Project Manager Plant

JAVIER REQUENA'S RESUME

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

La Porte, Texas 77571

Tel: 281-***-****

OBJECTIVE:

To seek employment within an organization where my various engineering knowledge and skills can be utilized in a team environment and make money for that organization.

EDUCATION:

1975 -- MIT (Monterrey Institute of Technology) - Monterrey, NL – MEX-- BS CHEMICAL ENGINEERING & ADMINISTRATION

Work Experience:

Summary and STRENGTHS: Over 30 years of Petrochemical plant operation and projects experience with the same company, but it changed name several times. . GOOD TROUBLE SHOOTER. EXPERIENCE with Polypropylene Plant Operation and Plant CONTROL SYSTEM( DCS), CAPITAL AND MAINTENANCE PROJECTS, PSV CALCULATIONS, FLARE OPERATIONS, PSM LEADER( MOC) , PHA FACILITATOR, ASSISTED IN DEVELOPING P&IDs, PIPING LAY-OUTS, on any safety, environmental, operations, and quality issues. Involved with several BIG PLANT EXPANSIONS.

2009- Present – REQUENA ENTERPRISES – President

• After I retired from TOTAL in 2008, I started my own business, but the economy in USA and Mexico, plus the death of my partner (My brother) in Mexico, slow down the business and I am looking for another opportunities.

• Consulting Business for solid transfer system for Plants in Mexico and South America.

• Selling any equipment (pumps, etc) & instrumentation needs in the above plants (flow, temp, pressure, and level).

• Turnaround Consulting Construction Manager at Dixie Chemicals (Cost = $ 100,000), Agrifos ($1 Million), Optim Energy- Altura Cogen ($ 200,000). Monitor the progress of the turnaround and made daily reports to Plant Manager. Procured all the materials and equipment to start the work on time and help at the commissioning.

• Consulting with some Houston construction companies. I was in charge in defining the scope of work. Made the cost estimation based on materials and labor. Wrote the quote for the customer. If customer approved it, then customer gave us the P.O. Then I ordered the materials and found the right people to do the job. Made the schedule and went as Project Manager for that project until job was completed. I took care of mobilization and demobilization of equipment and people. All the projects were complete on time and under budget.

2004-2008- Total Petrochemicals USA.- Polypropylene- La Porte, TX

Sr. Engineering ADVISOR / Project Manager– ALL PLANTS

(I RETIRED IN DEC. 2008 TO START MY OWN BUSINESS). TOTAL BOUGHT ATOFINA

Involved with Train 9 Expansion at La Porte Plant (THIS PROJECT WAS $ 10 BILLIONS). I took care of the tie-ins at the main Flare line and coordinated with operations to ensure it was safe. Also, all the tie-ins for the Propylene Lines by the bullets, plus the new Propylene dryer filters. Also, all the utilities tie-ins were my responsibility (Process, drinking, fire Water) (steam, air, and cooling water). I was in charge of the Turnarounds per unit to do all the Tie-ins ahead of the expansion. Identify all the tie-ins properly, talked to Operations Manager to discuss each action item to ensure that outage was scheduled properly.

I assisted during the PHA study on the beginning. I helped Jacobs Engineer to size some equipment and ensure to use the same spare parts as much as possible. I am an expert in designing pellet or solids transfer systems. I worked with Zeppelin to select all that equipment.

Supervised 1 operator/ 1 Pipe-fitter and 10 contractors to stop HRVOC (Highly Reactive Volatile Organic Compounds) leaks in the plant and ensure that LDR (Leak Detection Repairs) program is working good. Before, I came to this position, the plant had several fines. In the last 3 years, the leaks were reduced to ZERO and no more fines have occurred. This saved the company at least $ 1,000, 000/ yr on fines.

COMPLY with EPA Regulations for HRVOC leaks and TCEQ yearly Audits. Passed the 2006, 2007 & 2008 TCEQ Audits with no problems or fines.

