In 2006, Frank Cortez transferred from an Air Liquide Cogen Facility in Texas to the Air Liquide Geismar Cogen as plant manager. Since there was much industry expansion in the Baton Rouge, Louisiana, area at the time, Cortez’s biggest challenge was staff retention.
“We addressed this concern by educating employees and making them aware of the benefits of working in a smaller, cohesive, quality team in Air Liquide,” he explained. “Being a small facility enables each employee to take ownership of his or her location. This was a challenge years ago, but currently our newest employee has seven years with Air Liquide.”
Cortez is responsible for the operation and maintenance of two 40-megawatt cogeneration units with eight employees. Originally from Lake Charles, Louisiana, Cortez worked as a process technician at PPG Industries for four years and then as a construction electrician for six years. He has been with Air Liquide for 31 years, serving in positions including electrical/instrument technician, maintenance coordinator and operations manager for two Texas cogen units.
A key player
“Air Liquide is a key player, assisting in the growth of the chemical industry by developing new manufacturing processes using our strong pipeline infrastructure of oxygen, nitrogen and hydrogen along the Gulf Coast,” said Cortez.
In the U.S., Air Liquide, a world leader in gases, technologies and services for industry and health, has headquarters in Houston. More than 5,000 employees are based in over 200 facilities nationwide, including more than 140 industrial gas plants. American Air Liquide owns and operates approximately 2,000 miles of pipeline. Industrial gas is produced on-site at more than 300 customer facilities.
The Geismar plant, where Cortez has served as cogen plant manager for the past nine years, was built in 2001. Each cogen produces super heated steam and electricity for a dedicated customer.
“In my current position, mechanical and process understandings with the ability to relate to people and customers is the most important skill to have,” said Cortez. “Currently, we are challenged with the limited pool of trained people and the availability of new employees with good safety and operations background and a strong work ethic. This is a modern challenge.”
The Geismar team has done a respectable job of that so far. The site has not had an employee recordable accident since 2001.
“The main attribute to a safe workplace is empowering employees with the authority and responsibility to handle any situation they deem unsafe without any repercussions,” said Cortez.
Air Liquide has a Time Out Policy that promotes such empowerment and reinforces this concept. Further, the company has a Life Critical Safety Program, safety and environmental leadership training, SafeStart and behavioral safety observations programs.
“During large outages, our staff is given safety prizes to hand out when witnessing contractor safe work, and this recognition is often appreciated,” said Cortez.
Along with working safely together, the Geismar team and the business unit (Mississippi River Pipeline) are involved in the community, sponsoring a golf tournament benefitting the American Cancer Society. They also participate in Relay for Life and sponsor the PRIMETIME Family Reading Program.
Air Liquide actively promotes Responsible Care® and is a member of the American Chemistry Council, the Compressed Gas Association, the Louisiana Chemical Association and other local industry associations.
“We are active members to promote safety in our daily operations and to have the best management practices in our industry,” said Cortez. “We focus on safety, reliability and efficiencies, which all bring value to the customer.”
Air Liquide is currently developing a new cogen technology on the Texas Gulf Coast and has growth plans in Louisiana for airgas supply as well as a new, world-scale air separation unit for a methanol producer in St. James Parish by 2018.
Cortez is more optimistic than ever about the future.
‘To put it simply, I died’
On May 16, 2012, Cortez was driving when he had a heart attack. He crossed the opposing lane of a busy highway, went through a deep ditch and a barbed wire fence and ran into a large tree. A former emergency room nurse administered CPR for 20 minutes until the ambulance arrived. The ambulance “shocked” Cortez a few times and transported him to the hospital.
“I was in a coma for five days, and with God’s grace, I kept going,” said Cortez.
Cortez’s left upper arm was broken in four places (“It was my sissy arm anyway,” he said.). His chest was crushed, and he had six broken ribs. His head injuries included a broken cheekbone, a concussion and amnesia.
“I added a few more ‘tough man’ scars to the collection on my face,” he said.
Cortez’s wife, Andra, later told him when he was left alone in the hospital, he would go around to the other rooms and take chairs back to his room because “the guys are coming for a meeting. Hurry! We’ve got to get ready!”
“I guess in my head I was still at work,” he said.
While in the hospital, Air Liquide executives would visit him from the local corporate office as well as the Houston headquarters, giving Andra a break by taking her to lunch.
“They offered assistance by ensuring all of our needs were being met and by encouraging Andra,” Cortez said. “During this time away from work, we were told to ‘not think about work; just think about getting well.’”
Cortez spent four weeks in ICU, three weeks in rehabilitation and four months in outpatient physical and occupational therapy. His heart attack was caused by an artery blockage nicknamed the “widowmaker” because it causes death 90 percent of the time — and that is without wreck injuries.
“When I went back to work, my manager gave me an assistant for six months to reintroduce me to my job,” he said. “That was very thoughtful and another example of the support and confidence Air Liquide had in me. Everyone has compassion and has been extremely supportive.
“It took a few months, but after being exposed to it, things started ‘coming back.’ I am a witness to Air Liquide’s true heart with their loyalty, support and patience, giving me assurance in doing my job.
“I am aware surviving and recovering from my accident is a miracle and without the prayers and support from my church, friends, family, work and, most of all, my wife, I’d probably still be laying in that ditch on the side of the road. My wife’s unfailing love in such a crisis is proof I made the right decision 35 years ago to marry her. She is good.”
For more information, visit www.airliquide.com or call (225) 744-5700.
‘Please give me a sign you’ll make it’
When I arrived at the hospital, my dad was in the emergency room in a coma with bruises, black eyes and dried blood all over his face. Friends and family crowded the waiting room. My older brother Frankie, who lives in Atlanta, and my younger brother Collin, who had just joined the Navy and was in boot camp in Chicago, flew in as quickly as they could. We had the whole family there painfully waiting for any sign of “life upstairs.” The day my brother had to fly back to boot camp, he was extremely upset to have to leave without any progress or answers from my father. He went in his room one last time to tell him not to give up and he’d be back as quickly as he could. Collin said, “Before I leave, just please give me a sign you’ll make it.” Our dad opened his eyes! I’ll never forget my little brother running into the waiting room in his handsome Navy service uniform with tears rolling down his face screaming, “He’s awake; he’s awake!”
Today, a little over three years since the accident, my dad, at the hand of God, has conquered the struggles that were once before him. He’ll never admit it, but he’s smarter than anything he comes up against. That hasn’t changed. He overcomes whatever challenges he may face, and because of it he’s excelled just as he did before he went back to work. He’s used this accident as a testimony to God’s grace and mercy. He’s a miracle, a living miracle, and he humbly gives all the glory to God.
— Carmen Cortez, safety coordinator and business development, M&C Oilfield Services LLC
