Process Engineer Resume Examples

Process Engineer Resume Example

Meet Lars Wickstrom, a fictional process engineer with 7+ years optimizing continuous chemical processes. This example highlights yield improvement, variability reduction through designed experiments, and the troubleshooting that keeps a plant running at rate.

Lars Wickstrom

(225) 555-0172 ◇ Baton Rouge, LA

lars.wickstrom@example.com ◇ linkedin.com/in/lars-wickstrom ◇ larswickstrom.com

Objective

Process Engineer with 7+ years optimizing continuous chemical processes at a 400,000 ton per year plant. Raised first-pass yield from 88.6% to 94.2% through 5 designed experiments, cut steam consumption by 19% worth $1.6M a year, and led the troubleshooting that recovered a unit stuck at 70% of rate for 4 months. Works from plant data rather than from what the process was supposed to do on paper.

Education

B.S. in Chemical Engineering, Bayou Ridge State University 2014 – 2018

Coursework in Reaction Engineering, Separations, Process Control, and Transport Phenomena.

Six Sigma Green Belt, American Society for Quality 2021

Certification project reduced product variability on a key specification by 42% over two quarters.

Skills

Process Optimization

Yield improvement, heat and material balances, energy integration, debottlenecking, rate testing

Analysis & Experimentation

Design of experiments, statistical process control, regression modeling, root cause analysis, data reconciliation

Plant Support

Troubleshooting, management of change, process safety reviews, HAZOP participation, turnaround support

Tools & Systems

Aspen Plus, AVEVA PI, Minitab, MATLAB, Python, DeltaV, Microsoft Excel, SAP, AutoCAD

Experience

Process Engineer 06/2021 – Present

Delta Reach Chemical Company Baton Rouge, LA

Own 3 continuous units at a 400,000 ton per year plant, supporting daily operations and the annual improvement plan.
Raised first-pass yield from 88.6% to 94.2% through 5 designed experiments on temperature, residence time, and catalyst loading.
Cut steam consumption by 19% through a heat integration project, saving roughly $1.6M a year with a 14-month payback.

Process Engineer 08/2018 – 05/2021

Atchafalaya Point Refining Lake Charles, LA

Supported 2 process units through daily operations, 3 planned turnarounds, and 40 management of change reviews.
Recovered a unit stuck at 70% of design rate for 4 months by tracing the constraint to a fouled exchanger the model had assumed clean.
Reduced off-specification product from 4.8% to 1.3% by implementing statistical process control on 6 key variables.

Process Engineering Co-op 01/2017 – 08/2017

Terrebonne Line Industries Houma, LA

Built a mass balance model for a separation unit and reconciled it against 6 months of plant data.
Identified a 3% product loss through a vent stream that had never been metered, prompting a permanent instrument installation.
Updated piping and instrumentation diagrams for 4 sections after finding 28 discrepancies against the field.

Projects

Yield Improvement Campaign. Ran 5 designed experiments across temperature, residence time, and catalyst loading, using plant data rather than laboratory assumptions. First-pass yield moved from 88.6% to 94.2%, worth about $2.8M a year in recovered product.

Heat Integration Project. Built a pinch analysis across 3 units and specified 2 new exchangers to recover waste heat. Steam consumption fell 19%, saving roughly $1.6M annually against a $1.9M capital cost.

Rate Constraint Investigation. Traced a 4-month rate limitation to exchanger fouling that the simulation had assumed away, using field measurements against the model. The unit returned to full rate within 3 weeks of the finding.

Extra-Curricular Activities

Member of the American Institute of Chemical Engineers, serving on the local section programming committee since 2022.
Mentor 3 chemical engineering students a year through a university industry partnership, including plant tours.
Volunteer with a Baton Rouge STEM outreach program, running hands-on sessions for about 100 students a year.

Leadership

Lead the plant's process improvement team of 6 across engineering, operations, and maintenance.
Serve as process engineering representative on 12 HAZOP studies, chairing 3 of them for smaller unit changes.
Trained 24 operators on the statistical process control charts, which is what made the off-specification reduction stick.

