INDUSTRIAL
CONTROLS
For Manufacturing
Quality & Quanity....
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.
CONTACT DETAILS
San Diego, CA, 92126
ControlsCare