P L Qual Pckg 1 15 2009

General Overview

Process-Logic Qualifications of 22 Last Update: Jan 2009

INTRODUCTION TO PROCESS-LOGIC Since our inception in 1997, our mission has been to achieve excellence in process design, process control, and system integration services.

The range of Process-Logic’s services and capabilities go well beyond those offered by typical system integration firms. We offer a unique blend of process engineering skills and process experience to our clients, to help them achieve their automation objectives.

We offer exceptional design capabilities, including development of comprehensive drawing and specification packages for process, electrical, instrumentation, and control system equipment. We excel at writing bullet-proof logic and visualization software on a wide variety of popular PLC, DCS, and Operator Interface platforms. We offer professional and highly competent project and construction management services, and finally, we have the resources and experience to expertly start up and commission these systems in a methodical, efficient, and safe manner.

The Company is now wholly-owned by Stephan J. Sosik, one of the founding members of the original LLC. The company employs 14 people, providing ongoing project services and support to several large manufacturing firms around the USA and Canada, including Arch Chemicals, Pactiv Corporation and Wyeth Pharmaceuticals.

OUR MANAGEMENT APPROACH Our corporate philosophy is quite simple: We have a total commitment to excellence in all that we do, with customer satisfaction at the top of our list of metrics for performance evaluation.

OUR TECHNICAL APPROACH Central to our technical approach is our belief that accurate, thorough, well-organized documentation is the key to success on any project. Our overall project approach follows the so-called ‘V-model’, described in the ‘Good Automated Manufacturing Practices’ guide, published by the ISPE organization. This lifecycle approach emphasizes the development and maintenance of increasingly detailed specifications on the leading edge of a project effort (engineering and design), followed by the execution of appropriate qualification testing on the trailing edge of the project (execution and commissioning). This approach, when followed correctly, virtually guarantees that the project outcome will match the client’s expectations for cost, scope, and functionality.

An equally important guiding principle for us is the understanding of the human-factors side of automation: People have to interact with the complex systems we put in place. Thus the systems have to be easily understood, easy to work with, and easy to maintain by our clients’ technicians and operators.

To this end, we strive to imagine ourselves in our clients’ roles as we design our systems, insuring that the systems make sense, operate safely and effectively, and help them to achieve their objectives.

Personnel Resumes


Stephan J. Sosik, President & Principal Engineer Experience 1997 – Present: President & Principal Engineer, Process-Logic, LLC § Pharmaceutical Processing Suite: Successfully completed a major software project to

automate the extraction and purification of a high-potency Active Pharmaceutical Ingredient (API) for hormone replacement therapy products.

§ Compounding Area Relocation: Successfully completed process and control system engineering, design, and commissioning services for the relocation, installation, and commissioning of 53 process vessels into a brand new Compounding Area for a major manufacturer of top-of-the-line hair care products. The new Compounding Area consolidates the manufacturing of five product families (including shampoos, hair colorants, and wave lotions) into one large integrated manufacturing system.

§ Surface Treatment System: Provided process and control system engineering, design, and commissioning for a proprietary surface treatment system for toner.

§ Self-Cleaning Transfer Line: Provided process and control system engineering, design, and commissioning for a state-of-the-art dilute-phase vacuum conveyance system for toner material that is self-cleaning. The system permits changeovers from one colored material to the next in 30 minutes.

§ cGMP-Compliant Recipe Management System: Provided consulting services to define the User Requirements Specification document describing the global requirements for the replacement of a VAX-based recipe management system with a new CFR 21 Part 11 compliant relational database management software application.

§ Control Room HVAC: Provided automation consulting services and PLC controls to rectify chronic control problems in the HVAC system serving a 100% make-up air-purged control room located in a Class 1, Division 2 classified hazardous manufacturing area.

§ Pharmaceutical API Plant Automation: Provided systems engineering, design, programming and validation testing to upgrade two manually-operated bulk API plants to PLC controls. System architecture included eight processors, 22 operator interfaces, and >2000 remote I/O points, distributed across nine Class 1, Division 2 classified process areas. Scope of Services included conceptual and detailed design, specifying and bidding of components, writing PLC and MMI code, and providing construction support, start-up, and IQ/OQ testing of the system (AB SLC Platform).

§ Bio-Processing Plant Utilities: Provided systems engineering, design, and programming for a pharmaceutical utilities facility which provided 800 GPM Hot Glycol, 800 GPM Cold Glycol, Breathing Air, USP Purified Water, and a Special Waste Handling System for a Bio-Processing Pilot Plant. Scope of Services included conceptual and detailed design, specifying and bidding of components, writing PLC and MMI code, and providing construction support and start-up of the system.

§ Solvent Handling Upgrade: Provided design work and PLC programming for three dye preparation rooms. The project provided automated supply and distribution of isopropyl alcohol, methanol, ethanol, and acetone to any one of six batching tanks, mounted on load cells.

§ Chemical Reactors Upgrade: Provided automated solvent (isopropyl alcohol, hexane, methanol, and acetone) metering system as part of a $1.5 million “Alpha Site” upgrade of synthetic organic chemical reactors.

