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Machine Learning Software Design

Location:
Ashland, KY
Posted:
June 11, 2024

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Resume:

OSCAR A. ETA Jr.

**** ****** ***. *********: 606-***-****

ASHLAND, KY 4101 Email: ad6daj@r.postjobfree.com

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OBJECTIVE:

Principal Engineer/Director with hands-on as well as directing experience in python and VB.net programming, software design, troubleshooting, automation, modeling & simulation, controls and optimization. Looking to impact an organization by utilizing decades of python, visual basic, C#, SQL server, Javascript and dotnet skills solving challenging problems including engineering calculations for several industries. Seeking a challenging opportunity to utilize my skills in Artificial Intelligence and Machine Learning, coding, graphics and database skills. Experienced in both .net framework software design and python programming. I bring excellent troubleshooting, innovative and programming skills combined with the ability and zeal to learn new technology.

Enrolled in the University of Texas at Austin Post Graduate Program in Artificial Intelligence & Machine Learning: Business Applications.

Background summary:

Over 28 years of engineering experience, Software development and process optimization utilizing process engineering, process control principles and modeling and simulation techniques. Experienced in using Petro-Sim to perform kinetic and LP modeling and Python programming for Linear Programming (LP) and scheduling.

Expert in the design and implementation of Regulatory APC and Model-based, Multi-variable Predictive Controls using RMCT, DMC/DMCplus and Perfecter software packages. SCADA and I- FIX32 HMI experience. DCS configuration experience using Honeywell TDC3000 & Experion, Yokogawa CS3000, ABB 800xA and Fisher Rosemont RS3. Developer and Creator of Software Packages for Calculations and Simulation of Vapor-Liquid Equilibrium (VLE), Batch, Simple, Fractional and Azeotropic/Extractive Distillation as applied to Chemical and Petroleum systems and Reservoir conditions using Equations of State in Phase Equilibrium and Thermodynamics. Extensive use of Chemcad, Hysis and Petro-Sim simulation packages. Program was designed in VB.net and converted to python program. Model Predictive Control and modeling packages used include DMCplus, RMPCT, and Pavilion’s Process Perfecter. Other packages include Tuning,

Expert .NET Programmer (VB, C# and C++) and sole developer of numerous software packages including PID controller tuning package. Over 18 years of .Net experience. Scrum Developer Certification, Scrum Master Certification and Scrum Product Owner Certification. Work Experience:

Sr. Modeling & Sim Engr: - Marathon Petroleum Co., Corp Ops Research., OH. (06/20 - Present)

• Assess/develop LP partials, build models for Petro-SIM full-plant applications, and support catalyst selection, project evaluations, and kinetic model tuning to test run data. Developed LP partials for FCCs and non-linear models for Reformers.

• Developed python code to mimic LP calculations for troubleshooting of LP solutions.

• Currently developing python codes to perform Linear, non-linear and neural network regressions, statistical analysis and deep learning algorithms to the development of Reformer models.

• Continuing to utilize advanced machine learning techniques, including deep learning, NLP, computer vision, and reinforcement learning, to create innovative solutions.

• Develop predictive models and integrate them with Business Intelligence tools. Optimize model performance by addressing issues such as overfitting, underfitting, and bias.

• Continuing to develop and maintain data pipelines for efficient data retrieval and processing. Collaborating with applications and data engineering teams to deploy models at scale.

• Currently leading multiple data science projects, ensuring alignment with business goals. Engaging with Senior Leadership to inform strategic decisions using business intelligence insights. Constantly improving models with recent technological advances.

• Researched and adopted cutting-edge technologies and methodologies in data science. Continuously conducting exploratory data analysis to identify patterns and insights.

• Provide technical support to engineers using process and kinetic models. Serve as point of contact for troubleshooting and knowledge transfer/training.

• Utilize KBC’s Petro-Sim software package for plant simulation and crude assay management.

• Developed code using .NET languages. Upgrading, configuring and debugging existing systems. Providing technical support for desktop or mobile applications in an agile environment.

• Set Petro-SIM applications to calculate the SCD parameters for crude units. Also performed testing of the closed form SCD in PIMS v11 for future use corporate wide. Sr. Production Planning Engr: - Marathon Petroleum Co., Catlettsburg Ref., KY. (01/20 – 06/20)

• Improved refinery margins by updating refinery planning models with a streamlined planning model update workflow using process simulation solution calibrated to plant data. Responsible for ensuring the accuracy of shared assay data between planning and process engineering tools.

