Process Safety Senior

Walter S. Kessler

**** ***** ******* **.

Houston, TX 77084

Cell: 832-***-****

*********@***.***

OBJECTIVE: To utilize my education and 30+ years’ enoingeering and process safety experience to acquire a permanent senior engineering or safety leadership or management role.

ATTRIBUTES

Set high goals and standards for myself

Love challenges – the tougher the challenger, the more I excel

Great Engineer and up to date on processes and technology

Very good mechanically and electrically and have done mechanical, electrical and some civil engineering work besides my normal chemical process responsibilities

Very organized and take a lot of pride in my work

Very respectful of company’s finances - set budgets for projects and push to maintain or come in under budget

Always over deliver on my work and projects to satisfy clients and management in organizations

Work well in office and plant/production settings and have done both throughout my career

Very safety conscious – always double and triple check things to ensure they are correct

Great leader & respect other’s input to do things right the first time and on time

Always learning in a constantly changing work environment

-Oct 2020 certificate for completion Basic water operation course (1426) through AWC

-Dec 2020 certificate for completion of the OSHA Process Safety Management (PSM) course

Focused – go to work to work and do not allow personal and useless outside distractions to interfere with my work, as turnarounds, process and project work can be very dangerous if not planned, designed, installed, started up and maintained correctly.

EDUCATION AND HONORS:

01/04-Dec 2014 UNIVERSITY OF HOUSTON – Master’s Degree in BCHS - GPA 3.441

October 2002 Universal EPA Certification

April 2000 Passed EIT/FE Exam

PENNSYLVANIA STATE UNIVERSITY, STATE COLLEGE, PA

May 1994 Bachelor of Science - Chemical Engineering

Summer 1993 Research Assistant - Dr. Kristen Fichthorn - Computer Simulated Study of Catalytic Chemical Reactions

QUALIFICATIONS:

20+ years of experience in process design and development for refineries, gas and chemical plants, wastewater, pukpp and paper facilities, pharmaceutical, manufacturing, pilot plants and power plants, plant/process optimization and improvement, process startups, maintenance, and equipment reliability

7 years Process and general safety, PSM and incident investigations.

PHAs (Process Hazard), DHAs (Dust Hazards), HAC, MOC & PSSR, Incident Investigations, Process & Plant Start-ups

Process Safety Management (PSM) – audits, compliance, program development and documentation improvements

Project and turnaround management

Proficient in Hysis and Aspen, Flarenet, AutoCAD, Microsoft-Word, Excel, Power Point Presentations, Access, Outlook.

Process control and PLC Programming

Six Sigma/Statistical Analysis - process and data

Familiar with ASME, API, TEMA, ANSI, NEC, NFPA, IIAR

Experience in Process Hazard Analysis (PHA), Layers of Protection Analysis (LOPA), Safety Integrity Level (SIL)

ISO certifications, GMP, FDA Regulations and associated documentation completion

Research and Development, Product Laboratory analysis, and Product Quality

Supervisory roles - project and turnaround management, training of their engineers, and personnel/employee process training

40-Hour Hazardous Materials Training, Medic First Aid Care Initiator, Respiratory Fit Certification

Universal EPA Certification, HVACR troubleshooting and repair

Advanced HACCP course certificate – Dec 2018

OSHA PSM course certificate – Oct 2020

AWCC Basic Water Operation certificate – Dec 2020

Walter S. Kessler

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PROFESSIONAL EXPERIENCE:

Technical Professional Lead – Engineering & Safety KBR – Houston, TX (4/24/23-Pres)

Process safety design and engineering for LNG, refinery & chemical plants. Lead & facilitate and serve as SME for HAZOPs and lead Process Changes & MOC efforts for a PLNG. Also did the FSA 1 and 2 documentation & audits for SIS systems.

