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- 1. Wagner, Mark 1 Mark A. Wagner,PE Senior ProcessEngineer Summary of Experience Mr. Wagner has over 25 years of experience in a variety of chemical processing and manufacturing operations. He has a strong background in development and execution of projects to improve operability, quality, cost, reliability and health/safety/environment, as well as a strong background in chemical process safety. Detailed Experience Sr. Process Engineer (Jacobs) Provided Process Safety Management (PSM) services to client companies, for OSHA compliance and continuous process safety improvement. Used Process Hazards Analysis (PHA) methods to lead project EHS Design Review of new regenerative thermal oxidizer for an acrylic-styrene-acrylonitrile resin process. Led and documented multi-week team efforts for new comprehensive Initial PHAs of a polybutadiene latex facility and an ASA resin facility. Led and documented Initial PHA for a petroleum tar process vent gas collection and abatement system, identifying and offering solutions for multiple scenarios with catastrophic risk. Developed expertise with Leader PHA software. Provided PSM audit services, including pre-audits and assistance to clients corporate audit team. Conducted and documented a thermal relief valve minimization study, resulting in recommendation to eliminate up to 11 relief valves (~$50,000 annualized savings), while also identifying unprotected equipment and offering solutions to optimize coverage. Assisted large-cap project team (polypropylene catalyst) by performing hydraulic studies for design of utility piping networks, facilitating scope changes (including P&ID updates and sizing of pressure relief devices), and quality-checking P&IDs and other deliverables. Assisted large-cap ASA resin project team by performing heat transfer and hydraulic studies for design of tank jackets, heaters and tempered water loops. Software tools used include AFT Fathom, AFT Arrow and 3EPlus. Served as process/mechanical lead for early phase scope development of a multi- million dollar upgrade to a hydrogen cyanide tank farm, including a new 50,000 gallon horizontal tank.
- 2. Wagner, Mark 2 Led process efforts to upgrade a sulfur dioxide feed system (~1MM project). Evaluated multiple technologies for discharge of liquid containerized SO2 and influenced clients adoption of electric vaporization system over other proposed systems with low chance of success. Responsibilities included P&ID generation, scope and basic data development, hydraulic and heat transfer calculations. Led process efforts to install a new bagging and palletizer system for a potassium monopersulfate powder product (~1MM project). Responsibilities included P&ID generation and compressed air system design. Led process efforts to replace a 30M gallon 93% sulfuric acid tank (~$1MM project). Responsibilities included P&ID generation, scope and basic data development including pump and pipe sizing. Served as process lead for early phase P&ID and scope development of a large-cap upgrade to a soy protein isolate process, utilizing horizontal decanter/centrifuges. Served as process lead for a $1.5MM project to upgrade an electronics-grade polymer facility. Responsibilities included P&ID generation, scope and basic data development, equipment specification and requisitioning. Technologies involved include steam/glycol temperature control, pressure relief, clean-in-place, and glass and Teflon lined equipment for ultra-low metals exposure. Provided expertise to a junior team in a $120K P&ID walkdown/verification project. Process/Project Engineering (Owner-Operators) Siloxanes (Reliability, Process Improvement) Improved OEE from 90% (2007) to 95% (4Q08) thru team efforts to reduce process upsets and MTBF. Increased production by 50% in two processes with debottlenecking including a steam-to-Syltherm conversion. Participated in 6-Sigma teams to qualify process for REACh legislation thru improvement of vacuum, heat transfer and process control. Automotive Assembly Paint Shops (Quality, Supervision, Project Mgmt.) Six-Sigma black belt certified w/ several DMAIC projects for >$100K/yr hard cost savings. Served as principle project engineer and resource for all project management issues, including project writing, equipment selection, purchasing, and funds management for department. Managed over $6MM in projects. Used troubleshooting and investigative tools (cause / effect, FMEA, etc.) and manufacturing management tools (TPM, Lean Mfg., OEE / MTBF / MTTR analysis, etc.) for improvements in safety, quality, delivery and cost. Managed labs (paint and phosphate / e-coat) and supervised lab support personnel and quality / SPC technicians. Instrumental in ISO and other quality initiatives. Developed procedure methodology. Wrote and updated many procedures and performed numerous audits.
- 3. Wagner, Mark 3 Experienced in electrocoat deposition, sealer & paint automation, waterborne and solvent-borne paint systems. Coatings Resins (Chemical Process Safety) Developed Process Safety Management and other OSHA-mandated programs for multiple sites to greatly improve compliance, reduce liability, and facilitate operations. Developed plant documentation (P&IDs, equipment specs., etc.) including implementation of a technical file system, electronic document management systems, and standards and specifications. Hired and supervised designers/ draftsmen and summer intern for development of engineering drawings. Established proper development and use of written procedures to facilitate both PSM and ISO registration. Introduced and led team-oriented investigative programs (process hazards analysis, pre-startup safety reviews, incident investigations, audits). Implemented comprehensive management of change program. Led efforts to develop a mechanical integrity program and implement a computerized maintenance management system. Developed confined space entry and lockout programs, including a user-friendly Safe Work Permit. Led many formal training sessions on various PSM and safety topics. Served as lead engineer on several process development/improvement initiatives, including pilot batch reactor for a new modified resin and formaldehyde facility modifications for operability and control of air emissions. Ethylene Oxide & Polymer Polyols (Process Improvement) Developed and managed tank projects. Replaced API 650 tanks, including accelerated plant turnaround schedule. Identified and corrected design flaws in tank vent and vapor recovery systems. Provided technical support for repair of 93% sulfuric acid tank. Developed and managed fluid transfer projects for spill control, maintenance replacement and debottlenecking. Identified scope reductions for one proposed project resulting in $37K savings. Diamines (Process Improvement) Identified and corrected process-to-service tie-in violations for improved safety and regulatory compliance. Solved melt pump, scrubber, and waste incinerator/boiler operational problems to eliminate occupational health hazards and reduce waste. Polyester Film (R&D) Led development of radio frequency drying for PET film regrind as part of team effort to develop recycling technology ($1.1MM project) including pneumatic conveying, moisture analysis, PLC programming and supervision.
- 4. Wagner, Mark 4 Developed radiation source level monitor system for polymer vacuum vessels to improve process control and reduce maintenance costs. Solid Peroxygens (Process Improvement) Installed novel borax railcar unloading system ($150K) to solve a persistent transfer problem and save $300K/yr. Conceived and implemented cost-effective bulk ship container loading/unloading system (<$100K) in only 2 months for new English market and developed alternatives for other European customers, preserving employers new position as a major supplier in Europe ($5.4MM business in 1988) and saving over $1MM/yr in bagging costs. Implemented upgrades to oleum storage facility ($400K budget) to greatly improve safety of its operation. Improved utility of dehumidified air system that eliminated need for a $100K refrigeration upgrade. Education B.S. Chemical Engineering, Tennessee Technological University Registrations/Certifications Professional Engineer (Kentucky #19355) Six Sigma Black Belt (Ford Motor Co., DMAIC)