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Senior Process Engineer Resume Example

Meet Ingrid Vasquez-Moreau, a senior process engineer owning technical direction across multiple units and mentoring junior engineers. This example demonstrates plant-level economics, capital project leadership, and the judgment that comes from having seen processes fail in specific ways.

Ingrid Vasquez-Moreau

(713) 555-0169 ◇ Houston, TX

ingrid.vasquez-moreau@example.com ◇ linkedin.com/in/ingrid-vasquez-moreau ◇ ingridvasquezmoreau.com

Objective

Senior Process Engineer with 14 years owning technical direction across 6 units at a large petrochemical site. Delivered $11.4M in cumulative annual benefit, led a $34M capital debottleneck that added 22% capacity, and mentors a group of 5 engineers. Brings the judgment that comes from having watched specific processes fail in specific ways, which is what a simulation will not tell you.

Education

M.S. in Chemical Engineering, Gulf Meridian Institute of Technology 2009 – 2011

Thesis on reactor modeling for exothermic systems; Professional Engineer licensed in Texas since 2015.

B.S. in Chemical Engineering, Sabine Crest University 2005 – 2009

Graduated summa cum laude; Six Sigma Black Belt certified through the American Society for Quality in 2017.

Skills

Technical Leadership

Multi-unit ownership, technical mentoring, capital project leadership, plant economics, technology selection

Advanced Analysis

Rigorous simulation, kinetic modeling, design of experiments, pinch analysis, reliability and risk modeling

Safety & Compliance

Process safety management, HAZOP leadership, layer of protection analysis, relief system design, incident investigation

Tools & Systems

Aspen Plus and HYSYS, AVEVA PI, Minitab, Python, MATLAB, PHA-Pro, DeltaV, SAP, AutoCAD

Experience

Senior Process Engineer 02/2018 – Present

Buffalo Bayou Petrochemical Houston, TX

Own technical direction for 6 units at a site producing 1.2 million tons a year, and mentor a group of 5 process engineers.
Led a $34M capital debottleneck that added 22% capacity, delivered 5 weeks ahead of the turnaround window and $2.1M under budget.
Delivered $11.4M in cumulative annual benefit across 7 years through yield, energy, and reliability improvements.

Process Engineer 07/2013 – 01/2018

Trinity Reach Chemicals Pasadena, TX

Supported 4 units through 5 turnarounds and 2 major expansions, owning the process side of each scope.
Cut unplanned downtime on the primary reactor from 340 hours a year to 90 by redesigning the fouling mitigation strategy.
Led the incident investigation into a relief event, and the resulting 6 changes have held with no recurrence in 9 years.

Process Engineer 08/2011 – 06/2013

Neches Grove Industrial Gases Beaumont, TX

Supported an air separation unit, improving specific power consumption by 8% through column and compressor optimization.
Built rigorous simulation models for 3 units that became the site's basis for rate and energy studies.
Completed 22 management of change reviews and participated in 8 HAZOP studies within the first two years.

Projects

Capacity Debottleneck. Led the process scope of a $34M expansion, from constraint identification through equipment specification, vendor review, and commissioning. Added 22% capacity, delivered 5 weeks early and $2.1M under budget.

Fouling Mitigation Redesign. Modeled fouling rate against operating conditions to replace a fixed cleaning schedule with a condition-based one. Unplanned reactor downtime fell from 340 hours a year to 90, worth roughly $4.2M in recovered production.

Site Simulation Standard. Built and validated rigorous models for 6 units and defined how they must be maintained against plant data. The models are now the site's required basis for every rate, energy, and capital study.

Extra-Curricular Activities

Serve on the industry advisory board for a chemical engineering department, reviewing curriculum twice a year.
Present annually at a regional process safety conference, most recently on relief system design to about 180 attendees.
Mentor 4 early-career engineers a year through a professional society program, with 5 of 12 past mentees now senior engineers.

Leadership

Lead a technical group of 5 process engineers, setting priorities across 6 units and reviewing all major technical decisions.
Chair HAZOP studies for the site, having led 18 studies covering new units, expansions, and major modifications.
Serve on the site capital review committee, which has evaluated 40 proposals and approved 14 projects since 2020.