Personnel Resumes


Stephan J. Sosik, continued § Pharmaceutical R&D Pilot Plant Upgrade: Directed engineering and design activities for

process control and instrumentation of two batch reactors, three mix tanks, two receivers, four vacuum pumps, and associated TCUs, condensers, and utility services. All areas designed as Class 1, Division 1, Group C&D rated Hazardous Areas to allow for use of organic solvents.

§ Distributed Control System Retrofit: Provided consulting and design services for Delta V Fieldbus/ASI-bus distributed control system retrofitted to a large dedicated manufacturing line of organic resins. All process areas designed as Class 1, Division 1, Group C&D rated Hazardous Areas. Design included upgrades to solvent tank farm (IPA, toluene, hexane and xylene), to provide metered deliveries of specific solvents.

§ Process Safety Compliance: Organized and managed program to review over 100 batch organic chemical reactors for large Rochester-based firm to assure compliance with OSHA 1910.119 Process Safety Management regulations.

1994 - 1997 Senior Engineer / Process Automation and Control Systems,

Johnson and Johnson Clinical Diagnostics, Rochester, NY 14652 § Provided Engineering, Programming and Equipment Validation services for FDA-regulated

manufacturing line that produces HDL diagnostic medical devices. § Developed, implemented, and validated on-line fluorescence detection sensors that provided

100% inspection of product fill on dedicated manufacturing line that produces HDL diagnostic medical devices.

§ Managed development effort to improve product formulation of HDL diagnostic reagent. Wrote and executed Process and Product Validation Protocols for new formula.

§ Provided engineering and programming services to install an on-line machine vision inspection system for 600 ppm capper line. Wrote validation plan and protocol for acceptance of equipment changes.

§ Conducted Failure Mode Effects Analysis (FMEA) reviews on validated high speed vial filling line to assist in trouble-shooting and process improvement efforts.

§ Conducted FMEA reviews on out-of-plant supplier’s manufacturing processes to achieve large improvements in historically low-quality incoming components.

§ Wrote and executed Validation Protocols for FDA-regulated processes (Disposable Reservoir Filler), new products (Fluorescent HDL reagent), formulation changes (TIBC alumina material) and process modifications (HDL Empty Tube Detection, Disposable Reservoir Cap Replacement).

1987 - 1994 Senior Process Control Engineer/ Application Coordinator, Eastman

Kodak Company, Rochester, NY 14652 Details available on request.

1980 - 1987 Senior Process Development Engineer, 3M Company, Graphic Preparation Systems, St. Paul, MN 55144

Details available on request

Personnel Resumes


Stephan J. Sosik, continued Education § BS, Chemistry, SUNY Brockport, 1979 § Chemical Engineering Diploma, ICS - 3M Sponsored Program, 1981 § New York State E.I.T. Exam taken and passed, 1986 § Masters Program, Manufacturing Systems Engineering, College of St. Thomas, St. Paul,

MN, nine credit hours completed, 1987 § Masters Program, Manufacturing Systems Engineering, National Technical University, nine

credit hours completed, 1993 Skills § Modicon ‘Concept’ and ‘Unity Pro’ Programming for Quantum and Momentum processors § Wonderware 7.0 and 9.5 § RSLogix 500, 5000 § FactoryTalk Studio § RSView32 § Rockwell Software Panelbuilder 32 § Intellution SCADA § Citect SCADA § AutoCAD 2006 Professional Organization Affiliations § Instrumentation, Systems, and Automation Society (ISA) § International Society of Pharmaceutical Engineers (ISPE) § National Fire Protection Association (NFPA) § American Society of Mechanical Engineers (ASME)

Personnel Resumes


Daniel Galley, Senior Engineer & Project Manager Experience Present: Senior Engineer & Project Manager, Process-Logic, LLC § Currently providing on-site Project Engineering and Management Services to a multi-national

manufacturer of active ingredients for personal care products, biocides, and wood treatment chemicals.

2007 – 2008 Senior Staff Engineer, ATSI, Amherst, NY § Support engineer on $350 million blast furnace project at Severstal Steel in Dearborn,

Michigan. Assumed lead engineering role in November 2007. Responsible for electrical and control systems design of pump house, furnace, and stoves. Control system included multiple Control Logix PLCs with redundancy along with Devicenet and redundant Controlnet communications. Oversaw the development of SCADA graphics utilizing Wonderware software. Commissioned 5KV and 480 volt switchgear, MCCs and pumps along with control systems associated with each. Commissioned furnace controls and assisted in the commissioning of stove controls. Provided construction support and coordination among several contractors. Provided training for Severstal technicians and maintenance personnel.

1985 – 2006 Process Control Engineering Technologist, Eastman Kodak

Company, Rochester, NY § Lead technologist on process control capital projects responsible for engineering, design,

software, and commissioning teams. Successfully fulfilled roles as Engineering Manager and Commissioning Manager on a wide variety of capital engineering projects.

