Engineer Process

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Robert Adair, P.E.

Senior Process Chemical Engineer

OVERVIEW

I have experience in plant operations, engineering, and construction working on projects in the refining, chemical, petrochemical, and polymer industries. My recent skills are in the areas of relief device sizing scenarios, evaluations and documentation in compliance with OSHA requirements. My Process Engineering responsibilities have included heat and material balances, PFD development, P&ID development, equipment specifications including datasheets for smart P&IDs, instrument specifications, relief valves and flare systems, safety evaluations, and process hazard reviews. I have held positions as Senior Staff Process Engineer, Principal Process Engineer, Senior Supervising Process Engineer, Process Engineering Manager, Plant Technical Supervisor, and Project Manager. I have led teams, projects, and process engineering.

My experience includes leading process engineering execution of revamps and expansions under a fast-track schedule and with minimum downtime.

In technology I developed expertise in HD and LD polyethylene, polypropylene, and EPDM production processes, and design experience with adipic acid. I have experience in refinery operations in alkylation, heavy oil processing, hydrotreating, and ultracracker. I have moderate experience in process simulation (HySys, SimSci, Pro/II, and Aspen Plus), heat exchanger rating and design (HTRI).

SUMMARY OF EXPERIENCE

Projects:

Chemical

Petrochemical / Polymer

Refining

Process Design

Midstream

Technology Development

Expansions and Revamps

Grassroots Facilities

Competencies:

Licensed Professional Engineer

Relief device scenario analyses,

sizing and selection of PRD’s,

and documentation

Simulations / Modeling

New Technology Development

Polymer Systems

Crude Processing

Solids Handling

Reliability Modeling

Separation and Purification

Systems

Robert Adair, P.E.

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2010 – Present S & B Engineers and Constructors, Ltd. Senior Staff Process Engineer

BASF Projects – Freeport, TX and Beaumont, TX.

I was Lead Process Engineer for several projects along with a small group of Process Engineers performing revalidation and thorough documentation of relief devices for several operating process units and utility support systems. I performed relief device evaluations and documentation. I reviewed evaluations performed by other Engineers developing and documenting valid scenarios and cases that govern sizing of existing relief devices. Over 400 pressure relief devices evaluated over three years. LEMM Corp.

I provided process support for an instrumentation upgrade project at an Illinois ammonia terminal, providing process narratives, process data for instrumentation and cause and effect diagrams, relief devices and P&ID updates. I was Lead Process Engineer for revalidation of relief devices at four terminals for ammonia and other chemicals. The summary total was nearly two years of effort involving over 250 PSV and tank relief devices.

OLIN Corp.

A group of three plant areas required revalidation of some PSV’s within their operating facilities. I performed calculations and led a group of Process Engineers in revalidation calculations and development of process PSV folders or packages for documentation. There was a total of 26 PSV’s in this work.

INEOS Olefins & Polymers, USA – Alvin, TX

• I led Process Engineering in a series of small projects being implemented leading into or as part of a major turnaround at Chocolate Bayou Works (CBW). Process group provided datasheets for several modifications, including water wash tower and caustic tower replacement of internals, a decoking cyclone, a dilution steam reboiler, a large condensate pump, et al. Process reviewed modifications for pressure safety requirements and revisions that required SIS/SIL instrumentation. Provided process data for instrumentation and piping, and P&ID modifications. Modeled plant networks for nitrogen systems to identify limits.

• I was Lead Process Engineer for the modifications to an LPG processing facility for INEOS in West Texas. Modifications were the result of LOPA recommendations and included SIS/SIL instrumentation revisions to satisfy safety requirements. Performed conceptual engineering and design specifications for a new high pressure flare, and the processing of collected flare liquid for an existing flare. Facilities were designed for the collection and vaporization of liquid collected following a major relieving incident.

• Conceptual studies were performed for two systems in the CBW olefins units. The first study was to define needed upgrade requirements for condensate handling from a cracked gas compressor, turbine drive, and surface condenser. The canned pumps have limiting capacity and are near EOL. Primarily this was an ongoing pump replacement project that had NPSHa and other limitations to overcome in the condensate handling system.

• The second study defined a permanent installation of air compressors in two olefin units that provide decoking air for the various furnaces contained in each unit. Decoking used Robert Adair, P.E.