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Entry Level Process Engineer Resume Example

Meet Casey Aldridge, an entry level process engineer straight out of a chemical engineering degree with two co-op rotations. This example shows how co-ops, a senior design project, and real plant data analysis carry a resume before full-time experience exists.

Casey Aldridge

(517) 555-0121 ◇ Lansing, MI

casey.aldridge@example.com ◇ linkedin.com/in/casey-aldridge ◇ caseyaldridge.com

Objective

Entry level process engineer with a chemical engineering degree and 12 months of plant experience across 2 co-op rotations. Built a mass balance model that found a 4% unaccounted product loss, and ran a designed experiment that cut a coating defect rate from 6.2% to 2.8%. Comfortable with Aspen, Minitab, and Python, and used to standing at a unit long enough to see what the data is missing.

Education

B.S. in Chemical Engineering, Grand Ledge State University 2021 – 2025

GPA 3.7; coursework in Reaction Engineering, Separations, Process Control, and Plant Design.

Engineer in Training Certification, Michigan Board of Professional Engineers 2025

Passed the Fundamentals of Engineering exam on first attempt; OSHA 10-hour certified.

Skills

Process Fundamentals

Mass and energy balances, unit operations, flowsheet reading, rate calculations, data reconciliation

Analysis

Design of experiments, statistical process control, regression, capability studies, root cause analysis

Plant Exposure

Field data collection, operator interviews, management of change basics, safety procedures, sampling

Tools & Systems

Aspen Plus, Minitab, Python with pandas, MATLAB, Microsoft Excel, AVEVA PI, AutoCAD, SAP basics

Experience

Process Engineering Co-op 01/2025 – Present

Saginaw Line Specialty Coatings Lansing, MI

Ran a designed experiment across 3 variables on a coating line, cutting the defect rate from 6.2% to 2.8%.
Built a mass balance model reconciled against 4 months of plant data, identifying a 4% product loss through an unmetered stream.
Updated 6 standard operating procedures after finding 19 discrepancies between the documents and actual practice.

Process Engineering Co-op 05/2024 – 08/2024

Huron Point Food Ingredients Battle Creek, MI

Collected and analyzed 3 months of drying unit data, building a capability study that showed a Cpk of 0.88 on moisture content.
Proposed a temperature profile change that reduced energy use on the dryer by 11% in a 2-week trial.
Documented the cleaning and changeover sequence for 4 product transitions into a standard the operations team adopted.

Undergraduate Research Assistant 09/2023 – 04/2024

Grand Ledge State University Lansing, MI

Ran 60 bench-scale reaction experiments for a catalysis research group, logging conditions and yields for each.
Built a Python analysis pipeline that cut the group's data processing time from 4 hours to 20 minutes per experiment set.
Co-authored a poster presented at a regional research symposium attended by about 200 people.

Projects

Senior Design Capstone. Led a 4-person team designing a 50,000 ton per year specialty chemical plant, including flowsheet, equipment sizing, and economics. The design showed a 21% internal rate of return and placed second in the department's capstone review.

Coating Defect Experiment. Designed and ran a 3-factor experiment on line speed, cure temperature, and coating thickness against a persistent defect. The defect rate fell from 6.2% to 2.8% and the new setpoints remained in place after the co-op ended.

Mass Balance Reconciliation. Built a balance model for a coating unit and reconciled it against 4 months of plant data. The 4% gap it exposed traced to an unmetered vent stream, and a permanent flow meter was installed as a result.

Extra-Curricular Activities

Vice president of the student chapter of the American Institute of Chemical Engineers, organizing 9 plant tours across 2 years.
Volunteer with a STEM outreach program, running chemistry demonstrations for about 150 middle school students a year.
Member of the university's Chem-E-Car team for 3 years, responsible for the reaction timing system.

