Curriculum Vitae

Forensic Consulting Experience

Warehouse Distribution Facility – Maryland – Evaluated a $10M (million) claim relating to purported construction defect claims by the 600,000 sq. ft. facility owner against the facility construction contractor and an original equipment manufacturer relating to installed infrastructure in the facility. Developed and provided an expert opinion and expert report regarding the analysis of the purported defects and a proposed repair solution to correct said defects. Reviewed numerous reports regarding the matter including structural, repair/maintenance, operations related etc. to determine opinion. The matter settled prior to federal court trial.

Psychiatric Hospital Facility – North Carolina – Evaluated a $28M (million) construction claim by the general contractor against a hospital facility concerning a $100M facility construction project.  Developed an expert opinion and report for general construction issues, constructability, design revisions, and corresponding delay analysis for mechanical, HVAC, electrical, smoke and fire, structural, security and building automation systems. Reviewed findings with multi – discipline experts for mediation, leading to a negotiated settlement favorable to our client.

Municipal Building/Facility – Northern NJ – Evaluated and provided expert witness mediation testimony regarding a $3M construction delay claim by general contractor against municipal facility concerning an $8M renovation and new construction project. Analysis included review of plaintiff’s claim, project schedules, critical path & time impact considerations, delays, pay applications, contract terms, change orders, consequential & liquidated damages, lien and bond issues, correspondence and numerous other project documents. Guided mediation to quickly develop a very favorable settlement for our client.

Construction Claims, Pa – Multiple Pennsylvania Locations – Reviewed and evaluated multiple construction defect claims of residential/commercial construction buildings considering or in active litigation. Performed site visits and inspections during tear-offs and provided forensic analyses of expert reports, materials & methods of construction, construction documents, building code requirements, and humidity infiltration. Developed expert witness materials for the relevant legal team for use in arbitration / mediation hearings.

EXPERT WITNESS FORENSICS WORK IN PROGRESS

2022 – Construction Defect Matter, Multiple Alleged Defects

2022 – Refrigeration Maintenance and Reliability Matter, Facility Operations, Slip and Fall Matter

2022 – Mechanical Products Fabrication Defect Matter & Analysis

2022 – International Trade Commission (ITC) Matter – Resin Manufacturing Facility Construction Delay / Completeness Analysis

2022 – Church Construction Related Defect Matter Relating to Structural and Roofing Failures

2021 – Industrial Manufacturing Facility Standard of Care Matter, Construction Defect, Construction Delay    

2021 – State Highway Construction Project Defect & Delay Matter

2021 – Electrical Distribution System Construction Defect Matter, Standard of Care

2021 – Hotel Facility HVAC Materials of Construction Related Defect Matter

2021 – Condominium Complex Construction Defect Matter

2021 – Structural Matter Relating to Alleged Construction Defects and a Collapsing Structure

2021 – Multiple Patent Infringement / Licensing Matters

2020 – State Highway Construction Project Defect & Delay Matter – Multiple Locations

General Experience

Mr. Pollock has 25 years of engineering experience working on regional, national and global projects in designing, consulting, project and construction management, operations, facilities and real estate, contract administration, engineering finance and economics.  He has provided subject matter expertise in engineering, facility design and operations, manufacturing, equipment and systems technology, product and raw material deficiencies, defect identification and elimination. As a problem solver, he has worked on insurance matters, supporting original equipment manufacturers (OEMs), numerous businesses and facility operations, consumers, and other stakeholders.

His expertise includes design and engineering of commercial, industrial, manufacturing, institutional, and residential venues, as well as efforts relating to services and products used in and around these facilities.  Business and industries include electronics, safety and construction, building materials, polymers and plastics, instrumentation manufacturing, petrochemicals, chemicals, pharmaceuticals, colleges, athletic facilities, textiles, coatings and resins, food storage, biosciences, supermarkets, inks & pigments, automotive, facility and real estate operations, agricultural, transportation, nuclear, healthcare, nutrition, retail, distributors, pulp and paper, packaging, utilities, apparel, and R&D centers.