Sr Technical Advisor PSM & Engineering Talascend @ KBR) – Houston, TX (3/16/22-4/23/23)

Same as above – just as contractor

Sr. Process & Safety Engineer Kessler Consulting – Jersey Village, TX (10/1/18- 05/11/20 & 10/29/21-Pres)

Working as an independent 1099 Sr. Engineer and Process Safety consultant for EHS, highly hazardous processes. Sizing, specifying and ordering equipment for processes, Implementing and upgrading PSM programs for highly hazardous and HACCP/HARPC/BRC programs for food safety. Also perform PHAs/DHAs, incident investigations, PSSRs, commissioning of equipment and start-ups.

SBM Company – Process & Project Engineering – New Herbicide line and existing processes & facility (10/29/21-Pres)

Oxford Int’l – Tesla – bulk tank farm, piping and pump design and layout for Fremont, Ca location. (6/1/21 – 6/18/21)

Performed environmental permit transfers for new owner of a sight, Did OSHA & ISO documentation and procedure updates. (1/29/20 – 05/11/20)

Performed 1 incident investigation for a client to find the root cause and gave recommendations to prevent the incident from occurring in the future (11/18/18-11/21/18).

Very instrumental in getting three client sites prepared for and passing their BRC (food safety) certifications, both from a facility standpoint and a documentation - PM program, procedures, process, combustible dust and general safety – standpoint to continue food production (10/01/18 – 03/29/19).

Served as a senior HVAC technician for a client performing refrigeration and air conditioning troubleshooting and repair and equipment up to 50 tons (7/17/19 – 9/5/19).

Sr. Process Safety Specialist - Consultant Chilworth Technology Inc.,-Princeton, NJ (11/13-09/28/18)

Sr. Process Safety Specialist/Engineer for PSM, PHAs, DHAs, Incident Investigations, Commissioning of equipment and Start-ups, Process Safety Engineering Design to achieve Process Safety Excellence in companies. Write and review reports, publications and presentations, prepare quotes, P&IDs, Cause & Effects Diagrams, Risk Analysis, Hazard Identification, Process Safety Management (PSM) implementation, etc.

Performed almost entire PSM program implementation for 2 clients including facilitating and serving as an SME for HAZOP

Performed 7 incident investigations with detailed reports and root cause analysis to find actual cause and contributing factors of the incident and gave recommendations to improve process and prevent the incident in the future

Conducted/facilitated/served as SME for over 10,000pages of HAZOPs, some with SIL & LOPA included, for an entire pharmaceutical facility in 8 months

Performed the interactions with OSHA and other governing agencies for 3 clients

Led PSSR, startup and training after helping to manage the shutdown and upgrades after leading thorough incident investigation to find the true root cause and interacting with OSHA for an anhydrous ammonia production facility

Sr. Lead Process Engineer Ventech-Engineering International Inc.-Pasadena, TX (10/12-10/13)

Lead Process Engineer for Refinery, Gas Plant, NGL, Chemical Plant & utility design - PFD, P&ID, & UFD development, Equipment Sizing (Columns, Vessels, Reactors, Heat exchangers, Pumps, Piping, etc.) and Specification, RFQs, Equipment Data Sheets, Equipment Lists, Metallurgy, etc.

Designed an entire refinery for a Canadian Co with 1 other good young engineer – Hysis simulation, equipment sizing and specifications, plant PFDs/P&IDs, layout and ISOs with drafters, equipment material of construction, specifications and selection with mechanical, instrumentation and electrical requirements and specification with I&E

Sr. Process/Project Engineer Dixie Chemical Co, Inc.- Pasadena, TX (05/11-09/12)

Batch reaction facility including distillation, hydrogenation, filtration, centrifugation, drying, and flaking processes at Specialty Chemical Company. Project AFE preparation and project management, Process development, design, and improvement, Energy reduction projects, Safety improvements. PHAs, P&ID Development, Process, Procedure, and specification writing, Equipment specification, AFEs and RFQs generation, and equipment and instrument ordering. Member of plant ERT Team.

