Process Engineer
Resume:
Houston TX *****
Douglas Chiau Funn Ma
*******.****@*****.***
Process Engineer
Dedicated, innovative, detail and process-oriented, customer focused professional with process design and 15 years mid-level management and manufacturing experience in the chemical industry. Successfully initiated capital and process improvement projects, managed Mechanical Integrity and Reliability programs, assisted FEED development, drive quality audit programs, new product development, ISO internal audits and process control initiatives.
Career Experience
Power Win Tech, Houston, TX April 2021 till current
Process Engineering Consultant
Instrumentation equipment service provider
Support customer base in process information requirements to integrate with control systems
Commissioning assistance in new control system installation
CF Industries, Woodward, Oklahoma
Leader in Nitrogen products (Urea, Ammonium Nitrite, Ammonia, Nitric Acid) manufacturing.
Process Engineer April 2019 till April 2021
Supported the Upgrade Plant with day-to-day process engineering needs and activities, e.g. troubleshooting, data analysis, technical support, etc.
Initiated, designed, executed and managed various capital and non-capital projects to improve safety, efficiency, mechanical integrity reliability and operability of the process equipment.
Worked with the EHS team to comply with various permit conditions and limits, e.g. perform event calculations, establish process variable limits, manage the allowable release quantities of various gases, etc.
Actively participated in turnaround activities, e.g. daily schedule planning and execution, equipment inspection and validation, help maintained uniformity by confirming the correct parts are dismantled, worked on and replaced, provide daily instructions to employed contractors and in house employees, logged daily findings and activities into turnaround report, etc.
Actively participated in all Upgrade long and short gauze activities, e.g. determine feasible project schedule, execute various MOC and capital projects, equipment inspection and validation, etc.
Monitor (through PI and DCS and manual data entries) and report Key Performance Indexes (KPIs) of key equipment and provide short- and long-term resolution inputs for performance improvements.
Participated, reviewed, evaluated and executed changes recommended by Process Hazard Analyses (PHA) audits
Participated in corporate wide Best Practice Meetings to communicate and implement various Best Practice Initiatives throughout the whole organization.
Lead, participated and provided technical support in various incident investigations / Root Cause Analysis
Chemtrade, Syracuse, New York
Specialty chemical manufacturer. Syracuse site manufactures Sodium Nitrite.
Process / Project Engineer January 2016 till April 2019
Managed, lead and executed all engineering efforts within the facility
Oversaw all production issues and participated in numerous troubleshooting efforts through observing and explaining the cause for abnormal behaviors, generating solutions, executing cost effective solutions and performing process improvements efforts.
Created, justified, scoped, managed, supervised, executed, commissioned and completed multiple capital investment projects ranged from $50k to $5 million.
Managed the site’s annual $2 million capital investment budget and portfolio. Utilized SAP to create, manage and approve purchase orders, manage project budgets, commitments and receivables. Reported monthly capital forecast, project spending and financial analysis for new projects to corporate representative.
Worked with external consultants for FEL (Front End Loading) design and scoping to generate +/- 15% budgeted project cost estimation and RFQ (Request for Quote) deliverables.
Coordinated and planned annual turnaround outage schedule as a site Project Engineer.
Participated in HSE (Health Safety & Environment) efforts of conducting safety meetings, incident investigations, writing safety and standard operating procedures and producing quarterly emission reports to the DEC (Department of Environmental Conservation)
Sole contributor to all process related information documents (Process Flow Diagram, Process and Instrumentation Diagram and Heat and Mass Balances)
Managed the operations of main processing equipment (Bulk Material Conveying System, Dust Collection System, Steam Boiler, Selective Catalytic Reducer, Cooling Towers, Cobalt Oxide Catalytic Converters, CEMS (Continuous Emissions Monitoring System), Absorption Towers and Evaporators)
Equipped operations personnel with unit operations, process chemistry and equipment reliability insights in order to find the process parameters and practices that leads to optimized production rate.
Utilized Infor to generate work orders to maintain and optimize production performance. Also assisted maintenance manager in improving site’s Mechanical Integrity (MI) program to pinpoint regular PM schedules and optimizing equipment reliability
Communicated regularly with operations personnel to generate ideas of process optimization practices, best practices implementation, process equipment optimization and continuous improvements.
Utilized IMS (Incident Management System), DMS (Documents Management System), PHA (Process Hazard Analysis), FMEA (Failure Modes and Effect Analysis), PSSR (Pre-Startup Safety Review) and MOC (Management of Change) to manage / track procedures, process / equipment changes, operator / safety trainings and equipment commissioning
Generated and managed PSM (Process Safety Management) relate documents and procedures
Interim Maintenance Manager March 2017 till Sept 2017
Managed and lead the maintenance department of four direct reports in daily reactive and preventive maintenance efforts.