Provided Technical assistance to identify and implement opportunities at the La Porte Plant. Excellent in debottlenecking units of operations, Yield or Prime conversion Improvements, energy and waste reduction. THESE ARE SOME EXAMPLES: A) Designed and installed Train 9 Pellet Recovery system. Savings around $ 1MM per year. The design was from the blowers, rotary feeder, piping, and bag filter. We recovered all the pellets from the H/C hills and any overfill pellets spills and send it to an existing OFF SPEC TK, and price was improved from $ 0.02/ lb to $0.10 / lb. B) Designed and installed a system to recover pellets from the dumpsters, and send the pellets to an existing TK, and from there, we can drop pellets into a H/C. Saved on Trucks and better price pellet cost.

Developed process design packages for capital projects (as the above pellet recovery systems), consisting of : process description, risk analysis, cost analysis based on P& IDs, wrote equipment specifications, changed the other P&IDs associated with those changes. This is an example:

I started with a P&ID sketch for any change or modification of an existing one, then we modified the formal P&ID, then I wrote the MOC for that change, made an estimation of the project cost, then I wrote the AFE (Authorization For Expenditures). After approvals of AFE, then we completed the PHA based on the P&ID. I procured all the equipment and materials, then I selected the contractor to fabricate and install this equipment based on my drawings for piping and equipment set –up and foundation design (If any). I followed the entire job of the project until was completed.

• Assisted with the check out, commissioning and start up of the above systems, including equipment, instrumentation and piping check out when I was doing the PSSR (Pre-Start-up Safety Review) and completed all the MOC requirements BEFORE TO START THE SYSTEM. Then:

• I revised Operation Procedures & Training Books to accommodate the above changes.

I am a good troubleshooter in any operating unit, and find the root cause, then find and implement solutions.

Monthly Reports to Management of HRVOC leaks were issued. Looked for problem leaker and then design a system or equipment to eliminate those leaks. Designed new gaskets for Mon II & Mon III –Wash Column OHVD Filters. Improved Mon I PC vapor Dust Collectors operation ( less leaks). Better gasket design for Propylene Feed Filters.

Leader of PSM (Process Safety Management) and MOC (Management of Change) programs. I was in charge of the PSM MANUAL UPDATES AND CHANGES. Passed two PSM audits from DNV with 85 –90 grade. Reduced MOC projects older than 2003, at ZERO. I am an expert on MOC, PHA, and PSSR. I was in charge of the PHAs (AS FACILITATOR) for the entire plant P & IDs and two revalidations.

1997-2004 - ATOFINA OIL & CHEM. –PP -La Porte, TX - Sr. Project / Sr. Process Engineer

NOTE: ATOFINA SOLD THE PLANT TO TOTAL PETROCHEMICALS

Supervised contractors (from 10- 20 persons) to complete projects from $ 50,000 to 50 Millions. The biggest one was to install Emergency Safety Valves (ESV) on each pump, compressor and tanks that contains explosive material. You can close those ESVS from the control room, remote panel, and local switch. So, operators can isolate the system without risking personnel. I was involved with the design, selection and installation for the actuators, valves and they were attached at the fire alarm systems.

I am very familiar with Honeywell TDC-300 DSC computer to control the entire plant.

Prepared BUDGET and AFE (Authorization For Expenditures) Scope, Estimates, execute schedules and budgets for budgeted projects, procured material for capital projects. Issued monthly reports of the Budget and control costs on the capital projects.

Developed heat and material balances, Process Flow Diagram (PFD) and P&IDs for any project in the plant.

I was involved with TRAIN 8 PP EXPANSION (COST at $ 5 Billions) . I helped in the design of the new equipment, specially the pellet transfer systems. Also involved with all the Tie-ins. After completion, I was part of the start-up team and we made good product in 3 days after completion day.

Replaced the old small Pellet Cooling Tower with a Shell /Tube Heat Exchanger. We were able to stop this tower and avoid mayor repairs and motor and fan problems ($ 250, 000 savings).

Installed one of the first Zeppelin ANGEL HAIR REMOVAL SYSTEM in connection with Zeppelin Engineers and design. Save many complaints and about $ 500, 000/ year on pellet quality.