Education § Trott Technical High School, Niagara Falls, New York

Graduated: June 1974 Diploma: Technical Drafting

§ Rochester Institute of Technology, Rochester, New York

Pursued degree in Electrical Technology Skills

Memberships Instrumentation, Systems, and Automation Society (ISA)

§ RSLogix 500 § Design for Reliability § RSLogix 5000 § Reliability Centered Maintenance § RSView Studio § Industrial Machinery § Rockwell Software Panelbuilder 32 § Process Safety Mgmt & Risk Analysis § UL508A – Electrical Panel § NFPA79 - Electrical Standard

Personnel Resumes


Charles P. Reagan, Senior Controls Engineer Experience Present: Senior Controls Engineer, Process-Logic, LLC § Currently providing onsite I&C engineering and commissioning support of the capital program

for a large, local manufacturer of Active Pharmaceutical Ingredients (APIs). § Provided I/O layout, Instrument Loop layout and Control Panel Design services for $4 million

Utility Systems expansion for major pharmaceutical manufacturer. § Provided preliminary design for PLC control and MMI software architecture for large organic

chemical manufacturer. § Provided conceptual and preliminary design deliverables for $2.2 million project to integrate

the support utilities systems for a large manufacturing complex using networked PLCs and MMIs.

§ Providing in-house consulting for AB-SLC/5 AB-PLC/5, Modicon Impact, or other current programming for data acquisition and control systems.

§ Providing in-house consulting for Moore DCS Programming and Wonderware MMI programming.

1998 – 2001 Contract Instrument / Electrical Designer, Arch Chemical (Olin

Chemical), Rochester, 14611 § Provided Engineering, Programming, Startup and Maintenance support for Custom Organic

Chemicals and API manufacturing. § Worked on PSM documentation, with concentration on mechanical integrity. § Designed and commissioned controls and data acquisition for new processes from pilot to

large scale production, specifying and programming AB SLC PLCs, Modicon Compact, Quantum and Momentum PLCs, Square D 400 series PLC, and numerous Wonderware Operator Interface installations for small DAQ to large I/O centralized control rooms.

§ Served as I/E Field Rep for $12 million production expansion, coordinating contractors and verifying work performed.

§ Programmed Moore APACS DCS to suit constantly changing process and stage Unit Operation commissioning.

§ Designed and installed heat trace control systems for multiple processes and utilities.

1992 – 1998 Instrument / Electrical Designer, Precision Design Systems

(Westheim), Rochester, NY 14624 § Provided controls, system and panel design, construction management and start up services

for several client firms including Pfaudler, Alean (re-melting furnace), Rapistan Demag (material handling), Bausch and Lomb (index machine).

§ Provided design, construction management, and start up services for numerous water and wastewater treatment control systems.

§ Managed calibration service contracts for several clients.

Personnel Resumes


Charles P. Reagan, continued 1991 – 1992 Instrument / Electrical Designer, Radec Controls, Rochester, NY § Provided design and construction management services for Georgia Pacific Electrostatic

Precipitator Electrical Control System, as well as numerous control panels for other clients. § Provided control system design, start up and training services for numerous Pfaudler

engineered systems. § Provided design, construction management and start up services for numerous water and

wastewater treatment control systems. § Managed calibration service contracts for several clients. 1987 – 1991 Instrument Engineering Technician, Burnham Process Controls,

Rush, NY § Provided contract services for numerous control system designs for Pfaudler Engineered Systems,

including start-ups and training.

§ Designed and managed the construction of numerous control panels, as well as water and wastewater treatment control systems.

§ Managed calibration service contracts for several clients. Education § Associate Degree, Industrial Instrumentation, Monroe Community College, 1987 (ISA student

scholarship, Treasurer, student section ISA) § ISA Certified Controls System Technician, CCST Level III, 1999

Skills § Graphical Operator Interface Software Configuration: Genesis, AB PanelView, Wonderware § Allen Bradley PLC Programming § Reliance Shark § Siemens S105 § Square D 400 series § DCS Programming


Personnel Resumes


John P. McCormick, Senior Process / Instr. & Cont’ls Designer Experience 1999 – Present: Electrical & Controls Designer, Process-Logic, LLC § Currently providing onsite I&C support of the capital program for a large, local manufacturer

of Active Pharmaceutical Ingredients (APIs). § Provided software and commissioning services on a large project to automate the extraction

and purification of a high-potency API for hormone replacement therapy products. § Pharmaceutical API Utilities Upgrade: Provided software and commissioning services to a

major pharmaceutical manufacturer to upgrade chiller capacity and chilled glycol distribution systems.

§ Provided I/O layout, Instrument Loop layout and Control Panel Design services for $4 million Utility Systems expansion for a major pharmaceutical manufacturer.

§ Provided consulting and design services for a Delta V Fieldbus/ASI-bus Distributed Control System retrofitted to a large dedicated manufacturing line of organic resins. All process areas designed as Class 1, Division 1, Group C&D rated Hazardous Areas. Design included upgrades to Solvent Tank Farm (IPA, toluene, hexane and xylene), to provide metered deliveries of specific solvents. Services included preparation of all instrumentation specifications and providing installation drawings and details.