Mr. Pollock is a subject matter expert in commercial and industrial engineering applications and projects, as well as engineering standards and applicable codes including: ASHRAE, ASME, NIST, NFPA, NBIC, ASTM, SAE, LEED, ASCE, GMP, ISA, BOCA, and EPA Regulations. Mr. Pollock has developed expertise and provided training on investment engineering economics, engineering standards, chillers, refrigeration, thermodynamics, water treatment, steam systems and boilers, power and utilities, energy conservation, environmental, safety, HVAC, project management and product development.  Mr. Pollock has also engaged with local, state, and governmental officials and agencies regarding numerous matters over his commensurate years of experience.

Commercial & Industrial Investigations

Research and Development Labs Buildings – Delaware – Researched and provided mitigating efforts for several electrical substation failures (500 KVA to 38 MVA) including fires and explosions.  Performed Root Cause Analysis (RCA) to determine contributing factors including oil issues, poor maintenance, age, insulator breakdown, and wildlife intrusion.  Developed preventative maintenance measures, design alterations, life expectancy and replacement criteria for substation capital planning. Performed consequence analyses including financial and personnel safety profiles to minimize risk.

Industrial Park/R&D Center – Delaware – Evaluated numerous process systems with wastewater environmental excursions.  Led process engineering efforts for the facility to manage the issue, reducing process excursions from 14 annual occurrences down to 1 occurrence, and avoided expected capex of $8M to $15M for a planned infrastructure project to correct the problem.

Agricultural Research and Processing Facility – Newark, DE – Investigated the catastrophic failure of a flue gas recirculation (FGR) fan on a high–pressure steam boiler with near miss potential, including materials of construction and metallurgical analyses.  Found traces of sodium on the carbon steel fan wheel along with corrosion and cracks, both macro and minor. The root cause analysis identified tube failures as the sodium source causing boiler water to introduce to the air side of the combustion system.  A stainless-steel fan wheel was specified for the new design to prevent future failures. The expedited project prevented facility downtime risk estimated at a $500K daily value.

Office & Research Facility – Delaware – Reviewed a near miss water hammer incident, where poor condensate removal during a steam system startup forced a slug to burst a valve assembly causing high pressure steam emission in a mechanical room where personnel were in general proximity.

Pulp and Paper Company – Chester, PA – Investigated structural and civil engineering of concrete foundations in the manufacturing facility underneath large paper processing equipment to identify causes of vibration.  Performed vibration analyses on rotating equipment and on concrete structure, isolating the problem areas to the lower foundation section.  Devised a solution with a resin injection company to reconstitute damaged portions of the foundations.  Efforts were done with di minimis interruption to operations, with a daily production rate of $500K in sales.

Four Star Hotel & Office Building – Rodney Square, Delaware – Investigated, engineered and improved many aspects of facility operation, mechanical systems, indoor air quality (IAQ), HVAC, building automation systems (BAS), boilers, combustion tuning, chillers, utilities billing and metering to 3rd parties, steam leaks, piping distribution, to achieve increased reliability for the overall facility.

Commercial Supermarkets – US Nationally (PA, MI, WI, CA, DE, MN, UT, NY, OH, FL) – Performed investigations of refrigeration system issues, including fires during maintenance activities.  Determined the cause of the fires were improper oil removal (vs. the perceived flammability of refrigerants) and advised owners and operators to fully and positively de–inventory refrigerant oil before the use of any open flame (torch) around the system.  This recommendation led to reduced risk for the facilities and reduced potential litigation.  This also prevented the release of incorrect information, such that the refrigerants were flammable, when they were not. Also, investigated the release of refrigerants to ambient due to improper replacement of seals and gaskets as recommended by the Original Equipment Manufacturer (OEM).

Roofing and Building Materials Manufacturer – Mexico & Brazil – Evaluated roofing and roofing membrane products, including general properties, sustainability, energy aspects, greenhouse gas (GHG) and life cycle properties (cradle to grave).  Findings were utilized in the development of product and marketing materials.

