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Usman Farooq

Resume

Work Experience

December 2021 - Present
McKinsey & Company

Specialist

  • I help industrial organizations improve their operations, project execution, and digital infrastructure
January 2020 - November 2021
Gap Engineering

Project Manager

  • Led control systems and emergency shutdown systems projects for manufacturing and petrochemical industries
  • Developed engineering documentation (e.g., control narratives, cause & effect diagrams, network architectures, control panel layouts, loop drawings, and single-line diagrams for electrical distribution systems)
  • Developed and implemented process control and process safety logic across various types of industrial automation systems (e.g., SCADA, DCS and PLC systems) including Honeywell TDC-3000, Honeywell Experion, Honeywell Safety Manager, Schneider Electric Triconex, Siemens SIMATIC S7, Rockwell RSLogix/Studio 5000, Inductive Automation Ignition, etc.
  • Programmed control systems using ladder logic, structured text, and FBDs
  • Designed and developed control systems HMIs utilizing industry best practices and client engineering standards
  • Implemented control systems communications using various protocols based on project needs (Ethernet, Modbus TCP/IP, RS-232, RS-485, ControlNet, etc.)
  • Setup control systems infrastructure including servers, operator stations, network switches, and firewalls
  • Provided cybersecurity advisory services to industrial clients based on ISA 99 standards (ISA99.00.01-04)
  • Developed budgets, schedules, and risk management plans for $220M projects as part of engineering services
  • Developed custom software applications for industrial clients (C#, SQL)
  • Led FATs (factory acceptance test), SATs (site acceptance tests), and on-site commissioning/start-ups
December 2017 - December 2019
Suncor Energy

Control Systems Specialist

  • Maintained the site wide operational technology and industrial automation infrastructure including Honeywell Experion Distributed Control System and the PCN/PIN/DMZ network infrastructure
  • Maintained the virtualization infrastructure consisting of the VMware ESXi hypervisors
  • Planned and implemented network changes including Cisco network switch and firewall configurations
  • Maintained the Acronis auto backup systems, McAfee ePolicy Orchestrator auto anti-virus update systems, and WSUS (Windows Server Updating Service) systems
  • Maintained the Honeywell Dynamo and PAS PlantState Suite alarm management systems and performed alarm rationalization
  • Maintained SolarWinds Orion, Expertune PlantTriage, and other third-party systems
  • Managed the cybersecurity of the critical plant operational technology infrastructure
  • Worked with operations team to continuously improve plant process control systems to improve production
  • Programmed process control and process safety systems and ensured quality control for changes by vendors
  • Followed the Management of Change (MOC) process for all system changes and engineering documents
  • Redlined drawings (P&IDs, cause & effect documents, etc.) for engineering projects on site
  • Evaluated vendor project proposals and engineering documents for additions and updates to infrastructure
  • Managed 3rd party vendors providing engineering solutions and services for the site
  • Investigated, reported, and performed root cause analysis for equipment trips and process upsets
  • Participated in HAZOPs and contributed to process improvement cross functional teams
September 2014 - December 2017
Cybertech Automation

Systems Integrator

  • Programmed various industrial automation systems (e.g. SCADA, DCS, SIS, and PLC systems)
  • Reviewed and updated client engineering standards, drawing, and other documents including P&IDs, PFDs, Cause & Effect matrices, control narratives, electric single-line diagrams, instrument loop diagrams, etc.
  • Performed design, development, and commissioning for the following major projects:
    • Albian Oil Sands Muskeg River Mines Recovery Compliance Project – Shell Canada (Honeywell Experion PKS R430 DSC)
    • SIS Gap Closure Project Phase 5B, Scotford Refinery – Shell Canada (Schneider Electric Foxboro I/A DCS, Triconex SIS)
    • CSU Phase 5A SIS Upgrade, Scotford Refinery – Shell Canada (Schneider Electric Triconex SIS)
    • Hydrocracking Unit Debottleneck Project, Scotford Refinery – Shell Canada (Schneider Electric Foxboro I/A DCS, Triconex SIS)
    • Quest Carbon Capture & Storage, Scotford Upgrader – Shell Canada (Honeywell Safety Manager SIS)
  • Provided software development services for various industrial clients
  • Developed a large-scale auditor database solution for Shell. It processed information from 14 different databases and file sources and generated reports to identify discrepancies and areas of concern for the production plant. [Link] – developed using C# and MSSQL Server
  • Developed a suite of applications for exponentially increasing efficiency and reducing human errors for the legacy Foxboro control system platform. [Link] – developed using C# and MSSQL Server
November 2012 - June 2014
Intech Process Automation

