J. G. (JAY) HUDSON, P.E.
PRINCIPAL CONSULTANT
EDUCATION, LICENCES & CERTIFICATIONS:
· 2006 - Certified Mediator for the North Carolina Superior Court
· 1988 - Registered Professional Engineer (NC)
· 1976 – Bachelors in Chemistry, Catawba College, Salisbury, NC
· 1973 –Associate in Manufacturing Engineering Technology,
Rowan Technical Institute, Salisbury, NC
EXPERIENCE:
Over 30 years experience in various technical positions including
Plant Process Development Engineer, Plant Project Engineer,
Process Engineer in A&E firms and Project Manager in A&E firms.
Experience includes such diverse areas as polymer production and
fiber spinning, plant utilities, air conveying of plastic chip, rotating
equipment, organic and inorganic chemical production, rubber
processing and material handling.
Project responsibilities have included conceptual process design,
project scope development, project estimates and appropriation
requests, project management and construction supervision. As a
plant engineer, he was instrumental in several projects where he
managed the complete project from process concept, project scope
and estimate, design, installation, through startup.
Significant experience in Process Safety Management and RAGAGEP
standards as defined in the OSHA Code. See Process Safety
Experience, below.
Performed many project and engineering functions on the following
types of projects:
THERMAL FLUID SYSTEMS:
Very strong technical skills in the area of thermal fluid system
equipment specification and design, including fuel fired and electrical
fluid heating equipment, high temperature pumps, thermal fluid
specification and selection, system design, installation and
operation. He is also experienced in specification and application of
rotating equipment and has specialized training in Process Safety
Reviews (Hazard and Operability Studies).
REPRESENTATIVE THERMAL FLUID PROJECTS:
· Designed thermal fluid system for PBT Solid State+
Polymerization unit utilizing high flow secondary circulation
loops for precise temperature control.
· Conducted Process Safety Reviews for a BP/DPO (Dowtherm)
liquid/vapor thermal fluid system that encompassed 10 primary
fluid heaters, 14 primary circulation pumps, and approximately
350 individual vapor and liquid users. The review also included
such equipment as fluid preheaters, fluid storage and handling
and spent fluid recovery and disposal.
· Scoped, estimated and submitted appropriation requests
improve the system described above. The projects were to
increase operability and to respond to recommendations from
the Process Safety Review.
· Authored the heat transfer fluid pipe specification, pump
specification (sealed and seal-less), and the mechanical seal
specification used by a major producer of polyester polymer
and fiber.
· Designed system, specified three (3) 40 million BTU thermal
fluid heaters and associated circulation pumps to replace the
thermal fluid utility at a major polyester polymer and film
manufacturing plant. These heaters operate at 90% (LHV)
efficiency and meet all current and predicted emission
standards. Installation included 150 ft. smoke stack with all
breaching.
· Designed numerous skid mounted thermal fluid systems for
chemical, pharmaceutical and polymer manufacturers, including
several high / low temperature “single fluid” systems.
· Designed process and specified a high flow, low delta-T thermal
fluid system for a major utility expansion at a large polyester
fiber manufacturer. The heater’s duty is 50 million BTUH, and it
fits in a space originally designed for a 35 million BTUH unit. It
operates at 90% (LHV) efficiency on natural gas, No. 2 fuel oil
and No. 6 fuel oil. Additionally, the burner will accept a waste
gas stream from the polymerization process, containing
acetaldehyde and other glycol side-reaction products. Heat
transfer media is BP/DPO (Dowtherm A)
· Designed, specified equipment, and managed field installation
of safety upgrades to meet upgraded insurance requirements
at a foam board manufacturing facility. The equipment allows
remote isolation of heat transfer media supply to laminator rolls
in the event of a rotary joint or pump seal failure. The
upgrades were installed with minimal upset and down time at
the facility.
· Performed study and made recommended changes to increase
production rate in an oil heated veneer laminating press at a
major furniture manufacturer.
· Performed troubleshooting study on a vapor phase HTM system
at a specialty nylon manufacturer to define reasons for
operational deficiencies and recommended changes to the
system.
· Lead Engineer and Project Manager for a 6,500 gpm cooling
system that operates at –55 deg F and will replace an existing
system which is 40 years old. The system had to be designed
to be installed parallel to the existing system to allow operation
of the plant’s 26 users while the new system is installed.
· Performed study and made recommended changes to increase
production rate in a hot oil heated veneer laminating press at a
major furniture manufacturer.