Building Materials Manufacturer – Richmond, VA & Wilmington, DE – Evaluated product properties of Tyvek building wrap including general product properties and infiltration benefits to residential and commercial buildings.  Investigated blower door data, performed ASHRAE, TRANE and “Energy 10” simulations to estimate a 10% reduced infiltration for buildings with certain types of moisture barrier protections.  Issued findings and co–authored a paper on the findings which were utilized in aiding the development of product claims and marketing materials. Interfaced with EPA, Department of Energy (DOE), and Oak Ridge National Laboratory (ORNL) as part of the effort.

Residential & Commercial Foam Insulation Manufacturer – Wilmington, DE – Performed a product comparison of spray foam insulations including R-Values, manufacturing and application costing.  Performed a product liability analysis for a proposed next generation drywall material (vs. gypsum) and determined flammability risks of the new application were too high and recommended against the new application.

Coatings and Colorants Manufacturing Facility – Investigated an EPA refrigerant release due to a large centrifugal chiller, finding the root cause to be contract maintenance.  Met with the owner and the contractor to discuss and prevent future occurrences ($1 million value).  Investigated a large process cooling tower causing reliability and downtime losses in production valued at $1M per day.  Implemented changes with plant operations to correct maintenance issues to deliver uptime benefits.

Country Club & Golf Course – Delaware – Investigated a new product application failure on an HVAC system causing reliability and potential Indoor Air Quality issues (IAQ).  Worked with multiple OEMs with recommendations for the supplier OEM to use the new product only in compatible units, avoiding substantial commercialization costs and potential litigation.

Petrochemical Manufacturing Facility – West Virginia – Investigated the (vacuum) collapse of a large product storage silo and implemented corrective action, including reforming the vessel and safely welding stiffener rings (in a Class 1 Div. 1 atmosphere) in strategic locations.  Investigated a large production fire caused by a plugged rotary blower on a pneumatic product conveying system.  Implemented a 2 of 3 voting control scheme to provide safety interlocks to shut the system down to prevent future fires.  

Petrochemical Facility – LaPorte, TX – Reviewed OSHA findings and the facility owner’s operations and maintenance activities regarding four fatalities that occurred during the facility startup after maintenance activities on the unit. Findings indicated unfamiliar situations for operations personnel.

Consumer Products/Injection Molding Manufacturer – Milford, CT – Performed a Route Cause Analysis (RCA) for a consumer product line regarding quality and safety concerns. Reviewed both the intermediate materials manufacturer, and the end use manufacturer’s facilities (injection molding), and determined the problem was contamination at the former’s facility.  Investigated the relevant quality and operations procedures and found operations had not performed the requisite quality checks appropriately.  Additionally, an equipment overhaul was required.  Led the expedited $600K machine overhaul to successfully rebuild the manufacturing equipment per OEM specification.

Electronics/Coatings Manufacturer, Joint Venture – Sayreville, NJ – Evaluated failures of hot water heat exchangers (HX) used to condition HVAC systems of Class 1,000 and 10,000 clean room operations, causing product quality and downtime issues. Determined the Materials of Construction of the HX were prone to erosion due to fluid velocity and recommended replacement with Stainless Steel.

Mixed Use Facilities – Globally – Reviewed and investigated personal injuries and incidents including slips, trips and falls, hand injuries, back injuries, fork truck incidents, ergonomic injuries, hearing loss, an electrical related loss of limb accident, a breathing air fatality, construction and facilities injuries, vehicle accidents, NESHAPS exposures, asbestos incidents, asbestos remediation, lock tag try incidents, excavation incidents, confined space and asphyxiation risks, trenching and shoring up incidents.

