Lead Automation Engineer
Alfozan for Food Industries Factory
Total years of experience :13 years, 6 Months
This plant is Installed recently I was leading Team of Engineers for the Installation, Commissioning and Startup Planning and Activities. We did it successfully. The Cost of the Project was 2 Million USD $ Approx. . Now I am Leading Automation Department.
• FDS Review
• Prepare IO testing checklist
• Prepare VFD and Soft starter testing checklist
• Prepare Sequence checklist for FAT
• Software Management (Backup of software, Licenses and Images for offline).
• History Management (Info plus trending, SQL Servers).
• PIDs and Operational parameters optimizations.
• Automation Hardware Management.
• SCADA servers and client configurations and backup management.
• Report management for batch analysis, CIP reports masked items.
• Software Management (Backup of software, Licenses and Images for offline).
• Development of Application programs and HMI’s
• PIDs and Operational parameters optimizations.
• Automation Hardware Management.
• Coordinate personnel (e.g., contractors, Engineers, Technicians, etc.) to ensure the objectives are satisfied.
• Ensure management of documents (manuals, diagrams, software packages/licenses etc.) through archiving procedures.
• Manage relationship with external service providers, including time schedules, and Projects implementation and
• Modification in existing production lines in line with hygiene engineering and process optimization
Responsibilities:
-Develop PLC programs ensuring the process safety and Product Quality
-Develop HMI interfaces as per requirement
-Coordinate personnel (e.g. contractors, Engineers, Technicians, etc.) to ensure the objectives are satisfied
-Ensure management of documents (manuals, diagrams, software packages/licenses etc.) through archiving procedures
- Server maintenance
- PM for MCC cabinets and MCC
-PM for Drives
-PM for Motors
-PM for Servers, Client PC's and PLC's
-Project Execution Support
-Operation and Maintenance Support to enhance Productivity.
-Calibrations of Instruments.
-Training to technician for troubleshooting AS-I network, Profibus DP and profinet.
Projects:
- Inline Cream Dosing Project
-Aspen Historian Deployment
-B2B Milk and Cream Sending Line.
-Juice Plant complete Project (FAT, SAT, Commissioning).
Responsibilities:
-Develop PLC programs ensuring the process safety, -NEAT standards and product quality (Rockwell AB).
-Develop HMI interfaces as per requirement ensuring NEAT standards. (Wonderware Intouch, Archestra, FactoryTalk VS)
-Implement networking system like as Control Net, Device Net, and Ethernet etc.
-Coordinate personnel (e.g. contractors, Engineers, Technicians, etc.) to ensure the objectives are satisfied.
-Ensure management of documents (manuals, diagrams, software packages/licenses etc.) through archiving procedures.
-Manage relationship with external service providers, including time schedules, and Projects implementation and modification in existing production lines in line with hygiene engineering and process optimization
Projects :
-Maggi Noodles Plant automation & commissioning (Development of HMIs, PLC Programs, Instruments & IOs selection)
-Confectionery (Chocolate filled Cereal biscuit) Plant Automation & Commissioning.(Project Cost: 600 Million PKR)
-GEA Pasteurizers HMI designing & PLC Program development Cold skimmer circuit programming with Separator Bypass.
-Commissioning of GEA Niro Soavi UHT (30KLtrs/h) and ATS (50KLtrs/h) (With GEA-TDS)
-Automation of Butter Milk, Butter Packaging, Palm Oil, Rapeseed Oil, Lecithin, Recodon and additive dosing, Scanima .
-Development of HMI (Panel Screen), PLC Logics Programming of STS RO Water Plant
-Performed Automation and commissioning of Descon Boiler (15 Ton Steam Capacity).
-GEA Grasso Ammonia Chillers automation & commissioning.
-PLC Programming of NH3 Leakage Detection System.
-Dry Tipping and Fonterra Dosing System automation & commissioning
-Butter oil Plant CIP extension for UHT recovery system automation & commissioning
-Recipe Management system and Fail over for recipe Management system
Reposibilities:
-Coordinating with the vendors for ordering Instrument’s, tools, Spare parts and Component for specific Project. .
-Designing technical layouts of projects of automation and Control Systems
-Supervising & Execution the of automation, Electrical and Control System
-Analyzing for Training and Development needs for client team.
-Preparation of scheme designs, C& I& E diagrams, control loop diagrams, Control system Description.