Complete turnaround management – from identifying turnaround items, acquiring costs, scheduling overall and individual item timelines, assigning appropriate leads and acquiring contractors to perform work, managing overall turnaround and leading some of the projects, ensured any necessary MOCs and PSSRs were generated and completed, conducted PSSRs where necessary, verified PLC and safety critical devices were functional for start-up, ensured any necessary training was conducted with appropriate personnel

Wrote over 25 detailed AFEs (Acquisition for Expenditures) for work, both process and safety, with complete details, cost estimates and appropriate contractors/personnel that needed to be completed to improve safety, process performance, equipment and piping enhancements

Managed other large & small projects from planning, to detailed project costs, acquiring and scheduling appropriate qualified personnel and contractors, creating and documenting the required MOCs & PSSRs per PSM rules and regulations, installing equipment, performing the PSSRs with appropriate personnel, and doing process training and startups

Also responsible for unit performance and maximizing yields and total production without compromising safety

Walter S. Kessler

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PROFESSIONAL EXPERIENCE (CONT.):

Sr. Process/Project Engr. Industrial Engineering Management, Inc.-League City, TX (11/16/10-05/13/11)

Gas treatment plant sizing, layouts, and design including interconnecting piping and slug catchers. Gas Plant (Amine train & Dehydration unit) Sizing, design and layout–utilized WinSim to simulate both Amine & Dehydration trains. Relief valve sizing and specification, Flare Manifold calculations, Pump and hydraulic calculations. PFD’s & P&ID’s, Report writing.

HVAC Consultant Houston, TX (7/6/09 – 11/15/10)

Commercial & Residential service and repair, design/specification-heat load and airflow calculations, estimates and sales. Sr. Process Engineer Aker Solutions – LaPorte/Houston, TX (7/25/07-3/9/09)

Project Management, Process Design and Project Execution for refineries, chemical plants and storage tank facilities. Utilized Hysis/Aspen process simulations and well as some Flarenet for flare header analysis. Heat and Material Balances, Equipment calculations, sizing and specification for Lines, Pumps, Relief valves, Separator Vessels, and Instrumentation. PFD, and P&ID development. Completed FEL I through FEL III process studies. Participated in Process Hazard Analysis (PHA) and Layers of Protection Analysis (LOPA).

Complete isobutylene plant design with a few other engineers – PFDs/P&IDs and Isometrics, equipment, piping, PSV and instrumentation and electrical sizing, specification and acquisition.

HVAC/Home Improvement Self employed - Houston, TX (7/02-01/04)

Maintained, Repaired, Installed, and Designed Heating, Venting, and Air Conditioning systems for residential and small businesses.

Process/Project Engineer; US Filter/Scaltech – Houston, TX (4/3/02-7/22/02)

Wastewater, Oil and gas sludge separation and recycling. Equipment design (belt presses, ball mills, centrifuges, augers, tanks, piping, pump, flow meters, process controls, etc. for modular/skid systems), specification, buying, refurbishing, building, installation and optimization. Worked on polymer systems and seals for various applications, as well as other design and process improvement.

Process/Project Engineer; Abbott Laboratories - Austin, TX (Manpower-contract) (7/01-1/02)

Pharmaceutical solutions. Batch and continuous processes. Complete Aminosyn project management and coordination; filling process design and development; statistical process analysis for process development and control parameters; vendor interaction for price quoting and on-time parts completion, procedure development and process training; and stability run coordination. Interaction with plant personnel, from managers, to QC, laboratory, purchasing, R&D, technicians and operators. Also responsible for process control implementation, PLC programming, and drawing completion/changes for both new parts and modifications. Various class clean room environment. Supervisory experience – included project organization and training 8-10 plant personnel, operators and mechanics to complete tasks. ISO certifications, automotive documentation - PFMEAs, PEPAPs, etc.. Supervisory experience included project organization and interacting with 2 technicians and 4 operators on procedural changes and new equipment installation, testing, and documentation.

Polymer Process Engineer/Project Lead; Raytheon Commercial Infrared - Dallas, TX (Manpower-contract) (11/13/00-7/13/01)

Infrared cameras. Existing Polymer Process analysis and improvement recommendation based on six sigma/statistical/lean manufacturing principles. New process development for advancement and next generation of products. Process Training of personnel.