· Following a vapor release and fire associated with a BP/DPO
(Dowtherm) vaporizer, performed a study and recommended
changes to the operation and equipment management of the
system.
PROCESS SAFETY / PHA EXPERIENCE
· Conducted Process Safety Reviews for an existing 25 year old
BP/DPO (Dowtherm) liquid/vapor thermal fluid system that
encompassed 10 primary fluid heaters, 14 primary circulation
pumps, and approximately 350 individual vapor and liquid
users. The review also included such equipment as fluid
preheaters, fluid storage and handling and spent fluid recovery
and disposal. The recommendations from those reviews
resulted in seven capital safety improvement projects totaling
$2MM total installed Cost. Chemicals reviewed included:
· Participated as Technical Specialist in Process Safety Review
for installation of three (3) new 40 MM BTUH Thermal Fluid
Heaters and their associated pumps and other ancillary
equipment. Chemicals reviewed included:
· Developed as-built P&ID’s and conducted Process Safety
Review for listed chemicals at small, privately owned specialty
chemical company. Assembled materials and completed
documentation for Process Safety management for that plant.
Chemicals reviewed included:
· Checked as-built P&ID’s and conducted Process Safety Review
for listed chemical at small, privately owned specialty chemical
company. Chemicals reviewed included:
· Conducted Process Safety Review for new equipment installed
for a process expansion at an existing acrylic polymer
plant. Chemicals reviewed included:
· Designed, specified equipment, and managed field installation
of safety upgrades to meet upgraded insurance requirements
at a foam board manufacturing facility. The equipment allows
remote isolation of heat transfer media supply to laminator rolls
in the event of a rotary joint or pump seal failure. The
upgrades were installed with minimal upset and down time at
the facility.
Contact Us:
J. G. Hudson & Associates, PC
P.O. Box 4064
Salisbury, NC 28145
704-637-1714
PRINCIPAL CONSULTANT
EDUCATION, LICENCES & CERTIFICATIONS:
· 2006 - Certified Mediator for the North Carolina Superior Court
· 1988 - Registered Professional Engineer (NC)
· 1976 – Bachelors in Chemistry, Catawba College, Salisbury, NC
· 1973 –Associate in Manufacturing Engineering Technology,
Rowan Technical Institute, Salisbury, NC
EXPERIENCE:
Over 30 years experience in various technical positions including
Plant Process Development Engineer, Plant Project Engineer,
Process Engineer in A&E firms and Project Manager in A&E firms.
Experience includes such diverse areas as polymer production and
fiber spinning, plant utilities, air conveying of plastic chip, rotating
equipment, organic and inorganic chemical production, rubber
processing and material handling.
Project responsibilities have included conceptual process design,
project scope development, project estimates and appropriation
requests, project management and construction supervision. As a
plant engineer, he was instrumental in several projects where he
managed the complete project from process concept, project scope
and estimate, design, installation, through startup.
Significant experience in Process Safety Management and RAGAGEP
standards as defined in the OSHA Code. See Process Safety
Experience, below.
Performed many project and engineering functions on the following
types of projects:
- Scope and estimate studies
- Small project management and implementation
- Facility and utility upgrades
- Grass roots facilities
- Process improvements/changes
- Equipment specification/modification
THERMAL FLUID SYSTEMS:
Very strong technical skills in the area of thermal fluid system
equipment specification and design, including fuel fired and electrical
fluid heating equipment, high temperature pumps, thermal fluid
specification and selection, system design, installation and
operation. He is also experienced in specification and application of
rotating equipment and has specialized training in Process Safety
Reviews (Hazard and Operability Studies).
REPRESENTATIVE THERMAL FLUID PROJECTS:
· Designed thermal fluid system for PBT Solid State+
Polymerization unit utilizing high flow secondary circulation
loops for precise temperature control.
· Conducted Process Safety Reviews for a BP/DPO (Dowtherm)
liquid/vapor thermal fluid system that encompassed 10 primary
fluid heaters, 14 primary circulation pumps, and approximately
350 individual vapor and liquid users. The review also included
such equipment as fluid preheaters, fluid storage and handling
and spent fluid recovery and disposal.
· Scoped, estimated and submitted appropriation requests
improve the system described above. The projects were to
increase operability and to respond to recommendations from
the Process Safety Review.