Leadership

Led a 4-person senior design team through a full plant design, delivering the 90-page report 1 week ahead of deadline.
Served as vice president of a student chapter of 70 members, organizing 9 industry plant tours across 2 years.
Trained 3 incoming research assistants on the laboratory procedures and the Python analysis pipeline.

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Process Development Engineer Resume Example

Meet Rania Haddad, a process development engineer taking processes from laboratory bench through pilot to commercial scale. This example highlights scale-up work, experimental design, and the transfer packages that let manufacturing actually run what development invented.

Rania Haddad

(609) 555-0176 ◇ Princeton, NJ

rania.haddad@example.com ◇ linkedin.com/in/rania-haddad ◇ raniahaddad.com

Objective

Process Development Engineer with 9 years taking processes from bench through pilot to commercial scale in specialty chemicals. Scaled 7 processes to commercial production, with 6 hitting target yield within the first campaign, and cut average development cycle time from 22 months to 14. Writes transfer packages that manufacturing can actually run, which is the part of development that decides whether the work mattered.

Education

Ph.D. in Chemical Engineering, Raritan Crest University 2012 – 2016

Dissertation on mixing effects in scale-dependent reaction selectivity for multiphase systems.

B.S. in Chemical Engineering, Delaware Bend University 2008 – 2012

Graduated with highest honors; two industrial internships in process development before graduate study.

Skills

Scale-Up

Bench to pilot to commercial transfer, dimensional analysis, mixing and heat transfer scaling, risk assessment

Experimental Design

Design of experiments, quality by design, response surface modeling, kinetic studies, robustness testing

Technology Transfer

Transfer package authoring, operator training, first campaign support, troubleshooting, process characterization

Tools & Systems

Aspen Plus, DynoChem, JMP, Minitab, Python, LabVIEW, Microsoft Excel, electronic lab notebooks

Experience

Senior Process Development Engineer 04/2020 – Present

Millstone Reach Specialty Chemicals Princeton, NJ

Own development for 4 product lines, taking processes from bench through a 200 liter pilot to commercial scale.
Scaled 5 processes to commercial production, with 4 hitting target yield in the first campaign against a historical rate of 1 in 3.
Cut average development cycle time from 22 months to 14 by front-loading robustness testing instead of discovering limits at scale.

Process Development Engineer 08/2016 – 03/2020

Hopewell Line Fine Chemicals Trenton, NJ

Developed and scaled 2 processes to commercial manufacture, supporting 6 first campaigns on site.
Raised yield on a flagship intermediate from 71% to 89% through a solvent and temperature study across 40 experiments.
Reduced a reaction cycle time from 18 hours to 7 by identifying mixing as the true rate limitation rather than kinetics.

Graduate Research Assistant 09/2012 – 07/2016

Raritan Crest University Princeton, NJ

Ran 400 experiments investigating mixing effects on selectivity across 3 reactor geometries.
Published 4 peer-reviewed papers and presented at 6 conferences on scale-dependent reaction behavior.
Mentored 5 undergraduate researchers, 3 of whom continued into graduate programs in chemical engineering.

Projects

Front-Loaded Robustness Testing. Moved edge-of-range and failure-mode testing from post-pilot to the bench stage, so scale-up surprises surface when they are cheap. Average development cycle time fell from 22 months to 14 and first-campaign success rose sharply.

Mixing-Limited Reaction Study. Demonstrated that an 18-hour reaction was mixing-limited rather than kinetically limited, using dimensional analysis and targeted experiments. Redesigning the agitation cut cycle time to 7 hours and added 40% capacity to the unit.

Transfer Package Standard. Redesigned the technology transfer package around what operators and plant engineers actually need, including known failure modes and their signatures. First-campaign troubleshooting time dropped by roughly two thirds across 5 transfers.

Extra-Curricular Activities

Review manuscripts for 2 chemical engineering journals, assessing roughly 12 submissions a year.
Mentor 3 graduate students a year through an industry partnership, focused on the transition from academia to industry.
Present annually at a process development conference, most recently on scale-up risk to about 150 attendees.