§ Provided I&C design support for local API manufacturing plant upgrade, developing numerous man/machine interface applications using Wonderware.

§ Provided I&C design support for $25 million bulk API plant upgrade . This included providing control device procurement specifications, AutoCAD control drawings for bid packages, and man/machine interface screens using PanelView.

§ Provided I&C design support for $18 million pharmaceutical R&D pilot plant upgrade. Included providing control device procurement specifications, AutoCAD control drawings for bid packages, man/machine interface screens using PanelView, and A/B SLC 500 programming.

1995 – 1999 Designer M/E/I Division, Sear Brown Group, Syracuse, New York § Designed power distribution plans, schematic design for motor controls, and panel layouts. § Designed instrumentation loop diagrams, field termination boxes, instrument location plans,

and PLC I/O drawings. § Developed electrical engineering drawings using AutoCAD and MicroStation. 1980 – 1995 Electrical Engineering Design Technician, Stone & Webster

Engineering Corporation, Cherry Hill, New Jersey § Performed electrical engineering design functions such as sizing, assigning, and scheduling

cables and conduits, developing raceway schedules, and generating bill of materials. § Utilized AutoCAD and MicroStation CAD systems for drafting and development of various

electrical drawings, including wiring diagrams, schematics, one-line diagrams, control panels, test loop diagrams, electrical grounding, electrical duct-line, and raceway plans.

§ Developed CAD protocol, standard libraries, and trained in-house personnel. § Developed modules for 3D CADD substation.

Personnel Resumes


John P. McCormick, continued § Developed new applications, work methods, documentation, procedures, and technical

guidelines for new and modified software systems. Education Associate Degree, Computer Studies, Camden County College, Blackwood, NJ Skills § Modicon Concept Programming for Quantum & Momentum Processors § Wonderware 7.0 and 9.5 § RSLogix 500 § RSLogix 5000 § RSView Studio § Rockwell Software Panelbuilder 32 § Maple Systems HMI configuration § ABB Process Measurement & Control § AutoCAD 2006 § MicroStation 5.0 § CADDS 4X § CADAM


Personnel Resumes


Gary Sanford, Senior Electrical Engineer Experience 2006 – Present: Senior Engineer, Process-Logic, LLC § Pharmaceutical Processing Suite: Successfully completed a major software project to

automate the extraction and purification of a high-potency Active Pharmaceutical Ingredient (API) for hormone replacement therapy products.

§ Pharmaceutical API Utilities Upgrade: Provided instrumentation, software, and commissioning services to a major pharmaceutical manufacturer to upgrade chiller capacity and chilled glycol distribution systems.

1992 – 2006 Senior Engineer, Eastman Kodak Company, Rochester, New York § Provided technical leadership to deliver innovative and successful applications that met the

client's needs. Developed standard designs of hardware and software, saving thousands of dollars.

§ Lead electrical engineer for $40 million Thermal Coating Process. Directed the upgrade of the building to code, design of seven chemical manufacturing processes, auxiliary equipment and process software design. Designed the communications network for the manufacturing equipment that was controlled by several Allen-Bradley ControlLogix. Delivered on scope, schedule and budget for the project.

§ Electrical engineer for $20 million Clean Room Project. Developed the process and its controls with a Japanese company. This consisted of a cleaning station, three coating systems, conveyance systems and a packaging line. Successfully completed an acceptance test prior to delivery.

§ Design engineer for $3 million Gelatin Packaging Process. Developed the process, purchased and installed the hardware and PLC control system. This project blended gelatin, dispensed it into super sacks and/or drums based on weight with an accuracy of +/- 1% of amount requested.

§ Lead engineer for $1 million upgrade of reactor systems at Kodak Colorado Division. This involved replacing the controls from pneumatic to Allen-Bradley PLC with RSView as the Human Machine Interface. The client was extremely pleased as they could now make good products repeatedly.

§ Project engineer for $1 million Data Collection system for Synthetic Chemicals Manufacturing. Expanded an ABB MOD300 control system, installed a new historian and software programming so production could analyze their process while operating.

§ Managed the design, programming, installation, and commissioning of electrical and process control systems for manufacturing equipment.

§ Engineer for $1 million building communication and alarm system (Simplex) for a manufacturing plant. Designed and installed new system prior to removal of obsolete system within budget and schedule.

§ Software engineer for $10 million upgrade to Polyester Recovery Plant. Defined the operation specifications, wrote the software and debugged it offline prior to commissioning. This was a two year project which had to be integrated with existing equipment while still manufacturing good product.

§ Lead electrical for $5 million replacement of three chemical reactor systems, their auxiliary equipment and an ABB MOD300 control system. This project allowed for the manufacture of chemicals within specifications via the use of recipes and without offline testing.

Personnel Resumes


Gary Sanford, continued § Electrical engineer for $3 million new extruder process, auxiliary equipment and an Allen-

Bradley control system for the manufacture of polymer. This project allowed for the manufacture of many different products with the use of recipe control.