Mixed Manufacturing / Armored Products Facility – Deepwater, NJ – Participated with the investigation team to review a serious fire that occurred on a thermal oxidizer system (newly refurbished) incineration unit just after startup of the armored products intermediates manufacturing unit.  Team findings showed the design-build firm failed to consider the possibility of backflow in a portion of the circuit.  As such, the materials of construction in this section were inappropriate for use with high temperature flue gas which melted that section and caught fire. The team’s recommendations included upgrading materials of construction, increased instrumentation and unit controls, and awareness training for both the design firm & unit operations.  The estimated value of lost downtime for this event was $20M.

Electronics Developer & Manufacturer – Santa Barbara, CA – Led design, engineering, and construction management of a semi-works facility scale up. The scope included upgrades to building and structural infrastructure, utility systems, prototyping/production areas, clean rooms and labs, as well as office and administrative areas at multiple locations.  Maintained a fast-paced project schedule and kept project on budget to successfully complete the $40M project.

Automotive Coatings Production Facility – Philadelphia, PA – Investigated new products in the development, scale up and commercialization of automotive resins, coatings, and inkjet inks. Ran R&D efforts for new formulations, catalysts, processed test batches on reactors and media mills, and performed product quality and performance tests.  Made recommendations to business stakeholders regarding whether to proceed with proposed formulations.  Managed operations, engineering, maintenance and scheduling of product wheel on 6 process manufacturing lines.  Purview included full administrative control over several production reactors with over $80M in annual production. Significantly reduced production overtime in a union environment. Analyzed customer failures (complaints) for truck, auto, and airline products by forensically tracing back to manufacturing batches and checking for process upset causation. Reviewed and led portions of consequence analyses (CA) regarding catastrophic failures of facility systems including explosions, detonations, fire, and potential loss of life calculations to ascertain risk of operations. Managed Toxic Substances Control Acts (TSCA) requirements in a High Hazard facility.

Textile, Safety, Armored Products & Construction Products Manufacturer – Richmond, VA – Performed an infrastructure risk assessment of a large industrial manufacturing complex (including products manufactured for U.S. Department of Defense contracts) with focus on risk of downtime valued at $1.5M/day.  Developed $70M in capital project recommendations including upgrades to the water and wastewater systems, chillers (18000-ton capacity review), 30MW turbine generators, utilities infrastructure and distribution systems, heat sink/spray pond. Implemented upgrade projects with site engineers over several years to deliver uptime improvement benefits for the site.

Commercial Research & Office Facility – Greenville, DE – Reviewed the failure of a 500 KW Diesel Generator used for peak shaving and determined the catastrophic failure of the supercharger assembly. Reviewed the electrical savings and financial impact related to the generator and determined no functional savings from continued operation.  Recommended ending the use of the peak shaving generator, avoiding a capex replacement savings of $300K.

Mechanical Systems Design Firm – Kalamazoo, MI – Investigated a new product failure, a one-ton hydraulic box dumping system, at a packaging and distribution facility.  Developed a design upgrade in conjunction with the design-build firm at the facility.  The main repair was the replacement of bushings on the main pivot shaft with sealed, internally lubricated bearings.  The device worked well following the upgrades and kept a $250K per day production online.

Extrusion Manufacturing Facility – West Virginia WV – Performed root cause analyses of two fires that occurred during operation: (1) extruder head and (2) extruder barrels.  Successfully implemented process and administrative controls to eliminate additional fires, with uptime savings estimated at >$1M.  Witnessed and reviewed a large absorber column and flare fire with serious catastrophic potential.  Findings included loss of operational discipline (O.D.) in a Process Safety Managed (PSM) facility.

Pulp & Paper Mill – Southeast PA – Reviewed uptime and reliability issues in the converting and packaging operations. Identified archaic equipment and controls, recommending upgrades to achieve a 4% to 6% uptime benefit.  Reviewed a fork-truck pedestrian incident, and other injuries at the facility and recommended upgrades to operating procedures to avoid future occurrences.

Petrochemical Manufacturer – Newtown Square, PA & Houston, TX – Investigated a reactor (bomb) explosion caused by a polymer decomposition in an R&D Lab.  Determined chemistry was likely incorrect and recognized that the vessel ruptured disc was inappropriate.  Made recommendations to process chemist and modified the ruptured disc design to avoid future occurrences.