Coordinated and planned annual turnaround outage schedule as a maintenance manager.
Coordinated maintenance efforts with both internal employees and outside contractors.
Managed the database and continued improvement efforts in the switchover of the Mechanical Integrity program (from Maximo to Infor).
Managed, reorganized and improved the spare parts ordering efficiency and inventory system.
Supported HSE (Health Safety & Environment) efforts in improving workplace safety.
INEOS Olefins & Polymers USA, Alvin, Texas
Global chemicals manufacturer. Major focus of Alvin (Chocolate Bayou Works) site is olefins and polymers.
Utilities / C4 Engineer April 2014 till July 2015
Interfaced with operations, laboratory, commercial team and maintenance to help maintain, support, troubleshoot and maximize unit performances.
Assisted olefins production personnel to maintain optimized production capacity
Supported utilities and C4 process units of entire site with engineering expertise
Participated in multiple capital projects, MOCs (Management of Change), PSM (Process Safety Management), LOPA (Layers of Protection Analysis), Unit Startups and Shutdowns, Turnaround Planning, Preventive Maintenance, Emergency Engineering Support
Utilized PI Process Historian to managed process systems including Raw and Demineralized Water, Potable Water Distribution, Steam and Condensate, Plant and Instrument Air, Wastewater Treatment, Cooling Water and Pipelines
Utilized process design tools (Aspen HYSYS, ASPEN Plus) in aide of troubleshooting real process problems / debottlenecking
Collaborated with Nalco in improving water related (cooling water, steam and condensate) reliability issues
Supported SHE activities, meetings and inspection to ensure assets’ compliance with plant policies and procedures, OSHA, PSM, DOT, EPA, TCEQ and Coast Guard
Supported HAZOPs and HSE compliance audits by ensuring resources are available to participate and resolve recommendations by thoroughly evaluating, rejection or implementation
Participated in Six Sigma Green Belt and Black Belt Projects
Received multiple process safety training and provide inputs during safety meetings
Participated in safety observations programs such as GATOR (Gulf Coast-Action-Team-Observing-Risks), JSA (Job Safety Analysis), LCA (Life Critical Audit), BSP (Basic Safety Principles), SafeStart
Fluor, Sugarland, Texas
Global Fortune 500 Engineering, Procurement and Construction company. Major focus in Sugarland office is Energy and Chemicals.
Process / Specialty Engineer I April 2012 till Nov 2013
Performed multiple line sizing and hydraulics calculations, simulations and generated datasheets for vessels, positive displacement pumps, air coolers, heat exchangers, plug flow reactors, centrifuges and control valves, Centrifugal Pumps, Control Valves, Pressure Swing Adsorber
Assisted with Design Basis, Material Selection Diagram, Process Flow Diagram, Utility Table and P&ID development, Index Flow Sheets
Utility systems design for: Fire Water, Wastewater Treatment Systems, Sanitary Sewers, Storm Water, Multi Point Ground Flare, Ammonia Utility Line, Wet Air Oxidation (WAO) unit and Thermal Oxidation (TOX) unit, tanks design (as per API 650 standards), Pressure Relief Valves (PRV) Venting
Cast Film Plant, Inteplast Group Ltd., Lolita, Texas
Major supplier of stretch film throughout the United States, Mexico and Guatemala. Primary customers include Walmart, Pepsi, Kroger, PetCo and major packaging distributors.
Quality Control Supervisor January 2008 till April 2012
Oversaw the quality department of a 10 million pounds per month stretch film facility
Managed laboratory facility, seven technicians, daily product testing and overhead costs
Responsible for interviewing, hiring and training of new employees
Coordinate and implement quality improvements with production personnel.
Assist production in extrusion process, winding process and formulation compounding issues
Process Engineer July 2006 till January 2008
Managed, trained and supervised 10 employees to ensure 1.8 million lbs per month of stretch film produced
Subject matter expert in polyethylene, polypropylene, elastomer and metallocene extrusion process
Education
Master of Engineering in Chemical Engineering, Received Sept 2006
University at Buffalo, the State University of New York
Bachelor of Science in Chemical Engineering, Received Feb 2004
University at Buffalo, the State University of New York
Credentials
American Society for Quality’s (ASQ) Certified Quality Engineer (CQE) since 2011
EIT (Engineer in Training), currently in pursue of obtaining Professional Engineering License.
Computer Skills
Knowledge of PI Process Book, Tr@ction Action Items, TechSYS, SAP, Microsoft Visio, AFT Fathom, AFT Arrows, PALS (Fluor’s in house hydraulic calculation software), Smart Plant P&ID, Aspen HYSYS, Aspen Plus, COFE (Cape Open Flowsheet Environment), Flarenet, ProII, Minitab, AS400, C++, MS Office and Maple
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