§ Team member contributing to define Safety Instrumented Systems for Kodak.

1988 – 1991 Electrical Engineer, Eastman Kodak Company, Rochester, New York § Provided the design, programming, installation, and commissioning of electrical and process

control systems for manufacturing equipment.

§ Engineering Manager for a $1 million Toner Packaging Line for new product containers.

§ Led the design, installation and commissioning of computer equipment which collected manufacturing data for Clinical Products Division.

§ Designed a digital communication interface between an HP computer and Modicon PLC which allowed for data collection on production equipment.

§ Designed over 50 different digital and analog printed circuit boards for film and packaging manufacturing equipment.

Education Bachelor of Science: Electrical Engineering, Rochester Institute of Technology, Rochester, New York Skills

Memberships Instrumentation, Systems, and Automation Society (ISA) Military U.S. Navy – E5 – Secret Clearance

§ Batch Control using ISA S88.01 § AB SLC & Logix Platforms § Safety Instrumented System ISA EC50 § Process Safety Mgmt & Risk Analysis § UL508A – Electrical Panel § RSLogix 500 § RSLogix 5000 § RSView Studio § Design for Reliability § Reliability Centered Maintenance § Lean Manufacturing § AB Drive 1336+ § NFPA79 - Electrical Standard Industrial

Machinery § Rockwell Software Panelbuilder 32

Personnel Resumes


Jeffrey S. Moosmann, Senior Process Control Engineer Experience Senior Process Control Engineer with 25+ years experience in instrumentation and controls. Primary process control software author at over a dozen Eastman Kodak locations. Expertise includes: § All Phases of the Capital

Project Process § Process Control

Software § Troubleshooting

Instrumentation and Controls

§ Commissioning and Debug of New Equipment

§ Process Data Collection and Storage

§ Control System Management and Maintenance

§ Development and Reuse of Standard Designs

§ Software Specification and Documentation

§ Rockwell Software (RSLogix)

§ Chemical Processes (continuous and batch)

§ Batch Software (S88) § ABB Software (MOD 300 & Industrial IT)

2007 – Present: Senior Process Control Engineer and Programmer, Process-

Logic, LLC § Pharmaceutical Processing Suite: Lead Programmer for a major software project to

automate the extraction and purification of a high-potency Active Pharmaceutical Ingredient (API) for hormone replacement therapy products. Followed ISA S88 standard to develop control modules, equipment modules, and phases.

§ Synthetic Chemicals MACT Upgrade: Provided software necessary to convert pneumatically controlled batch reactors to DCS control. This included advanced temperature control and pressure control of the reactors to satisfy MACT regulations.

1991 – 2007 Senior Process Control Engineer, Eastman Kodak Company, Rochester, NY

§ Process Control Capital Projects and Process Improvements in Film Base Manufacturing, Polymer Production, and Paper Coating Divisions (2004-2007): Provided Technical support of the installed ABB & Allen Bradley control systems. Lead Software and E&I Engineer for capital projects to upgrade Adsorbers and control emissions. Established a standard design for Adsorber control. Software Engineer for upgrade of Polymer Mixers, Blenders, and Hot Oil System. Lead Software and E&I Engineer for several new resin conveyors controlled by PLCs. Upgraded the control system equipment and software to increase machine reliability. Trained technicians on the control systems, organized maintenance training, and wrote several standard procedures for the resident technical staff. Installed software improvements resulting in safer, more productive, and simplified operations (e.g., solved a re-occurring problem during setups that saved hours of waste at product change).

§ Control System Upgrade of Chemical Plant in the UK (2001-2003): Only US member of project team that replaced the computer system controlling the entire chemical plant. Utilizing knowledge of batch projects and ISA S88 provided key input to develop the requirements document and functional design specification. Developed software strategy and modular design. Enforced the usage of this standard design throughout the project. Specified system tests and acceptance criteria. Monitored testing. Important member of the plant commissioning and startup team. Assisted in writing the commissioning plan. Wrote a debugging program for use during on-site commissioning of the system.

Personnel Resumes


Jeffrey S. Moosmann, continued

§ Sole software person supporting the production night shift. New control system was directly responsible for increased production and 99.6% of batches meeting quality specifications the following year.

§ Hardner Chemical Production (2000-2001): Lead Software engineer. Implemented complicated three-reactor recipe. Led software team in developing new modules to existing standard design.

§ Data Collection in three Synthetic Chemicals Buildings (1999-2000): As Lead Software Engineer established standard for data collection on both DCS and PLC reactors. Trained production on utilization of data collection.

§ Polymer Reactor at Kodak Colorado (1998): As Lead Software Engineer wrote all the batch software and coordinated the efforts of three other programmers. Software communicated directly with drives and existing PLCs. Simulation capabilities were built into the software for testing and training. RSLogix and RSView were used.

§ Fluidized Polymer Reactors (1997-1998): As Lead Software Engineer taught production class on process control system.