Nuclear Power Generation Facility (Reactor Services) – Berks, PA – Participated in the investigation of a 1100 MW turbine trip during routine operation at the facility, with downtime losses estimated at $500K – $1M daily. Worked with the turbine and reactor services teams to determine that the cause was an electrical synchronization issue in the generator.  Findings included recommendations for some changes to routine maintenance practices as it pertained to these portions of the operation.

Subject Matter Expertise & Consulting

Dupont Company, Technology & Engineering Manager – Delaware – Led engineering technology, personnel, governance, and business oversight for 4 mixed use macro facilities in Delaware. Technology disciplines included mechanical systems, electrical, plumbing/piping (MEP), instrumentation, controls, chemical, automation, facilities, fire and life systems, power and utilities, information technology (IT), Building Automation Systems (BAS), site-wide security systems.  Facilities included manufacturing, product R&D, 3rd party leased spaces, a thermal waste treatment facility, offices and corporate HQ.

Key responsibilities included personnel management, capital and infrastructure planning, project management and execution, capital avoidance, operations cost administration and reduction, demand services, financial investment analyses and Process Technology (PT) Leadership for Process Safety Managed (PSM) Systems, both high hazard (HHP) and low hazard processes (LHP). Businesses included chemicals, polymers, electronics, safety and construction materials, agriculture, nutrition & health, biosciences. Provided Third Party Tennant technical support for Axalta^®, Chemours^®, Nemours^® Hospital, Incyte^® Corporation, Delaware Innovation Center^® and DOW^® Chemical facilities.

Research & Development Facilities > 50 Buildings – Delaware – As part of the site leadership team, led the facility Emergency Management Team (EMT) for planning, personnel management , communication system and protocol development, with management of site emergencies including: fires, electrical outages, loss of refrigeration for catalysts, hazardous and radioactive waste discoveries, Highly Toxic Material (HTM) exposures, site evacuations, fire drills, environmental management, spill management and containment.

Process Safety Management & Risk Managed Operations (PSM) – Delaware – Co-led the facilities PSM program, while leading the Process Technology (PT) element, for macro facilities in DE.  Managed authority of numerous elements of the process including, Management of Change Technology, Process Hazards Analysis, Process Hazards Review, Quality Assurance, Mechanical Integrity, Start Up Reviews, Standard Operating Procedures & Conditions (SOP’s and SOC’s).  Evaluated Requirements vs. Optional Items to optimize project and cost budgets of the facility.  Managed Factory Mutual/Hartford Insurance Inspections for national operations.

Mechanical Systems Engineering – Delaware – Led and provisioned the overall governance for the design and engineering for over 8000 mechanical systems, including HVAC, relief protection (RV’s), piping, pressure vessels, reactors, process engineering, process technology, pressure loss calculations, through utilization of a mixed engineering staff.  Classified systems in “Simple”, “Moderate”, “Complex” to track billable engineering hours for productivity benchmarking.  Increased overall engineering productivity by 10 to 15% by keeping appropriate metrics, KPI’s, and reviewing with engineering supervisors monthly.  Developed a screening requirement to ensure capital projects over $50K were in fact requirements under regulation (ASME) and intercompany standards. Managed contract engineering staff for Kellogg Brown & Root (KBR), Jacobs, Pennoni and Delaware Engineering including billing and invoicing, budgeting and reporting to upper management.  Reduced and/or increased contract engineering staff with ebb and flow of work.

Research & Development Facilities – Delaware – Conducted the R&D Tax Credit (RTTC) efforts for several facilities in Delaware for three years.  This annual program accounted for all expenses spent on R&D activities, including personnel, utilities, operations expenses etc., to be submitted for IRS tax credit purposes.  The annual benefit for the corporation was greater than $2M each year.

Site Security Systems – Delaware – Led technology aspects of building security, artificial intelligence (AI), camera installations (facial recognition), Andover Building Automation (BAS), tenant / 3rd party customer security systems, along with site and corporate security experts.  Replaced an inept service provider with a qualified provider to ensure functionality and reliability of systems.