Process Engineer; Sony Technology Center - Mount Pleasant, PA (8/98-10/00)

35” TV manufacturing facility. Small project management, Process capability studies and statistical defect analysis, DOE, process improvements for both defect reduction and safety consideration. Chemical dispensing system upgrades - saved 100K/year plus improved throughput by eliminating defects. Process control implementation, PLC programming. Vendor interaction of product defects. Personnel interaction and training. Production clean room environment. Supervisory experience included project management and interacting with technicians and plant personnel for testing, maintenance, cleaning, and defect reduction.

Chemical Process/R&D Engineer; OMG Americas - Cleveland, OH (Aerotek - 3 month contract) (11/97-8/98)

Crystallization of APT. Project management. Process design and development. Statistical process control. Statistical data analysis of final product to pass customer specifications. Research and development. Pilot plant production. Scale-up, recommendations and proposals for plant specifications for full-scale production.

Chemical Process/R&D Engineer; Lockhart Chemical Company - Gibsonia, PA (Aerotek-6 month contract) (3/97-9/97)

Sulfonated coatings. Incoming sample analysis and laboratory testing for product development and new product implementation.

Chemical Process Engineer; IsoGen L.L.C. - Naperville, IL (Avalon HR-contract) (5/20/96-8/29/96)

Pilot plant production of 25 Hydroxyvitamin D3. Process development and final product analysis. Batch and continuous process production, process improvement and small project management. Some experience and work with Glycol chillers.

Product Development Engineer; Fuchs Lubricants - Emlenton, PA (2/95-2/96)

Graphite coatings. Incoming sample analysis for product development. Product development and laboratory testing for both old and new product improvement, development and implementation. Batch process production.

Process Engineer – (co-op) Virginia Power - Mount Storm, WV (co-op) (5/91-1/93)

Designed bulk chemical delivery system. Procedure review and revision. Prepared audits for laboratory environmental certification and chemical hygiene plan. Process and unit performance analysis. Steam turbine air-inleakage study-Unit 3. Small project management, maintenance and outage recommendations. Performed various water and coal analysis for plant. Installed and calibrated new laboratory equipment.

References Available Upon Request

Walter S. Kessler

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PRESENTATIONS & PUBLICATIONS

SELECTED PRESENTATIONS

Kessler, W., Best Practices for Management of Change (MOC) and Pre Start-up Safety Reviews (PSSR), BST “Safety in Action” Conference, Orlando, FL, March 2015.

Kessler, W., Deciphering the Language Within Your Facilities’ Engineering Drawings, BST “Safety in Action” Conference, Orlando, FL, March 2015.

Kessler, W., Deciphering Key Engineering Documents for Process Safety, Webinar, July 2014.

Kessler, W., PSM Alert – OSHA Chemical Facility NEP is Issued Nationwide, VPPPA Webinar, July 2014.

Kessler, W., The Role of Programs in Achieving Process Safety Excellence, AIHce Conference, San Antonio, TX, June 2014.

Kessler, W., The Role of Programs in Achieving Process Safety Excellence, BST “Safety in Action” Conference, Dallas, TX, March 2014.

Kessler, W., Deciphering the Language Within Your Facilities, BST “Safety in Action” Conference, Dallas, TX, March 2014.

Kessler, W., Best Practices for Management of Change (MOC) and Pre Start-up Safety Reviews (PSSR), Mary Kay O’Connor Symposium, College Station, TX, October 2017.

PUBLICATIONS & PAPERS IN REFERRED JOURNALS

Ammonia Refrigeration Hazards and Safety Requirements brief for Chilworth Technology Inc. website distribution, January 2014

Kessler, W., Dust Control in the Chemical Processing Industries, Chemical Engineering, July 2014.

Arturo Trujillo, Walter S. Kessler and Robert Gaither, Common Mistakes When Conducting a HAZOP and How to Avoid Them, Chemical Engineering, December 2015.

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