§ Polymer Reactors and Dryer (1995-1997): As Lead Software Engineer established software standard design for all Polymer reactors. Record production levels reached within a year of startup.

§ General Purpose Batch Reactor Design (1994-1995): Established batch software standard design resulting in over 80% cost savings on future reactor upgrades. This was the first use of automated batches in Kodak’s Chemicals Division

§ Silver Nitrate Process (1993): Responsible for the control system of this continuous chemical process during the startup and optimization phases. Directed the efforts of two technicians. Process improvement team leader. Trained production operators and resident engineers. Modified hundreds of programs for optimization, debug, and installation of new equipment.

§ New Acetate Film Machine (1991-1992): Lead process control software engineer on this very large capital project ($80M) from conceptual design through startup. Led a team of engineers and technicians. Designed all of the process control software (HMI interface, control logic, and data collection).

1979 – 1991 Process Control Engineer, Eastman Kodak Company, Rochester, NY § Process control capital projects and PLC and DCS programming in Synthetic Chemicals

Manufacturing and Film Base Manufacturing.

EDUCATION § MBA, Rochester Institute of Technology, Rochester, NY

§ BS Chemical Engineering, Clarkson College of Technology, Potsdam, NY

Personnel Resumes


Robert D. Payne, Senior Project Manager Experience 1978-2006 Pactiv Corporation § Job titles have included Process/Project Engineer, Maintenance Supervisor, Project

Manager, Supervisor of project management team, Senior Project Manager for plant or Central Engineering department, operating, maintaining, optimizing, installing, and starting up equipment to make plastic bags of all sorts. Total responsibility for project work from $20,000 to $20 million, including project estimates, equipment specifications, equipment procurement, contract installation services, coordination with plants, safety, R&D, start up, and final cost accounting.

1972-1978 Corning § Process Engineer responsible for optimizing performance and maintaining glass

forming/finishing equipment.

1967-1972 Rochester Products Division, General Motors Corporation § Process Engineer responsible for developing, optimizing and maintaining performance of 2-

barrel carburetor assembly line and related equipment for the automotive industry.

Education § BS in Engineering (Mechanical), Cornell University, 1967

§ MBA (Operations/Finance), Cornell University, 1972 Skills Microsoft Project, Excel, Word, PowerPoint. Ability to effectively coordinate the efforts of several diverse work groups or individuals while maintaining project schedule, cost, and technical goals.

Personnel Resumes


David Pawlak, Senior Mechanical Engineer Experience § 36 years of engineering experience and a broad technical background developed through

continuing education and experience, with outstanding leadership ability and creative problem solving skills. Multi-skilled, cross-trained as a structural engineer, mechanical engineer and process engineer, with management experience as an engineering manager, project manager and building integrator. Experienced in every phase of the project life cycle from programming and conceptual design, to operation and maintenance, cost estimating, scheduling, producing contract drawings and specifications, writing contract bid documents, evaluating bids, contractor selection and inspecting work for compliance to bid documents. Experienced in site development, new building construction, renovating existing buildings, installing new equipment, auditing and upgrading existing equipment and building utility systems, relocating existing manufacturing operations, designing water treatment systems, and pipe stress analysis. Experienced in delivering turn-key projects, negotiating rental agreements, managing contractors, and resolving building code and piping code issues.

Education § AAS Civil Engineering, Erie County Technical Institute, Williamsville, NY § BS General Studies (Math Major, Physics Minor) University of Rochester, Rochester, NY § Advanced Water Pollution Control Certificate, 1992: Biological and Wastewater Treatment,

University of Texas § 2001 International Conference of Building Officials, Albany, NY. Successfully completed the

“Overview of IBC Fire and Life Safety Provisions” (December 11, 2001)

Military § U.S. Army Corps of Engineers, 1968-1970, Land Surveyor and Designer. Rank: Specialist

Fifth Class (Sergeant)

Professional Development and Training § Training in Project Management, Engineering Management, Project Life Cycle, Diversity,

Kaizen, Contracting, Value Engineering, Equipment Reliability (Total Effective Equipment Performance (TEEP) and Overall Equipment Effectiveness (OEE)), UBC Code Compliance, IBC Code Compliance, Pipe Flexibility Analysis (ALGOR Program), Microsoft Word, Microsoft Excel, NetMeeting, Microsoft Project and Microsoft Power Point.

§ ISPE (International Society for Pharmaceutical Engineers) courses in High Purity Water (Manufacture and Delivery), Plant and Process Validation, Clean in Place and Steam in Place (Delivery System Cleaning and Sterilization), Aseptic Facility Design, Compendial Water (Manufacture and Delivery).

§ AICHE (American Institute of Chemical Engineers) courses in Chemical and Petroleum Plant Fundamentals, Crystallization Fundamentals, Evaporation and Heat Transfer Fundamentals.