-Site Installation and Commissioning Activities
-Project Oriented of project
-Cable laying schedule and Cable Selection
-Selection of Pressure transmitters, temperature transmitter, flow transmitters, RTD’s
-Installation of field instrumentation and analyzers (Pressure transmitters, temperature transmitter, flow transmitters, RTD’s, GC and flow computers)
-Calibration of the all types of Transmitters
-Cold loop and hot loop testing.
-Establish communication between Yokogawa DCS and other controller such as Siemens and Modicon PLC’s through ModBus.
-Establish communication between Yokogawa DCS and other controller such as Siemens and Modicon PLC’s through ModBus TCP/IP.
-Establish communication between Yokogawa DCS and Three Compressor Units (Flash Gas Compressor, Export Gas Compressor and Propane Gas Compressors)
with Centurion Control and SCADA system using ModBus Protocol.
-Establish communication between Yokogawa DCS and Yokogawa Prosafe-RS
-Establish communication between Yokogawa DCS, SIS, RTU’s using FIBER Optics
-FAT of the System with simulation
-Hook up drawing and layouts of Instruments for ESD and PMCS
-System architecture and system topology
-Panel wiring Diagrams ( 1200 IOs and DCS hardware)
-Procurement and Panel fabrication
-Complete Engineering and Programming with Yokogawa DCS Centum VP and Pro- Safe
Alarm and events, HMI development, Linking with Tags, Faceplates, Communication with different packages ( Compressor unit, TLAS, Air Compressor, LMLS,
RTU’s)
-Well Head Control Panels
-Complete Redundant system
Projects:
1- OGDCL Qadir Pur Gas Field Metering Skid (Total IOs=150, Control Logix Controller)
2-Geo-Energy (IOs= 300, Siemens S7-400, Redundant System, Balgimbayev & Makat Kazakhstan)
3-OMV-MGDP (Maher Gas Development Project, IOs=1200, Centum VP, Pro-safe)
4-BAPEX (Shahbaz Pur Gas Field Development Bangladesh, IOs=400, Centum VP, Pro-safe)
5-DNO Yemen (Yaalen Early Production Facility Yemen, IOs=200, Control Logix, Wounderware)
6-Replacement of Refrigeration System GASCO BuHasa Plant, Abu Dhabi, UAE
Project Engineer (Instrumentation & Control):
Responsibilities:
-Industrial Automation, Instrumentation & Control Solution Planning & Design.
-Responsible for Installation, Commissioning, Automation & Maintenance
-Coordinating with the vendors for ordering -Instrument’s, tools, Spare parts and Component to maintain stock.
-Understanding the design and technical -specifications of the Process so as to provide comprehensive information to the management.
-Installation and procurement of LV and MV Switchgear
-Providing the Technical team with automated solutions.
-Monitoring the installation of equipment & Instruments.
-Conducting studies to determine the feasibility, costs, or performance benefits of the equipment.
-Designing technical layouts of projects of automation and Control Systems
-Supervising & Execution the of automation, Electrical and Control System
-Analyzing for Training and Development needs for Production and Maintenance Staff.
-Preparing project estimates to save energy cost and to improve production of plants.
-Preparation of scheme designs, C& I& E diagrams, control loop diagrams, Control system Description.
-Responsible for Planning Preventive & Corrective Maintenance for Electrical & Instrument Jobs
Projects:
1-Power House 4 MW:
-Errection, Commissioning & Synchronization of Steam Turbine (2MW) with Diesel Generator (2 MW).
-Erection & Commissioning of Backup Diesel Power House (4 MWatt) with Cummins diesel generators (2 MW) synchronized with 2 MW CAT rental gensets.
-Deployment of B-II WAPDA Connection 11kV, 500kW as a standby source with bi-directional feature for Power sale agreements
-Erection & Commissioning of 11kV Switchgear (ACB, VCB, and MCB), LV Switchgear, LV distribution Network, and 11kV distribution network
comprising of 9 Nos. 11kV / 400V transformers.
2-Process Mill Building
3-Rice Husk High Pressure Boiler
4-Utility section
-RO Plant, Cooling water, Soft water, Condensate recovery system, Boiler house, Steam distribution system.
-Instrument Air System
-Installation of Four Air Instrument Compressor (Atlas Capco ZT-250, Atlas Capco ZT-135, SAWAN & RENNER).
5-Phase II (GRAIN LOGISTIC SYSTEM).
6-Seed Processing Plant
7-Phase III (Extension of GRAIN LOGISTIC SYSTEM)