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a bank of portable air compressors at each location. These also provided supplemental plant air. The plant air and decoking networks were simulated using SiNet. The project planed to install flooded screw compressors to service the need. BASF Projects – Freeport, TX

• I was Lead Process Engineer for studies of several potentially large revamp upgrades for the Freeport facilities of Anone I, Anone II, and common distillation systems. Process performed detail conceptual design of the recovery and distillation systems involved in these Anone processes using HySys simulation. Process also developed simplified PFD’s via VISIO and estimated new or revisions for about 100 pieces of equipment in each study. These studies expanded into potential projects to upgrade the yield and flexibility of the Freeport Anone production facilities. Dow Chemical Projects – Freeport, TX

• I used Epcon’s SiNet network program simulation to model the OSBL potable water distribution facilities at the three major plant facilities at Dow’s Freeport, Texas site. Network distribution updates were needed to allow monitoring of current operations and capacity limitations, and to simulate future needs or excursions in potable water usage.

• For EDC plant life extension and compliance projects, I developed hydraulics via SiNet modeling and equipment datasheets for a small refrigeration unit and several pumps.

• I performed extensive analysis of the steam and condensate systems added to the facility and provided process data for new instruments in the steam/condensate system.

• I used Epcon’s SiNet network modeling program to model the OSBL condensate network in at Plant B in Freeport. The finished model allows Dow to monitor and simulate current and future needs in condensate production and usage.

• I assisted with the final process design, especially P&ID’s and process data for instruments for a new purification (drying) unit for propylene in an Allyl Chloride Unit. Cargill Plant Upgrade

I was Lead Process Engineer during a large, developmental, revamp project expansion to a Cargill plant producing an artificial sweetener. Expansion included over 100 new equipment items and an equal number of existing equipment evaluations to be performed. I supervised process engineers and participated in conceptual process design through detail engineering. Process developed detail process datasheets for equipment, provided input to conceptual design, P&IDs, H&MBs, performed hydraulic calculations, line list data, relief valves, and process data for instrumentation. 2004 – 2010 Jacobs Engineering

• I was Lead Process Engineer for several small projects (<$10 million) for revamp and upgrade for the BP Texas City Refinery. Primarily these were modifications and compliance projects for the refinery. I utilized existing HySys models and PI programs for the units to develop and refine process data for modifications. Process revised P&ID’s, and provided process data for equipment and facility modifications, including a seal flush isobutane system with a drying purification package. I participated in HAZOPS, MOC, LOPA’s, and other programs required for the modifications.

• I was Process Engineer for a grassroot adipic acid plant for Chevron Phillips in Saudi Arabia. The design was based on the licensor’s technology used in several existing plants. There was no heat and material balance data available. Design included production of adipic acid from reaction through to final packaging with unique Robert Adair, P.E.

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considerations for significant corrosion and undesirable side reactions due to the acidic environment. “Unlocked” the composition codes used on existing P&ID’s to functionally define the stream compositions so material of construction selections could meet the corrosion concerns. I was responsible for conceptual development of P&IDs and process datasheets for equipment of the adipic acid plant, part of nylon 66 production facilities.

• I was Process Engineer for an EPDM polymer plant PDP, for Exxon Mobil, Saudi Arabia. I helped develop finishing area P&ID’s and associated Zyqad datasheets. I assisted with development of the performance specs for major equipment in the finishing and packaging portions of the plant. I developed P&IDs and equipment datasheets based on the design input of the licensor of the technology. I conceptually designed innovative new features for the pellet water system of the extrusion process to effectively allow fines separation from the pellet water.

• I was Lead Process Engineer for an alky unit upgrade project, BP, Texas City, Texas. Modifications included replacement of critical pumps that were at end of life and defining and installing a new pump seal flush drying and distribution system to the critical pump seals in the Alky unit. Performed detail process design including equipment specs, P&IDs, and hydraulics. Timing of the projects was critical to planned shutdowns.

• I was Process Engineer for Whiting Atmospheric Relief Project Upgrades, BP, Whiting, Indiana. I was responsible for process design including equipment and P&ID revisions for reactor blow-down systems tied into the existing flare.