Leadership

Lead development projects with cross-functional teams of 8 spanning research, engineering, manufacturing, and quality.
Set the technology transfer standard now used for every commercial scale-up at the site, across 5 transfers so far.
Mentor 3 development engineers, 2 of whom now lead their own product lines end to end.

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Process Design Engineer Resume Example

Meet Bertrand Okafor, a process design engineer producing the flowsheets, mass balances, and equipment specifications that get built. This example demonstrates front-end engineering design, simulation work, and capital cost estimation on projects that reached construction.

Bertrand Okafor

(281) 555-0154 ◇ Sugar Land, TX

bertrand.okafor@example.com ◇ linkedin.com/in/bertrand-okafor ◇ bertrandokafor.com

Objective

Process Design Engineer with 11 years producing the flowsheets, mass balances, and equipment specifications that get built. Delivered front-end design on 14 projects worth $380M combined, of which 9 reached construction, and improved capital cost estimate accuracy from plus or minus 35% to plus or minus 12%. Designs on the assumption that someone will have to operate and maintain the result for twenty years.

Education

B.S. in Chemical Engineering, Brazos Meridian University 2010 – 2014

Coursework in Plant Design, Separations, Process Economics, and Equipment Design.

Professional Engineer, Chemical, Texas Board of Professional Engineers 2019

License current; also completed an advanced process simulation certification through a vendor program in 2021.

Skills

Design Deliverables

Process flow diagrams, piping and instrumentation diagrams, mass and energy balances, equipment datasheets

Engineering Analysis

Hydraulic calculations, relief sizing, equipment sizing, line sizing, utility load estimation, simulation

Project Delivery

Front-end engineering design, capital cost estimation, vendor bid evaluation, design reviews, constructability

Tools & Systems

Aspen Plus and HYSYS, AutoCAD Plant 3D, SmartPlant, HTRI, Aspen Capital Cost Estimator, PHA-Pro, Excel

Experience

Lead Process Design Engineer 03/2020 – Present

Westfield Bayou Engineering Sugar Land, TX

Lead process design on projects between $8M and $95M, currently running 3 concurrently with a design team of 6.
Improved capital cost estimate accuracy from plus or minus 35% to plus or minus 12% by building a benchmark database from 40 past projects.
Delivered front-end design on 8 projects since 2020, of which 5 have proceeded to construction and 3 are complete.

Process Design Engineer 06/2016 – 02/2020

Colorado Bend Process Consultants Houston, TX

Produced design packages for 6 projects covering separations, heat transfer, and storage across 3 client industries.
Reduced a client's capital cost by $4.2M on one project by replacing a proposed 2-column scheme with a single divided-wall column.
Sized and specified 140 pieces of equipment across 6 projects, with no design changes required during construction.

Process Engineer 07/2014 – 05/2016

San Jacinto Line Chemicals Baytown, TX

Supported 2 operating units while producing design packages for 9 small capital projects under $2M each.
Corrected 60 discrepancies between piping and instrumentation diagrams and the field across 4 units.
Completed relief system reviews on 30 devices, finding 4 undersized cases that were corrected during the next turnaround.

Projects

Capital Estimate Benchmark Database. Built a database of actual versus estimated cost across 40 completed projects, broken down by equipment class and installation factor. Estimate accuracy tightened from plus or minus 35% to plus or minus 12%, and 2 projects were stopped early on realistic numbers.

Divided-Wall Column Redesign. Replaced a proposed 2-column separation scheme with a single divided-wall column after simulation showed the separation was achievable. Capital cost fell $4.2M and the plot space requirement dropped by roughly 40%.

Design Review Standard. Introduced a structured constructability and operability review at 30% and 60% design completion, with operations and maintenance in the room. Design changes discovered during construction fell to near zero across 5 subsequent projects.

Extra-Curricular Activities

Member of the American Institute of Chemical Engineers, serving on the local section design practice committee.
Guest lecture once a year in a university plant design course, reaching about 70 senior students.
Volunteer engineering advisor for a clean water nonprofit, reviewing 3 treatment system designs a year.

