. Delivery Leader

Coordinated customer integrated engineering services requirements in the drug, food, and cosmetics industries with off-shore design engineering departments.

Reviewed and revised process, mechanical, instrumentation, electrical and structural

designs and specifications for final submittal to clients.

R. T. Patterson Company – Contractor 2012 – 2013

Sr. Chemical Engineer

Led process and piping design and construction projects in steel, aluminum, and zinc manufacturing plants; and assisted clients with development of expenditure authorization.

Directed the preparation of P&IDS, development of functional descriptions, and detailed

piping and instrumentation designs including evaluating alternate chemical analyzers, controls, and equipment; developing improved operating and maintenance procedures.

SNC Lavalin America – Contractor 2010 – 2012

Sr. Process Engineer

Led the design of process plant to manufacture ceramics and sulfur compounds for various clients.

Developed standard specifications for analyzers, compressors, HVAC equipment,

cooling towers, air pollution controls, maintenance services and material handling equipment.

Management Resources Group, Sandy Hook, CT 2002-2003, 2004-2005 and 2008-2010

Contents Manager / Field Services Engineer

Supervised development of hundreds of additional Failure Mode and Effects Analyses, preventive and predictive maintenance procedures and programs for expansion of this database.

Developed FMEAs and maintenance procedures packages for direct sales.

Provided reliability centered maintenance consulting services for power generation, packaging, food processing, corn milling, and iron ore mining and concentrating facilities

Identified plant components and develop comprehensive preventive maintenance routing procedures by walking down equipment systems in customer plants.

Provided Computer Managed Maintenance services and Failure Mode and Effect and Root Cause Analyses of existing systems to guide design and operating changes and implementation of maintenance programs

CTI Biochemicals Process Development, Pittsburgh, PA 2005 – 2008

Sr. Chemical Engineer

Managed project for the redesign and modifications to demonstration scale biodiesel production facilities to make operation commercially viable.

Provided detailed P&ID, instrument and control specifications, and supervised design

and installation of biodiesel production plants.

Supervised fabrication of modular processing units.

Aquatech Water Treatment Equipment, Canonsburg, PA 2001 – 2002

Field Process Engineer

Provided construction and project management, field process design and maintenance supervision to install and commission water and wastewater treatment plants including operator and maintenance training, laboratory tests, instrument calibration, troubleshooting and start-up supervision.

BECO Engineering Air Pollution Control, Oakmont, PA 2000 – 2001

Chief Engineer

Supervised the design, fabrication, construction and commissioning of multiple highly successful innovative air pollution control systems for chemical and power plants and incinerators including instrumentation, control, structural engineering and conceptual design engineering.

Process Engineer, Contract Employment (Veolia Water EPW, CF Stamping), Ohio and Pennsylvania 1999-2000

Provided process design and project management for water and wastewater treatment systems

Managed field construction of $25 million boiler feed water treatment plant.

Developed manufacturing processes and process improvements for polyurethane components

Supervised production team that fabricated exterior RRIM truck panels.

International Steel Services – Contractor, Pittsburgh, PA 1998

Project Manager

Managed the engineering and construction of a commercially successful $23 million plant to recover hydrochloric acid and produce iron oxide from steel processing wastewater.

Bayer Corporation, Polyurethane Processing Equipment, Pittsburgh, PA 1980 – 1997

Sr. Project Manager

Developed process designs and controls for new profitable products including batch and in-line blenders, closed loop calibration systems and specialized polyurethane reactants handling systems

Standardized process controls, designs, calculations and equipment specifications for

high pressure foam machines to reduce costs and improve product quality.

Provided project management, design, and customer field services to support business teams including preparation and presentation of sale proposals and preparation of failure mode effect and analyses and hazardous operation studies.

Provided successful customized process designs for nonstandard applications including

temperature controls, heating ovens, ventilation.

Project Manager

Managed the design, fabrication, installation, and start-up of 9 equipment projects simultaneously

Consistently controlled projects in the range of $90,000 to $2.5 million insuring that

equipment satisfied customer’s specifications within budget while meeting schedules.

Managed projects involving bulk storage and reactant handling, continuous and batch blending, high pressure foam machines, laminators, lance cylinder RRIM machines and mold fixture conveying.

Provided HAZOP and FMEA analysis of equipment and operations for customers.

Sr. Project Engineer

Successfully supervised completion and commissioning of an activated carbon adsorption water treatment facility, managed extensive field modifications and commissioning of an iron oxide solids treatment system, completed designs and estimates for frit furnace conversions and boiler and burner efficiency studies.

EDUCATI0N:

Colorado School of Mines

Professional Engineering Degree (Silver Diploma): Extractive Metallurgical Engineering

This is chemical engineering degree emphasizing inorganic chemistry. This degree required 176 semester hours 20.5 hours per semester plus two summer sessions. It included electrical, structural, geology, and mechanical engineering classes not normally included in a chemical engineering curriculum.

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