• Responsible for the continuous incorporation of new and specialized non-linear constraints such as oil price changes, crude quality, increasing and new demand patterns, stringent environmental regulations and new production capabilities into large-scale complex refining schemes using Aspen PIMS.

• Designed and implemented a distributed system using Python to simulate a multi-node environment on a machine. Utilized Python's multiprocessing and multiprocessing.managers.Base Manager modules to create and manage a shared task queue and result queue. Developed and coordinated a master node to distribute tasks to worker nodes, which processed tasks and returned results. Managed task distribution, task processing, and result collection, demonstrating effective parallel processing and inter-process communication.

• Utilized KBC’s Petro-Sim software package for plant simulation and crude assay management.

• Utilized advanced machine learning techniques, including deep learning, NLP, computer vision, and reinforcement learning, to create innovative solutions.

• Ideated and prototyped new solutions to meet emerging business requirements.

• Performed exploratory data analysis to identify patterns, insights, and communicate findings.

• Managed stakeholder expectations and delivered actionable solutions.

• Responsible for overseeing data processing pipelines ensuring data quality and consistency.

• Developed and maintained data pipelines for efficient data retrieval and processing. Collaborated with applications and data engineering teams to deploy models at scale. Sr. Refinery Engineer: - Marathon Petroleum Co., Catlettsburg Refinery, KY. (10/14 – 01/20)

• Involved in all facets of optimization of process units including implementing innovative solutions that have improved Operator understanding and reduced Operating interactions with the process. Modified and upgraded many unit controls from Bailey system to ABB 800xA.

• One of two plant wide APC engineers. Responsible for maintaining APC applications in the Crude/Vac/SGP complex as well as participating in new APC controller conception and implementation.

• Part of a developer team that produced several small software packages using the .NET languages

(C#, VB .NET) and python programming in an agile environment.

• Lead the development team in designing, developing, and implementing software requirements incorporating stakeholder, Operations and Management inputs. Facilitated several products through completion of all items, acceptance testing and deployment to plant environment.

• Provided functional expertise on Refinery and Petrochemical processes, Controls, Advanced Controls and Automation of Refinery systems.

• Developed project timelines and managed budget and resources to ensure on-time and on-budget delivery while ensuring the software packages were developed using best practices and industry standards.

• Troubleshot and resolved technical issues that arose during the development process.

• Conducted training sessions for Operations personnel to ensure optimal utilization of the software.

• Recently configured all the control strategies including innovative advanced control solutions and SIS system interface solutions for a new 320 MMBTU/HR Boiler on the DCS system. Overall solution utilized cross-limiting controls strategy which was first of its kind in the refinery. Boiler utilizes more than one fuel type. In addition to successfully handling all the fuel related challenges, other innovative controls were implemented to address weaknesses of the traditional cross- limiting controls scheme. The new Boiler utilizes the only Part 75 CEM analyzer in the refinery which provided extra interfacing and configuration challenges. These challenges along with all others were overcome successfully without impacting the schedule.

• Solely responsible for the implementation of advanced regulatory controls and optimization on the Cumene unit that has prevented in excess of 20 slopping incidents annually in addition to providing $millions in energy savings and increased throughput. The unit columns were modeled using my proprietary software package to provide relationships between variables to allow operating at a wide range of conditions rather than the traditional one operating point. These relationships were then integrated into innovative advanced control applications. The unique and transformative advanced control strategies push the cumene unit towards optimal product specs, minimal cumene in recycle stream, optimal reflux rates, minimal cumene in waste stream and proper distribution of feed to the two product cumene columns. Finally, benzene addition control was added to minimize process upsets from benzene inventory in the system and to optimize benzene usage.

• Implemented the Crude unit RMPCT advanced controller and optimizer which optimizes Kero and Diesel production, optimizes pre-heat and minimizes overall energy usage, handles heater constraints and meets all product specs. Singlehandedly conceptualized, developed and implemented the advanced controller and produced all necessary documentations. Continuously work with planning group to ensure RMPCT meets all product specs and targets. The controller consistently pushes feed towards the maximum limit with an increase of 450 – 750 bpd over operator rates.

• Responsible for developing regulatory and advanced control strategies on the TDC3000 and ABB 800xA DCS controls system with Experion graphics. Implemented several profitable DCS resident APC schemes in the Utilities and Crudes areas. Involved with scoping APC (both DCS and model-based) opportunities in other areas.