Global US Manufacturer – Delaware, Nationally & Internationally – Led project and process upgrades in global facilities, with focus on: (1) Uptime, Reliability, Capacity, Quality, Yield, Safety, (2) Operating Cost and Capex Avoidance (3) Utilities, Emissions Reductions, Sustainability (4) Training and Mentoring Personnel on methods.  Business methods included Lean manufacturing, Six Sigma (DMAIC), infrastructure management, Operational Excellence & Discipline (OE, OD), Quality Assurance (QA, QC), project and investment financial analyses (NPV, ROI), supply chain & pricing negotiations, leveraged engineering, utilities optimization, continuous improvement and problem solving. Technical Competencies included Process Technology, HVAC, Refrigeration, Cooling Towers, Automation & Controls, Combustion & Emissions, Cogeneration, Mechanical / Hydraulic / Pneumatic Systems, Concrete, Piping, Instruments, Structural, Maintenance, Reliability, Fire & Life Safety (FLS), IT systems and data and Process Safety Management (PSM).

Commercial Supermarkets – US Nationally (PA, MI, WI, CA, DE, MN, UT, NY, OH, FL) – Led technology, market, and sales development for Dupont’s refrigeration products in N. America.  Developed a national tech staff to support new product lines and support customers’ installations and field trials.  Granted a “Marketing Excellence Award” for building a new business segment from $2.5 to $25 million in sales, in 3 yrs.  Major customers were: Walmart^®, Kroger^®, Sears^®, Lowes^® and Target^®.

Nylon & Textile Manufacturer – Seaford, DE – Evaluated a 30 MW turbine generator to identify a condenser leak.  Devised methods for repairs, assisted in implementation, yielding $500M annual savings (in perpetuity).  Performed engineering for several DowTherm hot oil (high hazard) systems.

Major Global US Manufacturer – U.S. Concerns – Led Northeast and Eastern US energy, sustainability and emissions metrics and optimization for numerous commercial and industrial facilities.  Audited facilities, provided high ROI energy conservation projects, corrected utility billing errors and compiled emissions data for the DOE (CO2, VOCs, HAPs, NESHAPs, MACT). Developed energy reduction practices at facilities to reduce energy expense and Green House Gas (GHG & carbon credits), valued at ~$70M (2006 – 2015). Awarded an “Exceptional Merit” citation by the American Chemistry Council (ACC) for related projects and presented these publicly at the Industrial Energy Technology Conference (IETC) in New Orleans, LA.

Product & Intellectual Property Developer – Radnor, PA – Specified, assembled, commissioned, programmed, and operated CNC machine tool equipment for prototyping.  Built Solid works 3D models and simulated new product parts and assemblies.  Commissioned an SLA polymer 3D printer for prototypes and worked with fabricators to make components for products.  Revised products on beta testing, performed commercialization activity and authored / prosecuted patent applications.

Rockwell Automation – Wilmington, DE & Cleveland, OH – Engineered process controls, combustion controls, data and IT systems.  Involved in >$5M of projects over 10 years.  Equipment included fans, turbines, motors, drives, HVAC, dampers, pumps, valves, controls, tuning, PID loops, sensors (flow, pressure, temperature, O₂, NO_x, SO_x, particulate, opacity).  Led Layers of Protection Analyses (LOPA) and consequence analyses to ascertain controls and instrumentation (I&C), and process probabilities of failure.  Required higher reliability I&C to correct failure rates to an acceptable failure rate range. Reviewed “black box” concerns to find deficiencies in control systems.  Integrated changes to existing system to satisfy regulatory (NFPA), intercompany combustion and emissions requirements.

