George Constantinescu Portfolio

Over 30 years experience operating and maintaining fertilizer and petrochemical plants

George Constantinescu, MSc, P.Eng, MMPPORTFOLIO


AMMONIA PLANT Contributing to 30% reduction of maintenance cost through implementation of PM concepts and practices Graduating from MSc program with final thesis Optimization of Steam Methane Reforming Process. Implementation of the optimization actions led to 50% increase in catalyst lifeParticipating in the turnaround planning process, supervising and coordinating assigned areas during turnaround


PETROCHEMICAL PLANTS Being an active member of the turnaround planning and execution team contributing to overall reduction of turnaround time by 20% Coordinated the following projects in the Acrylonitrile plant: 1) Replace refractory lining of the Incinerator; 2) Replace Boiler Feed Water pumps and upgrade piping layout and instrumentation Directing process engineering team and train junior engineers on site (Acrylonitrile plant) Managing plant operation and personnel resulting in a consistent increase of the production rates by 12% (Ethyl Alcohol plant) Offered technical assistance and supervised the installation of a new alcohol loading facility ($ 200K capital project)


AMMONIUM NITRATE/NITRIC ACID PLANT

Managing multiple projects involving multi-disciplined teams: Unloading, Storage and Distribution Facility for anti-caking/anti-dusting agent for Ammonium Nitrate prills Upgrade of Loading Facilities for Nitric Acid and Ammonium Nitrate Recirculation Facility for Ammonium Nitrate 83% Solution


AMMONIUM NITRATE/NITRIC ACID PLANT and PEMAC

Participated at three ANNA (Ammonium Nitrate - Nitric Acid) conferences and partnered with the Process Engineering Manager to prepare a presentation on Instrumentation Upgrading of Ammonium Nitrate Neutralizer Enrolled and graduated from the MMP (Maintenance Management Professional) program endorsed by PEMAC (Plant Engineering & Maintenance Association of Canada)


AMMONIUM NITRATE/NITRIC ACID PLANT and PEMAC

Acted as Chair of the Eastern Ontario Chapter of PEMAC from 2003 to 2005 Being an active member of the PEMAC Board of Directors until 2011:

Founding member of the Professional Development Committee

Working with the Membership & Marketing Committee to increase membership, raise awareness and increase the visibility of the association


CARBON BLACK PLANT Implementing predictive maintenance concepts and techniques and optimizing preventive maintenance program leading to consistent performance with low operational downtime and virtually free of rotating equipment breakdowns resulting in 10% cost reduction Directing the planning and execution of turnaround projects with a strong emphasis on cost control; staying within the allocated budget and timeframe was the highlight of the last three years


CARBON BLACK PLANT Developed and implemented a plant wise structural steel inspection plan; evaluated the condition of the structures, planned and scheduled repair and/or replacement work for the incoming years Developed a refractory improvement plan for the tread and carcass carbon black reactors along with the assigned contractor. Training on refractory materials, selecting refractory materials based on new process conditions, improving process control/monitoring and planning major furnace repairs and refractory replacement were the foundation of the plan


CARBON BLACK PLANT

MANAGEMENT HIGHLIGHTSAfter 3 years when the maintenance budget was overspent generally by 15-20% , currently the budget is maintained at the 2009 level In the quest to better even further our performance the corporate established NAMET (North American Manufacturing Excellence Team) to identify, set up and implement best manufacturing practices; the Maintenance Manager and Planner were part of this team, responsible for reliability and uptime improvements


CARBON BLACK PLANT

MANAGEMENT HIGHLIGHTS Safety is paramount at Columbian and Maintenance department is a leader in promoting the culture of safe work; our department had only one recordable injury and no lost time incidents in the last 6 years Managing unionized and non-unionized employees by promoting an environment of free communication, trust and mutual respect recording only one grievance in the last 3 years


CARBON BLACK PLANTMANAGEMENT HIGHLIGHTS

Hired and provided on the job hands on training and coaching to our Planner, specifically for turnaround and special projects planning; prepared him as a viable successor for the Maintenance Manager position when need arises Developed a training needs matrix and encouraged professional training and development of our employees in areas such as pumps and turbines operation and maintenance, bearings and lubrication, valve and steam trap selection and repair


POWER PLANT CONSTRUCTION Directed and supervised the field installation of main underground piping (cooling water supply and return headers) and services (drainage and sewage, main fire water ring) Coordinated assembly of the steam turbine condenser (Holtec design) as per supplied fabrication drawings and prepared for field installation Coordinated lifting and crane operation on construction site and overseen the crane maintenance program Streamlined purchasing process by negotiating the lowest rental rates for equipment and a 30% discount on materials and tools


ETHANOL PLANT•Evaluated reliability improvement opportunities and initiated a short to mid-term action plan•Rectified successive bearing failures of

dryer exhaust fan in cooperation with fan expert

• Prepared contingency plan for loss of boilers for insurance purposes• Prepared maintenance procedure for electrical heat tracing on site• Coordinated troubleshooting project of one hammer mill by re-engineering dust collector and re-positioning mill• Conducted a plant wise survey of equipment guarding and prepared plan to rectify non-conforming guards


OIL REFINERY

•Coordinate site maintenance by reviewing and balancing daily schedule loads, optimizing resource allocation and analyzing compliance to established schedule• Drive the continuous improvement of maintenance systems by applying best maintenance practices, establishing precise performance objectives and directing execution and roll out of Maintenance Excellence program

George Constantinescu Portfolio

Leadership & Management

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