• Led automation activities using the ABB 800xA DCS system. Performed FAT and SAT for the Sulfur and GOHT units.

• Plant representative for Alarm Management and Operating Limits. Organize and conduct meetings with Operations, HES and other department limit owners to re-rationalize alarm limits, Consequences and Steps to correct. Update and maintain alarm database. Help other control engineers in the rationalization efforts as well as preparation of the updated database. Represent site on monthly meetings and annual face to face meetings. Responsible for developing site specific alarm documents.

• Process Control lead engineer for the Crude/Vacuum/Sat Gas Plant (SGP) and Utilities Complexes. Responsible for coordinating with Operations department for the optimization of all units in both complexes. Responsible for leading controls related MOC meetings and coordinating alarm changes. Responsible for upgrading several control schemes with new technology with or without equipment retrofit.

• Utilities area engineer responsible for new designs and equipment upgrades. Implemented innovative variable Softener Totalizer Setpoint logic to reduce overall brine use during times of low river water hardness as well as several other closed loop controls using analyzers and inferred values.

• Lead control engineer responsible for adding output (both analog and digital) I/O redundancy to live ABB 800xA DCS systems. The project involved upgrading to AO_16 and DO_32 modules and adding new IOPs.

• Developed a new and innovative control strategy that improves Boiler Windbox O2 controls and helps reduce NOx emissions by more than 20%. This strategy now controls the O2 to a target level utilizing the Flue Gas Recirculation (FGR) louver as a primary control point solving a problem that plagued the refinery for many years.

Sr. Refinery Engineer: - Marathon Petroleum Co., Detroit Refinery, MI. (05/11 - 10/14)

• Technical Service Lead engineer for the NHT, KHT and CCR units. Responsible for coordinating with Operations department for the optimization of the units. Responsible for leading MOC meetings, setting scope and priorities and driving the projects to completion. Other responsibilities involve updating PI calculations and graphics, carrying out engineering calculations on the ABB 800xA DCS system to evaluate the performance of units, sending out weekly and monthly reports and working with the engineering department on decision packages for upgrades and new additions.

• Lead control engineer responsible for an entire refinery complex which included Alky unit, Gas Oil and Distillate Hydrotreater (GOHT & DHT), SRU, Amine, Tail Gas and Wastewater treatment areas. Also involved in the Crude, FCCU and Coker controls and optimization. Made several improvements on the Sulfur block have yielded over a million dollars of savings in the past year.

• Developed ABB 800xA programming that allowed plant operations to control process manufacturing equipment and production.

• Performed several advanced controls schemes using the ABB 800xA DCS system.

• Utilized ABB 800xA Control Builder, Graphics Builder, and the Process Control Device Library to build complex control schemes.

• Responsible for developing new control strategies as well as reconfigure existing ones using Honeywell Experion, ABB 800xA, Bailey DCS and Triconex safety systems. Part of the DHOUP team for the revamp of the entire refinery and upgrade of the control system to Honeywell DCS, graphics and foundation field bus. One of two engineers responsible for creating configuration standards during the conversion from older Bailey and TDC3000 systems to Honeywell Experion for the entire refinery. Modified and upgraded many unit controls from Bailey system to ABB 800xA.

• Involved in all facets of optimization of process units. Responsible for developing regulatory and advanced control strategies on the Honeywell Experion PKS.

• One of two APC engineers responsible for the development of Advanced Process Control (APC) strategies for the entire refinery. Recently completed work on GOHT APC produced unexpected savings of nearly $400,000/yr.

• Lead distillation expert. Help to train other engineers on distillation and controls. Contract Engineering Consultant: - Dow Chemicals; Freeport, Texas. (10/10 – 05/11)

• Involved in conceptual design of multiple process and controls strategy updates. Reviewed and updated P&IDs to reflect new plant design changes.

• Lead DCS configuration efforts on the ABB 800xA system. Involved in the automation an configuration of several manual tasks on the ABB 800xA DCS system.

• Involved in both loop testing and functional testing including instrumentation and safety system

(ISS) testing and process functional testing using the ABB 800xA system.

• Part o the team that reviewed ABB Hardware and Software design. Engineering Consultant/ IT Director: - UDS.; Paducah, KY & Portsmouth, OH. (05/09 - 08/10)

• Directed a team of software engineers in creating several in-house applications using the .NET framework. Applications connected to common database created and maintained the team.

