KENT L. JOHNSON, Ph.D., P.E., FASM SENIOR CONSULTANT EDUCATION

Transcription

1 KENT L. JOHNSON, Ph.D., P.E., FASM SENIOR CONSULTANT EDUCATION Ph.D. Metallurgical Engineering, Illinois Institute of Technology, Chicago, Illinois, 1972 B.S. Metallurgical Engineering, Illinois Institute of Technology, Chicago, Illinois, 1965 REGISTERED PROFESSIONAL ENGINEER (P.E.) State of Illinois License No State Of Arkansas License No State of Wisconsin License No AREAS OF SPECIALIZATION Materials selection, welding & joining technologies, code and standards compliance Fabrication, construction/erection, design evaluation, nondestructive examination, & QA/QC Failure analysis, inspections, metallurgical testing, fracture mechanics, & defect growth studies Fire and explosion analysis, exemplar testing, reliability and risk assessments, fitness for service evaluations, & forensic investigations PROFESSIONAL EXPERIENCE Dr. Johnson has 40 years experience solving world-wide construction and fabrication problems that address materials selection, corrosion, defect growth, welding and quality/safety concerns, and field erection issues. He is also proficient in performing detailed metallurgical evaluations, root cause failure analyses, cause and origin investigations, fractographic examinations, forensic studies and exemplar testing. This includes hands-on, working experience with all forms of metallurgical and materials evaluation and testing, nondestructive testing, product evaluation tests, fracture mechanics and fatigue evaluations, and comprehensive manufacturing/construction methods assessments and testing. This broad construction, erection, welding and manufacturing background includes the areas of design evaluation, fabrication, construction & erection techniques, inspection and testing for large welded structures (i.e., petrochemical pressure vessels, storage tanks, boiler and steam generators, nuclear reactors/containment vessels, offshore oil and gas platforms, pipelines, off-highway equipment, railroad equipment, and hydroelectric weldments). As such, Dr. Johnson has an extensive knowledge and understanding of many US, as well as foreign Codes and standard, [i.e., ASME, Section I, Section II, Section III, Section IV, Section V, Section VI, Section VII, Section VIII, and Section IX, Section X, and Section XI, and various ANSI, AWS, ASTM, API, AWWA, ASNT, DOT, AAR, CGA, NFPA, NACE, as well as the British Standards (BS), German DIN Norms, and ISO standards]. Dr. Johnson also has extensive experience with nondestructive testing techniques and procedures as well as analyses using fracture mechanics & fatigue evaluations, fitness for service & remnant P.O. Box 5111 Wheaton, Illinois Fax N. Mill Street, Suite 112 Naperville, Illinois 60563