• I was Process Engineer, Alky Unit Upgrade, BP, Whiting, Indiana. Performed conceptual and detail design and development to upgrade an existing Alky unit spent acid handling system. Design included recovery and storage of spent acid, integrated into existing flare facilities. Developed a conceptual design for a neutralization basin used for the collection, and neutralization of waste spent acid streams.

• I was Process Engineer, for offsites and utilities, at Premcor’s, Memphis, Tennessee refinery. I developed conceptual design for tie-in of process and utility streams for a new diesel hydrotreater, and other active upgrade projects. They included tie-ins for a new sulfur recovery unit, a new sour water stripper, and a benzene stripping unit into the main complex infrastructure. I modeled the refinery steam distribution and condensate recovery system material balance.

2002 – 2004 Technip, USA Corp.

• I was Senior Supervising Process Engineer for a refinery upgrade project. Process developed conceptual design revisions via a series of proposal reports, based on pending TCEQ Chapter 115 regulations, regulating VOCs and HRVOCs in the refinery. These reports served as the basis for selection of modifications and evaluation of cost for the pending regulations.

• I was Lead Process Engineer for a grassroot HDPE facility, Chevron Phillips in Cedar Bayou, Texas. I supervised several Process Engineers during the EPC execution. Facility was successfully started up in 2003, and currently is operating. Extensively was involved in the HAZOP/PHA of the new design.

2000 – 2002 ECI, Inc. Process Consultant

• I was a Process Consultant for tubular polyethylene reactor train modifications for Equistar. I developed process design modifications and preliminary P&IDs to modernize, increase capacity, and expand the mix of produced polyethylene products.

• I developed conceptual design of a state-of-the-art, emergency blow down processing system for reactor dumps from high-pressure polyethylene reactors. HySys was used to Robert Adair, P.E.

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simulate the system. The design satisfied process and environmental requirements for containment of releases.

Robert Adair, P.E.

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1985 – 1992 Bechtel Corp.

• I managed engineering projects for Union Carbide through the joint partnering agreement and was Manager of Engineering for the Union Carbide / Bechtel Association.

• I was Project Manager for a $35 million revamp project to a UCC Seadrift, Texas, polyethylene unit for producing a new family of elastomers. This developmental project required significant evolution in conceptual design, and revised project execution. The final installation met all UCC expectations for this type of project execution and became an example for future projects.

• I led a task force effort that developed the work-process model for cooperative project execution in the UCC Association.

1978 – 1985, 1992 – 1999 KBR – Brown & Root Inc.

• I served as Process Engineering Manager / Process Engineer. Supervised Process Engineers and conducted technical audits as necessary to ensure compliance with safety requirements and ISO 9001 standards. Led teams in defining and developing large-scale projects and proposals. Evaluated staff, making project assignments that maximized productivity. I directed development of process engineering proposal for construction of a major petrochemical complex.

• I was Lead Process Engineer, Offsites Studies for Qatar. Scope included integrating existing facilities and a new petrochemical complex. This involved a trip to Qatar.

• I was Process Engineering Manager / Process Engineer for a Polifin polyethylene revamp project that involved several trips to South Africa. The project modifications successfully increased capacity by 25% while adding new product capability.

• As Lead Process Engineer, I directed a staff of Engineers in the development and documentation of a polypropylene licensing package based on new catalyst technology.

• I evaluated process technology alternatives for polymerizing naphtha cracking products. Licensing bids were solicited, and I developed a unique method to compare and rank processes, narrowing choices for client analysis.

1970 – 1978 Dart Industries, Inc. (Rexene Poyolefins)

• At Rexene, Bayport I was Technical Superintendent for a grassroots polypropylene plant in Pasadena, Texas. I Supervised and trained three Process Engineers during commissioning, start-up, and ongoing operation of the polypropylene plant.

• I was Senior Process Engineer at Rexene in Odessa, Texas. I was closely involved with two new polypropylene plant start-ups.

• As Process Engineer, I planned and executed experimental polypropylene production runs that exceeded expectations. I analyzed process operating data to determine operating conditions that produced superior product. Based on findings, I developed key parameters that guided future successful runs, spawning a new line of high impact polypropylene copolymer products. This led to commercialization and production of high impact copolymers for new markets.

EDUCATION

University of Colorado

B.S., Chemical Engineering

CERTIFICATIONS

Registered Professional Engineer, Texas – No. 74386 Active TWIC card

Active VISA

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