Responsible for supporting the plant, checked operation every day and help with any issues to keep the plant running all the time and make improvements on rates and quality. Support efforts to make the plant more efficient and improved quality problems: THIS IS AN ANOTHER EXAMPLE: REPLACED AN OLD HOT-FACE PELLETIZER WITH AN UNDER WATER GALA PELLETIZER SYSTEM TO IMPROVE PELLET CUT. I WORKED WITH GALA ENGINEERS TO MAKE SURE THE DESIGN WAS RIGHT. I was on charge on the installation of all the equipments and HELPED ON THE START-UP.

1984-1997- FINA OIL & CHEM.- PP- - Prod. Superintendent / Production Eng. NOTE: FINA OIL ACQUIRED ATOCHEM AND BECAME ATOFINA – SAME PLANT.

• I was involved with Train 7 Expansion, plus all the new Honeywell TDC 3000 DCS control system.

Reduced downtime and improved prime conversion. Keep good communication with operators and supervisors to run the plant at the best efficiency.

MANAGED THE MANUFACTURING FUNCTIONS ON THE SHIFTS, INCLUDING PRODUCTION SCHEDULES BASED ON MARKETING INFORMATION, TROUBLESHOOTING MANUFACTUING ISSUES, PLUS OPERATIONS AND MAINTENANCE PROBLEMS TO KEEP THE PLANT RUNNING AT 95 % OR MORE OF THE TIME, DEVELOPED AND ANALIZED OPERATING REPORTS, MADE A REPORT EVERY MORNING FOR THE MANAGERS OF THE SAFETY AND ENVIRONMENTAL ISSUES, PRODUCTION, QUALITY, AND ANY MAINTENANCE OR PEOPLE PROBLEMS.

Supervise 2 engineers, 4 supervisors, and 24 operators to run Mon I Plant Polypropylene Plant to make 500, 000 lbs / day of PP pellets at $ 0.50 / lb = $ 250, 000 per day X 365 = $ 91 Millions per year. Good quality and better prime conversion was obtained.

VERY FAMILIAR WITH OPERATION and start –up OF THE PP PROCESS FROM THE REACTOR, CHEMICALS INTO THE REACTOR, PURIFICATION, AND FLASHING SYSTEMS , PLUS ADDITIVES ADDITIONS INTO THE FLUFF (PP-POWDER), GALA, FARREL, BAKER PERKINS EXTRUDER AND PELLETIZERS, PLUS PELLET DRYERS AND CLASSIFIERS. AND FINALLY ALL THE PELLET TRANSFER SYSTEMS ALL THE WAY TO STORAGE TANKS. WE CONTROL ALL THE ABOVE PROCESS WITH A HONEYWELL TDC-3000 COMPUTER.

• Designed these projects to de-bottleneck Mon II Polypropylene Plant from 450 M lbs/day to 960 M lbs/day: Change higher speed Gearbox on Purge Column Rotary Feeder and BIGGER ZEPPELIN ROTARY FEEDERS, powder feeder and additives feeders, on-fly screen pack changers, trash-outs reduction. Gain $ 876,000, 000 in one year.

1980-1984 - ARCO (Atlantic Richfield Co.) La Porte, TX - Process Engineer

NOTE: ARCO SOLD THE PLANT TO FINA OIL AND CHEMICAL – SAME PLANT. Designed new Water Softeners to improve Boiler’s reliability. No more boiler tube’s ruptures and no more Hard water to boilers. Improve BO3 Incinerator operation and On stream factor. * Improved Mon II prime Conversion from 94 % to 97 %.

1975- 1980 DUPONT Matamoros, Tamps. MEX - Production Superintendent : Supervise 6 Engineers/Supervisors, 24 operators to make 1 MM tons of Sulfuric Acid and support HF plant. Completed all the above with no accidents, good rates and quality. Also, I was in charge of running all the boilers, compressors. Steam, water etc. We took water from the RIO GRANDE RIVER and treated it in the Clarifier with all the chemical additions to precipitate the solids, then sand filters, and cartridge filters, and finally the Water Softeners to stop Ca and Mg hardness, before to pump it into the boilers with the right chemicals to avoid corrosion and tube deposits, via BFW pumps, then make steam to move a turbine and keep the process hot.

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