2 life studies. This knowledge and insight is valuable in both failure analysis investigation as well as determining the fitness for service of industrial equipment. Upon leaving college, from 1968 to 1976, Dr. Johnson, joined the multi-national, heavy construction firm of Chicago Bridge and Iron (CBI). CBI engineers, fabricates, erects, inspects, and tests very large steel plate structures. They construct everything from nuclear reactors and containment vessels, heavy wall pressure vessels, crude oil storage tanks, all types of refinery and chemical plant processing equipment, liquefied natural gas facilities and ships, offshore platforms, liquefied petroleum gas storage, and even water towers that looked like a golf ball resting on a tee. This work is performed all around the world. This CBI career started with a two year training program, working as a boilermaker mechanic welder where he had the opportunity to work on essentially every type of field erection project that CBI undertook. He became adept, and qualified, on many of the various welding processes, learning how to weld an assortment of different materials, clad metals, and dissimilar metals. While working on numerous field sites, Dr Johnson also worked closely with the welding management there, and became knowledgeable in the construction and erection methods and techniques, as well as, the welding, inspection, testing and QA/AC codes (i.e., ASME, API, AWWA, and AWS). In particular he worked directly with ASME Section II, Section V, Section VIII, and Section IX, AWS D1.1, AWS D1.5, AWS B2.1, AWS A5, and AWS Z49.1, NFPA 51B, NFPA 70E, NFPA 921 API 620, API 650, and AWWA 100 codes and standards. During the period of time he worked on many different vessels and petrochemical pieces of equipment that contained refractory linings. The monolithic linings were secured using hex-grid or spot welded anchors. Sometime brick refractory was also employed. Additionally Dr. Johnson worked on both clad and coated vessels and equipment, and he became knowledgeable in the application and repair of both refractory and coatings. CBI had it own nondestructive examination (NDE) department, where Dr. Johnson also obtained a thorough hands-on experience in all of the various NDE procedures and methods, thereby gaining considerable knowledge and skill at all forms of NDE and the various codes and standards covering these methods. He also learned how to perform complex post weld heat treating of large structures in the field, determine the safety methods and procedures to reduce hazardous condition, and how to ensure that the welding, inspection and testing was in compliance with applicable Codes. After this field site training period, Dr. Johnson was assigned to various overseas management positions within the firm s Welding and Quality Assurance Group. This Group was under a larger Corporate Group, called the Operations Group, which was responsible for the proper execution of all of the firm s field erection projects. As a CBI Welding Manager, for Europe, Africa, and the Middle East Dr. Johnson was responsible for qualifying the firm s welding procedures, welder qualifications, selection of the welding processes to be employed, the nondestructive evaluations, and the overall quality assurance of the equipment and structures that were erected in the field in that part of the world. While overseas, also was given the responsibility of managing the European Welding Laboratory with the responsibility for qualifying all of the materials of construction and welding consumables, training and testing all field Welding Supervisors and all field nondestructive testing technicians, overseas. In this capacity, he worked directly with the CBI engineering groups regarding the welding, inspection, and QA/QC aspects of each project. He developed a deeper and more complete understanding of the ASME Boiler and Pressure Vessel Codes, the various API standards and Recommended Practices, and the American Welding Society s, AWS Codes and standards including detailed knowledge of numerous ASTM Standards and Specifications. Additionally, Dr. Johnson was working with the OSHA regulations at the very start of that Federal agency. As such, he became very knowledgeable about the OSHA regulations and safety aspects 2

3 at the work sites. Process safety management was one of his responsibilities, including mechanical integrity, process hazards analysis, management of change, training, incident investigation and compliance audits. Upon his return to the US, from 1976 to 1978, Dr. Johnson accepted the position of Corporate Manager of Welding Engineering Research, with the International Harvester Company. In this position he was in charge of the corporate welding laboratory responsible for applied research into the improvement of welding productivity and quality for the firm s five operating groups. He was also directly responsible for identifying, developing and successfully implementing state-of-the-art and leading-edge factory automation technology. In this position he co-authored several of the new codes and handbook chapters on robotic welding technology, and thereby gained experience and knowledge about regarding distributed digital control systems and interlocks. In 1978 Dr. Johnson started his own company working on industrial automation. He worked with protocols and procedures that eventually became ISA standards, and help to develop robotic tracking systems for welding applications. From this position, Dr. Johnson also gained further knowledge of code requirements for industrial equipment and products as well as ISA knowledge. This work expanded to the training of personnel in the industrial automation user group, and he also co-founded a post-secondary educational [Center for Robotic Technology] in Chicago, Illinois, approved by the Illinois Board of Higher Education. His work in these areas continued until 1990, when he accepted a position in the consulting engineering field. Dr. Johnson joined Packer Engineering, Inc in 1990, a multidisciplinary engineering consulting firm assisting clients in litigation, insurance, engineering, and problem solving. Dr. Johnson accepted a position at Engineering Systems, Inc in 1998, also a multidisciplinary engineering consulting firm and he was responsible for the same scope of work. During this time he was heavily involved in failure analysis and root cause failure determinations, life assessment determinations, the design of weldments, environmentally induced degradation, elevated-temperature service, fatigue and defect growth within equipment, and the assessment of damaged and heat-affected structures. He designed and oversaw various studies in remaining life analyses, especially those using the Fitness-for-Service [i.e., API 579/ASME FFS-1 recommended practice] methodologies. In 2009 he joined together with associates from Engineering Systems, Inc forming a business unit providing the same multidisciplinary engineering consulting to a variety of clients. Dr. Johnson has performed many inspections/investigation on defective welding and welding technologies. One particle project involved the improper welding of small bore piping socket weld joints in Kazakhstan, Russia. Specific issues included QA/QC evaluations, failure analysis, and the financial cost evaluation from the lack of QA/QC during Construction and Replacement Oversight (~28,000 welds repaired) for Freshfields Bruckhaus Deringer LLP. During the engineering consulting portion of Dr. Johnson s career, he performed work on many projects where refractory linings were involved, such as, FCCU [fluidized catalytic converter units] reactors and regenerators, hydrogen production units [HYCO units], primary metal production furnaces and ladles, petrochemical reactors and columns, etc. During these consulting projects he was introduced to both the API standard 936 and the API recommended practice RP 936. Many recent projects include fitness for service of corroded components, utility and industrial boiler fires and explosions, turbines, scrubbers, LNG facilities, HRSG, and petrochemical fires and explosions. The over twenty years of engineering consultation have given Dr. Johnson an expanded knowledge and understanding of the various codes of practice and standards, as well as the regulations and statutes involved in the practice of engineering. For over 40 years, Dr. Johnson was engaged with assessments regarding Process Safety Management (OSHA PSM) covering Process Hazards Analysis, Management of Change, Mechanical Integrity, Accident Investigations, Emergency Plans and Response, Training, and Compliance Audits as well as reliability studies, risk analysis, QA/QC and safety assessments or audits. He is currently a senior consultant to Applied Materials Technologies, Inc (AMTI). Dr. Johnson has taught courses in Metallurgy at IIT, as a member of the adjunct faculty, as well as at the ASM International Educational facility. He is a member 3