Affiliations and Certifications § International Society for Pharmaceutical Engineers (ISPE) to 2003 § National Institute for the Certification in Engineering Technologies (NICET) Certification Code

123 to 2003. § Genesee Land Trust, Committee Member representing Greece, NY to Date § Boy Scouts of America, Committee Chair Troop 197, Greece, NY to Date § Boy Scouts of America, Waterskiing and Motor Boating Merit Badge Counselor, Greece, NY

to Date

Personnel Resumes


Elizabeth J. Feeney, Documentation Specialist / Tech Support Summary Technical Writer with extensive experience in writing and editing standards, specifications, policies and procedures, with additional skills in data management, desktop help, software and computer training. Highly customer focused. Detail oriented, applying logical approach to prioritize and meet multiple objectives efficiently and accurately.

Experience Technical Writing / Editing § Wrote, edited and maintained specifications, standards, policies and procedures for the

project management, engineering and technical community. § Composed original correspondence in a clear, concise manner. Planned, prepared, reviewed

and provided input as appropriate. Distributed/disseminated to a variety of audiences via intranet, e-mail and voice mail.

§ Created and published Frequently Asked Questions and end-user documentation supporting various software rollouts.

§ Created and administered a variety of web-based surveys to ascertain customer satisfaction, employee ergonomic and education needs. Collected input, analyzed, and published summary reports.

§ Led Policy Teams researching and consolidating three organizational policy databases to eliminate redundancy. Identified and combined key elements to create cohesive policy statements. Created dynamic web site enabling employee input prior to management ratification.

§ Enforced adherence to organization's Document Control Procedure to support ISO certifications.

Information Technology and Systems Support § Designed and implemented internal organization web sites. Monitored overall site

performance, user accessibility, completeness, consistent site style, and site promotion. Created, edited, published and maintained content.

§ Created website that achieved $600K savings by eliminating hard copy publishing and distribution of standards and specifications.

§ Created SAP/ERP Job Collection Data website collecting user data from over 800 supervisors to understand applicable system component training requirements.

§ Created website and marketing materials that allowed outside sales opportunities for Eastman Kodak Company Shops Division, saving jobs and retaining valuable expertise and intellectual property.

§ Alpha Tester for web-based drawing management system. Application testing and problem reporting in development phase. Trained 1500 users to search/query, view, and plot drawings.

§ Training Coordinator for various system and software rollouts, requested vendor quotes, negotiated training costs, submitted purchase orders and approved invoices for payment. Managed all aspects of student reservations, scheduling logistics and communications. Also created and delivered training courses to employees in many areas including basic computing fundamentals, software installation, scanning, CD burning, and digital imaging tips.

§ Created and maintained server file share structures, created access groups, monitored over 800 gig of data, communicated disk space quota issues and provided data archival services.

§ Data Manager for multiple server migrations, matched data to owners. Developed data migration plans from decommissioned servers to new servers, sent detailed communications to end-users.

Personnel Resumes


Elizabeth J. Feeney, continued § Participated in Windows NT® Elimination project, matched users to computers. Tested and

certified specialized software applications for Windows XP®. § Resolved day-to-day computer help issues, including software installation and problem

solving.

Skills

§ Microsoft Office suite § Hands-On Web Development § FrontPage § Hypertext Markup Language § Visio § Adobe PhotoShop, Introduction § Lotus Notes § Active Server Pages § Information Mapping § JavaScript Programming § Halogen E-Surveyor § Cascading Style Sheets

Experience & Qualifications


RECENT PROJECT EXPERIENCE: Hair Care Product Compounding Area

P-L recently completed Process Design and Process Control Consulting services for the relocation, installation, and commissioning of 53 process vessels into a brand new Compounding Area for a major manufacturer of top-of-the-line Hair Care products. The new Compounding Area consolidates the manufacturing of five different product families into one integrated manufacturing system.

53 process vessels were distributed across three 2-storey platforms. Process controls for all the vessels were integrated into a dual processor, redundant Modicon Quantum PLC system architecture with distributed IO. A network of PC-based HMIs was distributed in convenient locations around the upper and lower decks of the platforms.

Key process controls were provided for the vessels, including:

§ High-Accuracy Temperature Controls with automated transitioning between direct Steam Heating & Chilled Water Cooling. The service piping was designed to provide a high recovery rate for condensate and chilled water, so that long term operating and chemical treatment costs could be minimized.

§ Variable Frequency Drive control of Agitators/Sweep Blades.

§ High-Accuracy coriolis-metered additions of RO Water, and Soap Oils.

§ High-Accuracy loss-in-weight additions of Ammonia Water, and Hydrogen Peroxide.

§ Routing of Product Fluids through two custom designed transfer panels to distribute compounded products from the 53 vessels to ten different product fill/packaging lines.

Contact: Jerold Boddy – LeChase Construction Services



Active Pharmaceutical Ingredient Processing Suite P-L recently completed a major software project to automate the extraction and purification of a high-potency Active Pharmaceutical Ingredient for hormone replacement therapy products.

The process system, designed by Turn-Key Modular Systems of Mississauga ON, is comprised of ten process units, including high-accuracy reagent delivery tanks, a high viscosity mixer, an auto-filter/dryer, reactor/receiver vacuum distillation vessels, two product receivers, and organic and aqueous waste tanks.