Leadership

Lead a design team of 6 across 3 concurrent projects, reviewing every deliverable before client issue.
Established the constructability review standard now applied to all company design projects at 30% and 60% completion.
Mentor 4 junior design engineers, 2 of whom now produce design packages independently for smaller projects.

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Process Validation Engineer Resume Example

Meet Delphine Marchetti, a process validation engineer working under regulatory requirements where an undocumented process may as well not exist. This example shows protocol authoring, qualification execution, deviation handling, and clean regulatory inspection outcomes.

Delphine Marchetti

(978) 555-0163 ◇ Andover, MA

delphine.marchetti@example.com ◇ linkedin.com/in/delphine-marchetti ◇ delphinemarchetti.com

Objective

Process Validation Engineer with 10 years in pharmaceutical manufacturing, where an undocumented process may as well not exist. Authored and executed 120 validation protocols with a 96% first-pass approval rate, supported 6 regulatory inspections with no process validation findings, and cut protocol cycle time from 14 weeks to 8. Writes protocols that survive both the deviation and the inspector.

Education

M.S. in Pharmaceutical Engineering, Merrimack Ridge University 2013 – 2015

Coursework in Validation, Regulatory Affairs, Sterile Manufacturing, and Quality Systems.

B.S. in Chemical Engineering, Charles Bend University 2009 – 2013

Graduated cum laude; certified quality engineer through the American Society for Quality since 2019.

Skills

Validation

Protocol authoring, installation and operational qualification, performance qualification, cleaning validation

Regulatory & Quality

Current good manufacturing practice, FDA and EMA requirements, deviation and CAPA handling, change control

Process Characterization

Critical parameter identification, design space definition, statistical justification, continued process verification

Tools & Systems

Veeva Vault, TrackWise, Minitab, JMP, Microsoft Excel, LIMS, electronic batch records, SAP

Experience

Senior Process Validation Engineer 01/2020 – Present

Concord Bay Pharmaceuticals Andover, MA

Own validation for 5 commercial products across 3 manufacturing suites, authoring roughly 20 protocols a year.
Supported 4 regulatory inspections including 2 FDA pre-approval inspections, all closing with no process validation findings.
Cut protocol cycle time from 14 weeks to 8 by introducing a pre-approval technical review before formal quality routing.

Process Validation Engineer 07/2016 – 12/2019

Nashoba Line Biologics Woburn, MA

Executed 70 qualification protocols across 12 pieces of equipment and 4 cleaning processes.
Raised first-pass protocol approval from 74% to 96% by standardizing acceptance criteria and pre-reviewing 3 recurring failure points.
Investigated 40 validation deviations, closing 38 within the 30-day target with root cause identified in each case.

Manufacturing Engineer 08/2015 – 06/2016

Assabet Point Medical Products Marlborough, MA

Supported 3 production lines with process troubleshooting and batch record review for about 90 batches a year.
Reduced batch record errors by 52% by redesigning 6 forms around the sequence operators actually work in.
Completed 18 change controls covering equipment and process modifications, all approved without rework.

Projects

Protocol Standardization. Rebuilt protocol templates around standardized acceptance criteria and pre-reviewed the 3 sections that failed most often in quality routing. First-pass approval rose from 74% to 96% and cycle time fell from 14 weeks to 8.

Continued Process Verification Program. Established ongoing statistical monitoring of critical parameters across 5 commercial products, replacing periodic revalidation with continuous evidence. The program was reviewed favorably in 2 regulatory inspections.

Cleaning Validation Rationalization. Applied a worst-case product grouping approach to 4 cleaning processes across shared equipment, backed by solubility and toxicity data. Validation execution effort fell by roughly 60% with the regulatory position strengthened rather than weakened.

Extra-Curricular Activities

Member of the International Society for Pharmaceutical Engineering, serving on a local chapter committee since 2021.
Present at a regional validation conference most years, most recently on continued process verification to about 130 attendees.
Mentor 3 engineers a year entering regulated manufacturing from other industries, through a professional society program.

Leadership

Serve as validation lead for 5 commercial products, coordinating with quality, manufacturing, and regulatory on every protocol.
Act as the site subject matter expert in regulatory inspections, having presented process validation in 6 inspections.
Trained 14 engineers and technicians on protocol authoring and execution, which is what lifted first-pass approval to 96%.