Packaging, Chemicals, Electronics, Petrochemicals Manufacturer – Sayreville, NJ – Performed numerous consulting activities including analyses of domestic (city) water hydraulics, a 1M gallon storage tank corrosion assessment, a cogeneration plant bankruptcy, site utilities and HVAC energy assessments, production reliability, building automation systems (BAS), commercial water treatment facility review including cost per 1000 GAL and underground aquifer analyses, leased equipment cost avoidance, fire tube boiler inspections, chilled water systems foaming, water conservation efforts, the elimination of unused buildings and utilities.  Effort benefits developed $4.5M annually with an NPV of ~$15M.

Oil Refinery – Delaware City, DE – Performed operations consulting to improve uptime of refinery systems including spent sulfuric acid recovery, thermal oxidizers and other High Hazards Processes (HHPs). Compared actual and permitted emissions and issued recommendations to simplify operation.

Pulp and Paper Processing and Manufacturing – Chester, PA – Led operations engineering to develop a 10% capacity increase with a financial benefit of $38M annually.  Refit existing paper converters and packaged product in new format with focus on machine design to increase unit throughput.  Performed engineering, installed, and maintained Perini^®, Paper Converting Machine Co. (PCMC^®), and Scott Paper^® machinery to drive reliability, uptime and quality optimization.  Qualified a new raw material process on manufacturing equipment to save $250K in cost annually.  

Nuclear Utility Facility – Peach Bottom, PA – Evaluated reliability related failures of cranes, including the reactor refueling bridge crane and an overhead 120 Ton Crane.  Reviewed reliability issues during outages causing production losses of over $500K / day. Worked with operations to increase reliability, reevaluate spare parts and perform maintenance (PM) on a recommended frequency.

Automotive & Instrumentation Manufacturer – Germantown/Philadelphia – Performed manufacturing engineering including product and equipment design, project management, vendor qualification and design build management.  Technologies included automated TIG welding fabrication, Failure Mode Effect Analysis (FMEA), intellectual property (IP), CNC manufacturing, stamping, and pressing, vision systems and GE Fanuc programming.  Manufactured products were airbag and electronics parts, involving claymore mine detonators.

Acid Recovery Facility – Fort Hill, OH – Developed a steam turbine generator project using excess process (exothermic) steam to produce electricity with a 40% ROI and $300K annual savings.

ARCO Chemical Company – Newtown Sq., PA/Channelview, TX – Performed all aspects of piping and pressure vessel engineering including drawing, modeling, pipe flexural stress analyses, ASME vessel calculations and Finite Element Analysis (FEA) to predict failures.  Performed several engineered repairs for a macro polypropylene and polyethylene production facility. Interpreted aspects of piping and pressure vessel codes and standards inclusive of ASME, 31.1, 31.3, ASME Section I, VIII. Performed engineering for numerous projects with Flour Daniels^®.

Project Management Expertise

Safety Products Manufacturer Facility – Cooper River, VA – Led many aspects of project management including developing business objectives, scope, engineering investment analyses, designing, planning, scheduling, sourcing, staffing, budgeting, designing, equipment specifications, estimating, cost over-run analysis, bidding, constructing and commissioning of a $500M Greenfield project installation. Relevant facilities commissioned successfully on time and budget.

Industrial, R&D, Lab and Office $400M Facility & Infrastructure Expansion – Led many aspects of project and construction management including design engineering, cost and capital management, planning, scheduling, managing overruns, conceptual design and production design for projects to expand and refurbish an existing $1B dollar facility which included: $19M Cooling Tower Project, $10M 38KV / 33MVA Purchased Power Substation, $21M Boilers Installation & Conversions Project, $18M Underground Piping Distribution Replacement and Relining, $8M Pipe Bridge Replacement, $7M Fiber – Network – Data Upgrades, $30M Fire & Life (F&LS) Upgrade Program including distribution systems, $12M Chiller Replacement, $5M Sewer Systems Upgrade, $4M Thermal Waste Incinerator Overhaul, HVAC & Air Handler upgrades, numerous multimillion dollar structural and building expansions, and several parking, roads & grounds improvements (including drainage management).  These efforts allowed the continued operation of this facility which had an estimated value of $2M per day.