The software, developed by Process-Logic, provides full manual control of all the process hardware, as well as fully automatic control via 53 automated processing sequences and ten automated rinsing/cleaning sequences. A “device-manual” feature also allows selected control devices to be placed into manual control, should it be necessary, while a sequence is active.

The sequences are selected and run by Process Operators from one of six large PC-based Touch Screen HMIs. The software provides crosschecks to ensure that only sequences that are correct for a given vessel may be selected and activated. The software also allows multiple sequences to be active within the system, providing that no equipment conflicts or contention issues are created by the active sequences. The software automatically pre-checks for these conditions.

High accuracy temperature control modules, utilizing chilled glycol along with steam heat exchangers, were deployed on vessels requiring temperature control, giving an effective temperature control range of -20°C to 100°C for each vessel.

Over 800 Intrinsically Safe I/Os were distributed throughout the 3-storey Process Suite to allow for the use of flammable organic solvents throughout the process.

Ancillary process equipment systems included the above-mentioned Auto Filter/Dryer and High Visc. Mixer, plus a Vacuum Pump, an End-of-Line Condenser, a hot and cold WFI system, process control interface to a Tank Farm, and process control interface to an Aqueous Waste processing system. All ancillary process systems were integrated into the overall control system architecture. In the end, we established integrated ControlNet communications between nine different PLC processors which included ControlLogix, MicroLogix, CompactLogix and SLC platforms.

In addition, we provided custom Modbus TCP/IP communication programming to continuously convey WFI water quality data to various chart recorders designated to monitor the system.

Contacts: Steve Trivett (Wyeth Organics), Michael Hallman (TKMS)



Arch Chemicals - Project / Construction Management Services P-L provided Project Management and Construction Management services in the replacement of a process waste neutralization system, including new polishing sand filters and controls and modification of the existing HMI. We specified, bid, and coordinated the work of Electrical, Mechanical, Millwright, and other related trades. The existing system was dismantled, cleaned, retrofitted with new internal components, and restarted, all within the allotted downtime.

P-L provided Project and Construction Management services in the replacement and enlargement of an old, disintegrating steel platform in a hazardous process area. We specified, bid, and coordinated the work of Steel Fabricators, Installers, Millwrights, and other related trades.

P-L is currently coordinating and overseeing the work to replace a key process vessel that has failed in place. At the same time we are renovating and improving the ventilation of the hazardous process area in which the tank resides. We are managing the project, specifying the procurement and modification of a replacement process vessel, bidding, and coordinating the work of Electrical, Instrumentation, Mechanical, Millwright, HVAC, and other related trades.

Contact: Brian Lachell (Project Manager for Arch Chemicals)

Arch Chemicals - Programming Services P-L provided PLC and HMI programming services (Modicon Concept 2.5 and WW ver 7.1) to automate the operational sequences of an existing batch chemical manufacturing process. The automation provides greater freedom for the process operators to work on this process while also working on other processes in the area thus achieving a higher degree of productivity.

P-L provided PLC and HMI programming services (Modicon Concept 2.5 and Maple Systems HMI) to control the operation of three parallel processing particle size reduction mills for the creation of a micro-particulate product used in wood preservative products.

Contact: Gloriana Kuswanto (Project Manager for Arch Chemicals)

Waste Management Landfill Riser House P-L recently completed the programming and HMI modifications needed to add a new Riser House/Pumping Station to Waste Management’s Mill Seat Landfill site in Riga, NY. Integrating the new Riser House programming into the existing system was technically challenging because the existing system, which relied heavily on fiber optic- and radio-transmitted signals over Modbus RTU and Modbus Plus protocols, was very poorly documented. After a great deal of “reverse engineering”, the system has been successfully commissioned and left in a much-improved, well-documented state.

Contact: Gene Dries (Waste Management Site Manager)

References


REFERENCES:

Jerry Boddy, P.E., Project Manager

LeChase Construction Services - 300 Trolley Blvd, Rochester, NY 14606 (585) 254-3510

Michael Hallman, Project Manager

Turn Key Modular Systems – 4090 Ridgeway Drive Unit #8

Mississauga, Ontario, Canada, L5L5X5 (905) 608-8006

Lorna Woychyshyn, Technology Manager, (204) 728-1511

Wyeth Organics - 720 17th Street East, Brandon, MB Canada, R7A 7H2 (204) 728-1511

Steve Trivett, P. Eng., Director of Operations

Wyeth Organics - 720 17th Street East, Brandon, MB Canada, R7A 7H2 (204) 728-1511

Brian Lachell, Project Manager

Arch Chemicals - 100 McKee Road, Rochester, NY 14611 (585) 436-3030

Dennis Bernhardt, Director of Engineering


John Frank, Senior Controls Engineer


Matt Demason, Operations Manager

Cincinnati/Northern Kentucky Int’l Airport Glycol Recovery Facility (513) 651-3440

P L Qual Pckg 1 15 2009

Business

Transcript of P L Qual Pckg 1 15 2009