WORK EXPERIENCE

Waste water SCADA systems for various water districts in California.

SCADA systems design , development and testing for water/waste water for various water districts.

Servers Setup.

Software Design Specs.

Graphics Object Templates and Graphic process screens development.

Generate tag database and object instances.

Alarms and Histroain Setup

Site Comms monitoring setup

Navigation and submenu tabs scripting/configuration

Reporting configuration

Dial out and paging system setup and configuration (For alarms and failiures)

Remote monitoring and Remoe HMI access setup.

DA server setup

IO testing , FAT, client workshops and training.

Waste water controls for one of the largest food company of North America

Upgraded plant waste water system from a SLC controller to Rockwell/Allen Bradley compact logix. Project included adding VFD control for dosing system, underground sum pumps, Screw press and skimmer motor. Other components included replacing chemical dosing system with a redundant dosing system, new turbidity meter, a new flocullant skid, pH meter and new level sensors for feed tanks and Underground tank. Also programmed new chemical dosing features to PLC and panel view HMI.Major resposnibitlities and sequence of tasks were as below

Project Proposal.

Project Setup for company EMS (Tasks & funds allocation).

Electrical Scope of Work and Mechanical SOW.

Engineering Scope of Work.

Project Schdule and planning.

Functional Specification.

Electrical Drawings and new panels design.

Bid walks with electrical and mechanical contractors.

Network drawings and IP address assignment for Ethernet IP devices

Order Hardware ( Controls, electrical components and new panels)

Migrate Controls from SLC 5 to CompactLogix.

Converted RSLogix 500 program to Logix 5000 V28

New AOI's for VFD control

IO Mapping routine.

Messaging instructions programming

Firmware upgrade on new controller 1769 L33ER

VFD's configuration and Setup

Stratix 8000 setup and configuration

Controller setup and configuration

HMI Graphics update and alarms configuration

Automation lead for expansion project of post surgical pain relieve drug.e(5 times expansion)

Manage Automation side of a large scale expansion project of FDA approved drug - five times capacity expansion.

Lead the design & planning of integrating batch historian, alarm data, site specific utilities, batch server, process history and reporting into SCADA system

Provide leadership role in defining scope of system and its various components. Review control modules and equipment modules template design.

Designed network architecture, specified IT equipment, controllers , IO modules, redundancy modules, E-Stops/Interlock strategy and other control hardware  (Application object servers, Batch server, Historian Server, Galaxy Repository, HMI client stations, operator work stations, engineering workstation, Network redundancy, controller redundancy, Wireless Access Points ).

Define SIS (Safety Instrumented Systems) / IPL (Independent Protection Layer) testing & schedule. Ensure compliance with role-applicable sections of the SIS standard.

Support development & maintenance of the Safety Requirement Specifications (SRS) and IPL Requirement Specification documents.

Define critical alarms, interlocks, phase holds, and system warnings.

Assist in FS (Functional Specification) and SMS (Software Module Specification), SDS (Software Design Specification) development and review.

Communicate project updates to corporate team. Work closely with corporate team to understand project expectations.

Assist in the developing of procedures for Factory Acceptance Tests (SFAT & AFAT), Pre-Startup Acceptance Tests (PSAT), Basic Process Control System (BPCS) testing.

VIT (Vertical Integration Testing) documentation and testing.

Coordinate between system integrator and skid fabricator on IO List, IO modules Rack Layout, VFD and PID types, IO module types etc.

Manage SI(System Integrator)  schedule and funding. Review and process change orders. Ensure timely completion of tasks within defined schedule and scope.

Work with Skid Fabricator on IO List and control panel/ electrical panel layout. Define TCM’s (Temperature Control Modules), Tank farm IO’s, Fill Line IO’s, COP station IO’s etc. Review data spreadsheets for various skid components.

SFAT and AFAT strategy and documentation review. PID and electrical drawing reviews

Define Batch model and process recipes.

Work closely with Process team on CIP, SIP, SOP & COP flow paths, phase hold conditions and phase steps transitioning. Review Bulk phases spreadsheets.

Controls Engineering of a fully Automated production system for post-surgical pain relieve  drug  (Primary Bulk Manufacturing system )

SCADA system design, implementation, integration, testing and commissioning. Also performed validation of complete system (Hardware & Software) in GAMP Pharmaceuticals environment.

Programmed RSLogix 5000 /Allen Bradley 1756-L74 ControlLogix Controller, WW InBatch for batch model and recipe development & WW System Platform for HMI/SCADA Development).

Define and document Safety critical alarms and interlocks. Perform Alarm and interlocks testing.