Cogeneration Plant, Mixed Use Facility – Sayreville, NJ – Engineered, designed, and performed project management for a $5.7M boiler facility project inclusive of boilers, de-aerator, water treatment systems, an economizer, distributed controls (DCS), emissions management, building & structural.  This effort avoided potential significant downtime of a $1.5M daily production rate facility. 

Facilities and Real Estate Business, Delaware. Received a “Business Excellence Award” for completion of projects.  Efforts reduced budget by $12M/yr. and avoided $17M in capex.  Projects also reduced the energy and environmental footprint of the facility, were completed on time, and $4M under budget.

 

Professional Training & Seminars

• American Arbitration Association – Construction Delay Arbitration
• Building and Facility Management (Dupont Training, spanning 2016 – 2019)
• Line Breaks, Lock Tag Clear Try, Pipe Codes, Process Safety Management, Pre-Start Up Safety Review (PSSR), Process Hazards Analysis (PHA), Mgmt. of Technology Change, Contracted Services.

• Mechanical Engineering – Mechanical Integrity Quality Insurance (MIQA), Pipe Codes, Rotating Equipment, Repairs & Changes, Reliability Engineering, MIQA Audits, Quality Control (QC) of Materials / Spare Parts, Maintenance Procedures, Welded Repairs / Alterations / Rerating, Piping and Insulation Systems, MIQA Program Awareness, Piping and Service Compatibility

• Construction – Scaffolding, Barricade Safety, Line Breaks, Lock Tag Clear Try, Contract Administration, Confined Space Training, Contractor Management

• Power & Utilities Power Systems – Steam Systems, Condensate Draining, Steam Generation, Stationary Generator Design, Thermal Waste Incineration, SOC’s, Process Hazards Anal. (PHA)
• Controls & Instrumentation – Alarms & Management, Electrical Safety Controls
• Environmental – Air Emissions, Hazards Communications, Title V Permit
• Safety Management – Asbestos, Barricades, Ergonomics, Fire Extinguishers, Diminished Capacity Employees & Supervisors, Driver Safety, Process Safety Management (PSM)

• Electrical Systems – Troubleshooting Circuits, Disconnecting & Removing Electrical Circuits, Electrical Standby Person Requirements, Electrical Safety Awareness, Electrical Area Classification

• Health – Access to Medical Records, Injury and Illness
• Safety Training – Slips, Trips and Falls
• Programmable Logic Controllers, Wilmington 2015
• Artificial Intelligence: Technologies for Smart Systems Design, Wilmington, 2014
• CNC Machining Technology, Wilmington, 2014
• EPA & OSHA Training, Wilmington, DE, 2006
• Professional Engineering Review – Mechanical Engineering, Drexel, 2007 (63 hours)
• ABB Control Systems, ABB University, Atlanta, 2005
• Decision and Risk Analysis (D&RA), Wilmington 2006
• Certified Engineering Manager Course for Energy Managers, Atlantic City, 2008
• YORK Industrial Refrigeration Training, York Process Systems, 2002

Profesional Awards & Certifications

• Granted two U.S. Patents, including 9,974,993, for consumer products.
• Successful Wastewater Process Controls Award, DuPont Facilities Services & Real Estate, 2018
• Business Excellence Award, DuPont Facilities Services, Real Estate, Energy Operations, 2017
• Team Project Excellence Award for Completion a $500M Manufacturing Facility, 2013
• Certified Energy Manager (CEM), Association of Energy Engineers, 2011
• Marketing Excellence Award for DuPont Refrigerants and Project Teams, 2008
• Refrigerant Recovery Certification, Delaware, 2006
• SIX SIGMA CERTIFICATION, Global Services Business, 2003
• Certificate of Achievement, Effective Combustion and its Control, North American Mfg. 2002

Building Information Modeling or BIM – Software & Programs

• Navisworks 3D
• Smartplant 3D (SP3D)
• PDMS Plant Design Management System
• AutoCAD
• Rhino CAD
• CAD/CAM – Computer Aided Machining (CAM)