4 of Alpha Sigma Mu (Metallurgical Honorary Society), a recipient of a NASA Fellowship, AWS, ASM International, ASNT, and the Association for Iron and Steel Technology (AIST). He was elected a fellow of ASM International and he has made numerous presentations in the areas of failure analysis, welding and manufacturing automation. Dr. Johnson has also published articles and various book chapters in technical publications throughout the world. Professional Affiliations/Honors NASA Fellowship Alpha Sigma Mu (Metallurgical Honorary Society) Registered Professional Engineer State of Illinois License No State Of Arkansas License No State of Wisconsin License No American Welding Society (AWS) Certified Welding Inspector - Certificate No Board of Examiners of the AWS Authorized National Body Board of Directors - Chicago Section Past Chairman - Chicago Section D8 AWS/SAE Joint Committees on Automotive Welding D8J Subcommittee on High Strength Low Alloy Steels D11 Committee on Welding Iron Castings D11C Subcommittee on Welding Processes & Procedures D11E Subcommittee on Testing & Inspection Handbook Committee Education Activities Committee ASM International Fellow of ASM Chair Handbook Committee Content Committee Past Chairman - Chicago Western Chapter Past Chairman Student Affairs Past Chairman Education Committee Materials Engineering Institute Committee American Society of Non-Destructive Testing (ASNT) The Heat Treating Society The Thermal Spray Society The Association of Iron & Steel Technology (AIST) 4