• Performed exploratory data analysis to identify patterns, insights, and communicate findings.

• Managed stakeholder expectations and delivered actionable solutions.

• Responsible for overseeing data processing pipelines ensuring data quality and consistency.

• Drove ethical considerations in model deployment and data utilization.

• Collaborates with external partners, research institutions, and subject matter experts to gather domain-specific knowledge and dataset.

• Directed the development team in designing, developing, and implementing software requirements incorporating stakeholder, Operations and Management inputs. Oversaw the work of the Technical Product Lead Engineers through completion of all items, acceptance testing and deployment to plant environment.

• Provided functional expertise on Refinery and Petrochemical processes, Controls, Advanced Controls and Automation of Refinery systems.

• Developed and managed project timelines and managed budget and resources to ensure on-time and on-budget delivery while ensuring the software packages were developed using best practices and industry standards.

• Directed and led the development of the SCADA system for a new Depleted Uranium Conversion plant. Activities include developing, verifying, modifying and testing control system design and updating programs as necessary on ABB 800xA system and AB PLC-5 with RsLogix 500 software. Developed additional base-level control algorithms for many of the process systems.

• Involved in both loop testing and functional testing including instrumentation and safety system

(ISS) testing and process functional testing. Developed DCS trends for DOE facilities to aid with functional testing. Reviewed and updated P&IDs to reflect new plant design changes.

• Cybersecurity program Director. Provided leadership and administration of daily operations and strategic planning for the Cybersecurity program including resource management. Contract Director of Engineering: - Sriya Innovations, Inc.; Marietta, GA. (02/09 – 05/09)

• Directed all engineering aspects of a bio-refinery startup project. Supervised the lab scale development of products including controls and optimization of process parameters. Reviewed process design of new pilot plant. Defined and developed controls and optimization schemes.

• Responsible for applying thermodynamic principles in the biotechnology industry project.

• Developed control schemes for pilot plant as well as advanced control schemes for commercial plant. Each control scheme was designed to meet specific requirements and took into account the operational requirements, cost, customer requirements, safety and schedule. APC/Applications Consultant/Supervisor: -Maverick Tech.; Houston, TX. (09/06 – 02/09)

• Lead Applications Consultant & Supervisor on Yokogawa/Maverick Alliance for Chevron

(YMAC) team responsible for the standardization of all applications that reside on the Process Control (PCN) and Control System (CSN) networks including interfaces for all Chevron fully owned refineries. Provided quarterly face to face presentations to Chevron.

• Lead Applications Consultant & Supervisor on YMAC team responsible for control system configuration and graphics design on the Yokogawa DCS for Chevron facilities. Travelled to several Chevron facilities to as part of the team that reviewed ABB Hardware and Software design for Chevron facilities.

• Production Consultant for Rohm & Haas. Single-handedly upgraded the Flocculant grade acrylic acid (FGAA), glacial acrylic acid and two Separations area DMCplus controllers. Developed and refined AspenIQ inferential calculations. Involved in the startup of processes after re-design.

• Managed the troubleshooting of start up problems on revamped Dehydration column which used MIBK to form an azeotrope with water. Utilized strong knowledge in chemistry, chemical engineering and distillation to continually solve plant problems.

• Developed and implemented MPC using DMCplus on revamped Dehydration/Crude columns. Sr. Advanced Control/Applications Engineer: - Praxair Inc. (05/04 – 09/06)

• Responsible for project management and scheduling. Activities include contacting and working with plant personnel, making sure plant is ready, developing schedule, assigning tasks and making sure the project is within budget. Implemented over 4 APC(DMCplus) projects annually.

• Gathered information, conceptualized controller design, developed and performed step testing, process modeling, and APC implementation. Developed FIX32 interfaces and Database controller tags. Analyzed measurement and prediction errors to enhance controller performance.

• Trained operators and provide detailed user documentation and project execution manuals.

• Developed detail benefits calculations to justify project and also to set a benchmark to measure the controller’s future performance. Successfully led effort to standardize benefits calculations for the entire range of ASU plant designs for Praxair. Sr. Process Controls Engineer / Director of Engineering: - Artcon Inc. (02/02 – 06/04)

• Designed and developed Vapor/Liquid Equilibrium (VLE)/Distillation Calculations software using equations of state. Utilized software to Characterize Chemical and Petroleum systems. Systems included Reservoir conditions for Enhanced Oil Recovery (EOR) and chemical plant units. Developed Phase Equilibrium data for many multi-component as well as binary systems.

