2. General Overview
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.
Process-Logic Qualifications Page 2 of 22 Last Update: Jan 2009
3. 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.
Process-Logic Qualifications Page 3 of 22 Last Update: Jan 2009
4. 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
Process-Logic Qualifications Page 4 of 22 Last Update: Jan 2009
5. 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)
Process-Logic Qualifications Page 5 of 22 Last Update: Jan 2009
6. 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
§ 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
Memberships
Instrumentation, Systems, and Automation Society (ISA)
Process-Logic Qualifications Page 6 of 22 Last Update: Jan 2009
7. 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.
Process-Logic Qualifications Page 7 of 22 Last Update: Jan 2009
8. 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
Memberships
Instrumentation, Systems, and Automation Society (ISA)
Process-Logic Qualifications Page 8 of 22 Last Update: Jan 2009
9. 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.
Process-Logic Qualifications Page 9 of 22 Last Update: Jan 2009
10. 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
Memberships
Instrumentation, Systems, and Automation Society (ISA)
Process-Logic Qualifications Page 10 of 22 Last Update: Jan 2009
11. 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.
Process-Logic Qualifications Page 11 of 22 Last Update: Jan 2009
12. 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
§ 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 § Rockwell Software Panelbuilder 32
Machinery
Memberships
Instrumentation, Systems, and Automation Society (ISA)
Military
U.S. Navy – E5 – Secret Clearance
Process-Logic Qualifications Page 12 of 22 Last Update: Jan 2009
13. 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 § Process Control § Troubleshooting
Project Process Software Instrumentation and Controls
§ Commissioning and § Process Data § Control System Management
Debug of New Equipment Collection and Storage and Maintenance
§ Development and Reuse § Software Specification § Rockwell Software (RSLogix)
of Standard Designs and Documentation
§ Chemical Processes § Batch Software (S88) § ABB Software (MOD 300 &
(continuous and batch) 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.
Process-Logic Qualifications Page 13 of 22 Last Update: Jan 2009
14. 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
Process-Logic Qualifications Page 14 of 22 Last Update: Jan 2009
15. 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.
Process-Logic Qualifications Page 15 of 22 Last Update: Jan 2009
16. 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
Process-Logic Qualifications Page 16 of 22 Last Update: Jan 2009
17. 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.
Process-Logic Qualifications Page 17 of 22 Last Update: Jan 2009
18. 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
Process-Logic Qualifications Page 18 of 22 Last Update: Jan 2009
19. 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
Process-Logic Qualifications Page 19 of 22 Last Update: Jan 2009
20. Experience & Qualifications
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)
Process-Logic Qualifications Page 20 of 22 Last Update: Jan 2009
21. Experience & Qualifications
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)
Process-Logic Qualifications Page 21 of 22 Last Update: Jan 2009
22. 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
Arch Chemicals - 100 McKee Road, Rochester, NY 14611 (585) 436-3030
John Frank, Senior Controls Engineer
Arch Chemicals - 100 McKee Road, Rochester, NY 14611 (585) 436-3030
Matt Demason, Operations Manager
Cincinnati/Northern Kentucky Int’l Airport Glycol Recovery Facility (513) 651-3440
Process-Logic Qualifications Page 22 of 22 Last Update: Jan 2009