· Authored the heat transfer fluid pipe specification, pump
specification (sealed and seal-less), and the mechanical seal
specification used by a major producer of polyester polymer
and fiber.
· Designed system, specified three (3) 40 million BTU thermal
fluid heaters and associated circulation pumps to replace the
thermal fluid utility at a major polyester polymer and film
manufacturing plant. These heaters operate at 90% (LHV)
efficiency and meet all current and predicted emission
standards. Installation included 150 ft. smoke stack with all
breaching.
· Designed numerous skid mounted thermal fluid systems for
chemical, pharmaceutical and polymer manufacturers, including
several high / low temperature “single fluid” systems.
· Designed process and specified a high flow, low delta-T thermal
fluid system for a major utility expansion at a large polyester
fiber manufacturer. The heater’s duty is 50 million BTUH, and it
fits in a space originally designed for a 35 million BTUH unit. It
operates at 90% (LHV) efficiency on natural gas, No. 2 fuel oil
and No. 6 fuel oil. Additionally, the burner will accept a waste
gas stream from the polymerization process, containing
acetaldehyde and other glycol side-reaction products. Heat
transfer media is BP/DPO (Dowtherm A)
· Designed, specified equipment, and managed field installation
of safety upgrades to meet upgraded insurance requirements
at a foam board manufacturing facility. The equipment allows
remote isolation of heat transfer media supply to laminator rolls
in the event of a rotary joint or pump seal failure. The
upgrades were installed with minimal upset and down time at
the facility.
· Performed study and made recommended changes to increase
production rate in an oil heated veneer laminating press at a
major furniture manufacturer.
· Performed troubleshooting study on a vapor phase HTM system
at a specialty nylon manufacturer to define reasons for
operational deficiencies and recommended changes to the
system.
· Lead Engineer and Project Manager for a 6,500 gpm cooling
system that operates at –55 deg F and will replace an existing
system which is 40 years old. The system had to be designed
to be installed parallel to the existing system to allow operation
of the plant’s 26 users while the new system is installed.
· Performed study and made recommended changes to increase
production rate in a hot oil heated veneer laminating press at a
major furniture manufacturer.
· Following a vapor release and fire associated with a BP/DPO
(Dowtherm) vaporizer, performed a study and recommended
changes to the operation and equipment management of the
system.
PROCESS SAFETY / PHA EXPERIENCE
· Conducted Process Safety Reviews for an existing 25 year old
BP/DPO (Dowtherm) liquid/vapor thermal fluid system that
encompassed 10 primary fluid heaters, 14 primary circulation
pumps, and approximately 350 individual vapor and liquid
users. The review also included such equipment as fluid
preheaters, fluid storage and handling and spent fluid recovery
and disposal. The recommendations from those reviews
resulted in seven capital safety improvement projects totaling
$2MM total installed Cost. Chemicals reviewed included:
- Dowtherm A, consisting of bi-phenyl and di-phenyl
· Participated as Technical Specialist in Process Safety Review
for installation of three (3) new 40 MM BTUH Thermal Fluid
Heaters and their associated pumps and other ancillary
equipment. Chemicals reviewed included:
- Dowtherm A, consisting of bi-phenyl and di-phenyl
· Developed as-built P&ID’s and conducted Process Safety
Review for listed chemicals at small, privately owned specialty
chemical company. Assembled materials and completed
documentation for Process Safety management for that plant.
Chemicals reviewed included:
- Formaldehyde
- Di-methyl sulfide
· Checked as-built P&ID’s and conducted Process Safety Review
for listed chemical at small, privately owned specialty chemical
company. Chemicals reviewed included:
- Propylene Oxide
· Conducted Process Safety Review for new equipment installed
for a process expansion at an existing acrylic polymer
plant. Chemicals reviewed included:
- Acrylic Acid
- Toluene di-isocynate
- Methyl di-isocynate
- Butyl Acetate
- Toluene
- Heptane
· Designed, specified equipment, and managed field installation
of safety upgrades to meet upgraded insurance requirements
at a foam board manufacturing facility. The equipment allows
remote isolation of heat transfer media supply to laminator rolls
in the event of a rotary joint or pump seal failure. The
upgrades were installed with minimal upset and down time at
the facility.
Contact Us:
J. G. Hudson & Associates, PC
P.O. Box 4064
Salisbury, NC 28145
704-637-1714
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| J. G. HUDSON & ASSOCIATES, PC P.O. BOX 4064 SALISBURY, NC 28145 704-637-1714 |
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