5 Positions Held Applied Materials Technologies Inc., Naperville, Illinois Senior Consultant 2009 Engineering Systems, Inc., Aurora, Illinois Senior Consultant, Bodycote Materials Testing Group, Taussig Laboratory, Skokie, Illinois Senior Metallurgical Engineer, Packer Engineering, Inc., Naperville, Illinois Manager, Field & Manufacturing Services, The Tectra Group, Inc., River Forest, Illinois Director of Consulting & Sales, Center of Robotic Technology, Inc., Chicago, Illinois Cofounder and President, Illinois Institute of Technology, Inc., Chicago, Illinois Part-Time Faculty, FMP Consulting Services, Inc., River Forest, Illinois Chief Consultant, International Harvester Co., Hinsdale, Illinois Corporate Manager, Welding Engineering Research, Harnischfeger Corp., Cedar Rapids, Iowa Chief Materials Engineer and Manager of Advanced products, Hydraulic Equipment Division, Chicago Bridge and Iron Co., London, England European Welding Manager, Publications Kent L. Johnson and Kenneth M. Smith, Jr., Failure Analysis of the ESTONIA, ASM International Advanced Materials and Processes, June 2009, Vol. 167, No. 6, pp Hineman, M.A., Danko, M.J., Johnson, K.L., and Schmidt, F.E., An Unusual Microstructure for a Carbon Steel Low Alloy Tube, 38 th IMS Proceedings: Microscopy & MicroAnalysis, August 2005, pp. 1580CD. Danko, M.J., Johnson, K.L., and Schmidt, F.E., Failure Analysis of Firearm and Ammunition Components, 38 th IMS Proceedings: Microscopy & MicroAnalysis, August 2005, pp. 1590CD. Bishel, R.A.; Bienlenberg, J.G.; Dybas, R.J.; and Johnson, K.L., "Chapter 5, Cast Irons," Welding Handbook, Seventh Edition, Volume 4, 1982, American Welding Society, Miami, Florida, pp Breyer, N.N.; and Johnson, K.L., "Liquid Metal Embrittlement of 4145 Steel by Pb-Sn and Pb-Sb Alloys," ASTM Journal of Testing and Evaluation, Nov. 1974, Vol. 2, (6), pp

6 Johnson, K.L.; Breyer, N.N.; and Dally, J.W., "Environmental Sensitivity of Structural Metals-Some Dynamic Aspects of Liquid Metal Embrittlement," Environmental Degradation of Engineering Material, Virginia Polytechnic Institute, Blacksburg, Virginia, 1977, pp Reeve, R.C.; Johnson, K.L.; Richardson, R.W.; Roden, W.; and Szabo, R.L., "Chapter 5, Automation and Control," Welding Handbook, Seventh Edition, Volume 5, 1984, American Welding Society, Miami, Florida, pp Warke, W.R.; Johnson, K.L.; and Breyer, N.N., "Liquid Metal Embrittlement of Steel by Pb and Pb Alloys," Paper from Corrosion by Liquid Metals, 1970, AIME, New York, pp Watkins, M.; Johnson, K.L.; and Breyer, N.N., "Effect of Cold Work on Liquid-Metal Embrittlement by Pb Alloys on 4145 Steel," Fourth Interamerican Conference Materials Technology, Caracas, Venezuela, 1975, pp Courses Taught at Illinois Institute of Technology (IIT) ( ) Introduction to Material Science Principles of Non-Destructive Examination Principles of Welding and Joining Technical Presentations "Supervision Training Courses for Welding Supervisors" Chicago Bridge & Iron Company, "ASNT Training Courses for Non-Destructive Examination Personnel" Chicago Bridge & Iron Company, a) Radiography b) Ultrasonics c) Magnetic Particle d) Liquid Penetrant e) Visual f) Solution Film & Pressure Leak "Contrasts in the Various Codes of Practice - Low Temperature Storage Tanks" Welding Institute Seminar, 1974, London, UK "Brittle Fracture in Welded Components" Chicago Bridge & Iron Company Seminars, "Fracture Mechanism in Welded Components" Chicago Bridge & Iron Company Seminars, "Automated Arc Welding Seminar, Robotic and Flexible Manufacturing System" American Welding Society Seminar, 1980 Flexible Automation Implementation for Arc Welding Applications Fourth Annual Robots in Manufacturing Seminar, 1980 "Identification, Selection, Engineering, Justification and Implementation of Flexible Automation Systems" American Welding Society - Oak Ridge Seminar,

7 "Capabilities of Robotic Arc Welding Systems" American Welding Society Convention, 1983 "Education and Training Programs for High Technology Fields" National Educational Association Convention, 1985 "Principles of Failure Analysis" ASM International Metals Education Institute Seminars, "Basic Metallurgy for Non-Metallurgists" ASM International Metals Education Institute Seminars, The Metallurgy of Welding ASM International Metals Education Institute Course, 1999 Welding Metallurgy ASM International Metals Education Institute Course, 2002 ASM International Metals Education Institute Course, 2003 Fundamentals of Nondestructive Testing ASM International Metals Education Institute Course, 2004 ASM International Metals Education Institute Course, 2008 Practical Metallurgy and Materials of Industry Moraine Valley Community College Technology Course