Batch Model development and recipe development. PLI – phase logic interface for Batch and PLC

System enhancements, Network upgrades, PLI programming for new phases in PLC and Batch & HMI screen modifications.

Filedbus network upgrade – upgrade from 1757 FFLD2 to 1788 EN2FFR. (Specify, Design, Document, program, test & validate)

Introduce Mass Flow meter technology to existing Systems ( Specify , Design , Document, Program , Test and Validate)

Optimize custom reporting ( update stored procedures)

Resolve Historian Time Synch Issues.

24/7 manufacturing phone support.

HMI/InBatch training for operators and manufacturing.

Work with Process engineers to optimize CIP’s/SIP’s and lower cycle time.

Implement Multi Monitor HMI stations ( 4 monitors- Specify and program)

Drafting, implementing and testing change controls.

Help Validation in writing IOQ’s and execute IOQ’s.

Worked on Risk analysis, planned deviations and CAPA for various issues.

Upgrade control software’s to latest versions ( WW system platform and WW Historian)

Rebuilt the entire Galaxy Repository (HMI database) after System upgrades.

Network infrastructure Upgrade for entire plant ( Food industry)

Interconnected entire plant control systems over Ethernet . This included packaging lines, processing lines, Kitchen mixers, Refreigreators, Engine room and waste water system. Separated network traffic by using different VLANS for different systems. Project responsibilities included

Configuring new startix switches

Manage electrical contractor for conduits run and electrical installation

Installing Asset center and Vantage point on FT engineering server

Configuring Asset center to automatically backup varipus logix programs

Add analog tags to vantage point

Create custom reports

Mixers control safety upgrade

Add Hygiene pushbuttons to add mixers Augar control, CO2 addition pushbutton , CO2 sensor and CO2 alarm function for 4 Kitchen mixers

Determine project requirements

Project proposal

Electrical SOW

Specify hardware and place order

Job walks with electrical and mechanical contractor.

Upload mixer programs from controller - SLC 500 controller- RS 232

Redline electrical drawings

Make programming changes - RS Logix 500 - add pushbutton control and safety interlocks

Manage electrical installation

Start Up and testing

Final electrical drawings

Fill lines integration to plant MES for a leading pharmaceutical company

Wonderware System Platform configuration and development. New Graphics development for filling, finishing and packaging line. Generate new graphics for MES modules. Integrate Controls to plant MES

Review control systems of existing lines

Create new graphic templates for MES modules ( Filling, Finishing and Packaging Line)

Configure topics to get tag data from multiple controllers and HMI's

Fix System platform setup issues

Resolve connection issues

City Water treatment plant controls

Part of team to develop controls for water treatment plant.

Functional Specification

State Model development ( Base template and AOI development)

Reviw electrical Drawings

Configure drives - Powerlfex 70

Add alarm function to detect AB 1609 UPS status

Define safety interlocks and process hold conditions

Testing and startup

Program E-Stop as per OSHA guidelines

Training development

Controls for raw material storage and transfer for a chemical industry

Integrate controls for new raw matrial storage and delivery system to existing plaant controls.

Specify required controls hardware.

Review controls and electrical compoenents

Redline plant electrical drawings.

Generate Scope of work for electrical contractor

Job Walks

Schedule resources

Program new controls to existing logix 5000 program

update graphics * RSView32

Startup, commissioning, test runs

Operators manual ( Standard Operating Procedure ) and training

Elevators and Escalators monitoring and safetry system for  one of the worlds busiest International airport

Study existing elevators and Escalotors and determine requirement to add monitoring system.

Setup new servers and install FTView SE

Develop new HMI graphics for various Escalotrs/Elevators

Devel network architecture to connect all escalotrs/elevators controls to a central server.

Start-up and testing

Automation/Validation Specialist for Plant RO-DI generation and distribution system.

Reverse Engineering of Siemens Microcontroller (S7-200) and touch panel (TP177A) for RO Generation. Program new controls to Compact Logix and replace Siemens drive with Powerflex with Ethernet communication card.

Develop URS (User Requirement Specification)

Document decommissioning of equipment to maintain SIS compliance.

Generate Functional Spec (FS), Electrical Layout and Equipment Modules Spreadsheets.

Program RO Generation and RO distribution system in Allen Bradley 1769 L-32 E controller with 1734 Point IO’s and panel view 1000 HMI.

Manage and work with electrical contractor for field wiring and control panels installation.

Update all drawings, Bill of materials & Network Architecture.

Manage Electrical Contractors & equipment purchase.

Generate IQ, OQ and Execute Software Acceptance Test, IQ and OQ with facilities Engineers.

Train Facilities and other users about functionality of new system.