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Process Control Engineer Resume Example

Meet Yusuf Demirci, a process control engineer working on the instrumentation, loops, and advanced control that hold a plant steady. This example highlights loop tuning, control strategy design, alarm rationalization, and the stability gains those produce.

Yusuf Demirci

(302) 555-0182 ◇ Wilmington, DE

yusuf.demirci@example.com ◇ linkedin.com/in/yusuf-demirci ◇ yusufdemirci.com

Objective

Process Control Engineer with 8 years on the instrumentation, loops, and advanced control that hold a plant steady. Retuned 240 control loops to cut variability by 38%, deployed model predictive control on 2 units worth $2.7M a year in tighter operation, and reduced operator alarms from 1,400 a day to 190. Fixes the loop that operators had quietly switched to manual three years ago.

Education

M.S. in Chemical Engineering, Brandywine Ridge University 2015 – 2017

Concentration in Process Systems Engineering; thesis on model predictive control for constrained units.

B.S. in Chemical Engineering, Delaware Crest University 2011 – 2015

Graduated with honors; certified automation professional through ISA since 2021 and current.

Skills

Regulatory Control

Loop tuning, cascade and feedforward design, valve sizing review, instrument selection, control narratives

Advanced Control

Model predictive control, step testing, model identification, inferential properties, constraint handling

Operations Interface

Alarm rationalization, graphics design, operator training, performance monitoring, benefit tracking

Tools & Systems

DeltaV, Honeywell Experion, Aspen DMC3, MATLAB, Python, AVEVA PI, PlantTriage, Aspen Plus

Experience

Process Control Engineer 05/2020 – Present

Christina River Chemical Works Wilmington, DE

Own control performance across 5 units and roughly 1,100 control loops at a continuous chemical plant.
Retuned 240 loops and rebuilt 30 control strategies, cutting average variability by 38% and returning 90 loops from manual to automatic.
Deployed model predictive control on 2 units, worth $2.7M a year by operating closer to constraints without exceeding them.

Controls and Automation Engineer 08/2017 – 04/2020

Naaman Point Polymers New Castle, DE

Supported control systems for 3 production lines, including 2 distributed control system migrations.
Reduced operator alarms from 1,400 a day to 190 through a rationalization covering 2,600 configured alarms.
Cut product transition time between grades from 5 hours to 2 by implementing a sequenced ramp strategy.

Process Engineer 06/2017 – 07/2017

Brandywine Ridge University Wilmington, DE

Completed a 2-month research engagement building a model predictive control simulation for a constrained distillation column.
Ran 40 simulated step tests to identify process models across 3 operating regions.
Documented the control strategy in a 45-page report that the sponsoring company used as the basis for a pilot deployment.

Projects

Loop Performance Program. Assessed all 1,100 loops for oscillation, valve stiction, and time in manual, then retuned 240 and rebuilt 30 strategies. Average variability fell 38% and 90 loops that operators had abandoned came back to automatic control.

Model Predictive Control Deployment. Ran step testing, identified models, and commissioned advanced control on 2 units, including operator training and benefit tracking. The deployment delivers about $2.7M a year by holding closer to constraints.

Alarm Rationalization. Reviewed 2,600 configured alarms against whether each required an operator action, then removed, reprioritized, or suppressed accordingly. Daily alarms fell from 1,400 to 190, and operators began responding to alarms rather than acknowledging them.

Extra-Curricular Activities

Member of the International Society of Automation, serving on the local section technical program committee.
Teach a short course on loop tuning at a regional automation event, reaching about 40 engineers a year.
Mentor 2 engineers a year moving from process into control roles, through a professional society program.

Leadership

Lead the site's control performance program, coordinating with 4 unit engineers and the maintenance instrumentation team.
Trained 45 operators across 3 shifts on the model predictive control applications, which is why they stayed switched on.
Chaired the alarm rationalization working group of 7 spanning operations, engineering, and safety.

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