• Analyzed reservoir data to develop P/Z vs Inventory graphs for gas inventory verification.

• Generated production forecasts for existing wells and recommended reserve bookings based on performance. Data was utilized to recommend rate and recovery predictions for future wells.

• Responsible for software sales to major manufacturing companies including Sunoco.

• Developed specialized engineering calculations involving distillation and heat transfer to optimize various facets of operating units. P&ID design.

• Responsible for the design and implementation of process enhancements for existing and developmental products. Utilized Neural Network technology to develop inferential models. Sr. Applications Engineer : - Pavilion Technologies Inc. (10/00 – 02/02)

• Developed advanced control applications and new strategic applications for the polymers and olefins process industries. Designed and built control strategies for Polyethylene, Polypropylene and PIB plants using the Multivariable non-linear PERFECTER software.

• Built Virtual Online Analyzers (VOA for Formosa Plastics and BP to reproduce plant analyzer values on DeltaV DCS. Applications were utilized mainly in the Power and Air Pollution CEM Controls (Nox reduction) areas.

• One-year residence in Belgium developing Virtual On-line Analyzers (VOA) and MPC solutions for BP Geel’s innovene polypropylene process. Solely responsible for the control and optimization of said plant. Developed VOAs that were over 95% accurate.

• Managed project to ensure all the deliverables and milestones were completed on time and that client fulfilled their commitments. Reviewed and managed project and general specifications, engineering procedures and engineering policy.

• Developed graphical interface for operations to monitor controllers on TDC3000. Built complex routines for calculations and biasing of inferential properties on TDC3000.

• Trained operations personnel and provide ddetailed user documentation and execution manuals. Sr. IT Software/Application Engineer: - Equistar Chemicals, (09/99 – 07/00)

• Developed software programs using visual studio vb.net that performed extensive and specialized engineering calculations that could not be performed on the Distributed Controls System (DCS). The software solutions were built on visual studio

• Worked with the chemical, mechanical and civil engineering teams to understand their software business needs and developed appropriate application solutions to integrate these needs.

• Continuously upgraded and tested these software packages before deployment, sometimes to live systems.

• Worked with Control systems engineer to develop advanced controls schemes on the DCS. Process/Process Control Engineer: - Mobil Oil Corporation (Later ExxonMobil), (10/97 – 09/99)

• Reviewed scopes of work, budgets, commitments, schedules and progress for new Cyclo-hexane unit. Involved in a Cyclo-hexane unit start-up, ensured that the new process and products met requirements, produced documentation and transferred technology to production.

• Upgraded DMC controllers to DMCplus for entire plant. Built Furnace DMCplus controllers for entire plant. Cyclo-hexane unit Loop Check for controls, alarms, and shutdown sequences.

• Developed Alkylation, Benzene/Toluene Splitters, Methanol, MTBE Ethylene/Propylene splitters, Bleed stripper and Saturate Gas Plant controllers.

• Developed Advanced Control schemes on the DCS to control polyethylene. In the process of developing a software package for polyethylene and polypropylene advanced controls.

• Maintained the Delayed Coker, Catalytic Hydrotreater, Hydrocracker and Fluid Catalytic Cracker. Secondary tasks included implementation of advanced Regulatory Control schemes. Control Engineer: - Honeywell Profimatics, Houston, TX, (09/93 – 10/97)

• Involved in the development and programming of Silo controls for Westlake polyethylene plant.

• Developed preliminary design, built points, and developed DCS graphics to be installed on Customer sites at Phillips Borger and Basis Petroleum. Involved in building an FCC Controller.

• Extensive AM/CL programming and HPM/CL programming, point building and configuration, LCN and UCN components building, fail-safe logic configuration and logic points building. Education:

B.Sc. Hon.:Chemical Engineering GPA:3.7/4.0 MINOR:Mathematics/Computer Science Prairie View A & M University, Prairie View, Texas, August 1993 M.Sc. General Engineering with emphasis in Chemical and Petroleum. GPA:3.8/4.0 Research Project: Reservoir Simulation of CO2 flooding in Enhanced Oil Recovery (EOR) using Equations of State Compositional Analysis.

Prairie View A & M University, Prairie View, Texas, December 1998 Professional Examination / Registration: Engineer in Training (EIT/FE) Certificate. April 1998 1 year of Law school at Hamline University School of Law.



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