Design & Application Engineer

  • Provided technical leadership for multiple large-scale industrial automation projects e.g., process control and SIL2 and SIL3 compliant process safety systems for:
    • Control and Safety System for Perla Gas Field Wells – Cardon IV, Venezuela – (Rockwell ControlLogix / FTViewSE (Plant PAX graphics))
    • Distributed Control & Safety System for Tioga Gas Plant – Hess, North Dakota – (Honeywell Experion DCS / Honeywell Safety Manger R145.2)
    • Integrated Control & Safety System for Petrocarabobo Heavy Oil Production – PDVSA, Venezuela – (Rockwell ControlLogix/ FTViewSE)
  • Led geographically distributed teams for the development and delivery of engineering projects
  • Programmed and led programming of SCADA, process control, and process safety systems
  • Established templates and best practices to drive standardization, quality, and speed of development
  • Provided mentorship and performed performance management for my team
  • Managed client communication, scope management, and change requests
  • Led multiple FAT (factory acceptance tests) and SATs (site acceptance tests) with client personnel
  • Conducted on-site commissioning and startup for the delivery of engineering projects
  • Performed project management to ensure delivery of projects within schedule, budget, and quality constraints
November 2011 - October 2012
Pakistan Refinery Ltd.

Distributed Control Systems Specialist

  • Managed 15+ resources for maintaining the refinery wide industrial automation infrastructure including Honeywell Experion PKS R400.1 DCS (distributed control systems) and OT network
  • Created detailed backup and restore procedures to respond to emergency situations (e.g., server failures)
  • Conducted drills to test infrastructure failure response plans and performed online replacement of critical infrastructure components (e.g., servers, network switches) without affecting refinery operations
  • Led the preventive and corrective maintenance activity of control systems department personnel
  • Managed vendors and other contractors providing engineering services at the site
  • Managed the work-permit and LOTO (lock-out tag-out) process for maintenance activities
  • Conducted HSE (health safety & environmental) trainings for instrumentation & control department personnel
August 2009 - November 2011
Avanceon

Project Engineer

  • Reviewed and modified engineering drawings and documentation (P&IDs, PFDs, C&E diagrams, etc.)
  • Created FAT (factory acceptance test) and SAT (site acceptance test) documents and conduct FATs and SATs
  • Created detailed project management plans for engineering projects
  • Developed and implemented HMI (human machine interface) displays for various control systems
  • Developed and implemented control logic for PLCs, SCADA, and DCS (distributed control systems)
  • Developed and implemented process safety logic in ESD systems (e.g., Honeywell Safety Manager)
  • Designed and implemented operational technology infrastructure (e.g., servers, network switches, firewalls)
  • Reviewed and modified AutoCAD drawings (e.g., cable schedules, loop drawings, control cabinet layouts)
  • Performed design, development, and commissioning activities for the following major projects:
    • Distributed Control System Migration for Pakistan Refinery Ltd. (Honeywell Experion PKS DCS R400.1)
    • Process Control and Emergency Shutdown System for Engro Fertilizer Expansion Project (Honeywell Experion PKS DCS R310 / Honeywell Safety Manager ESD R131.2)
    • Process Control and Emergency Shutdown System for CO2 Recovery Unit of Engro Fertilizer Expansion project (Honeywell Experion PKS DCS R310 / Honeywell Safety Manager ESD R132.1)
    • Heat Recovery Steam Generation project, Dawood Hercules Chemicals Ltd. (Honeywell Experion DCS R310)
    • Control system migration for Dawood Hercules Chemicals Ltd. (Honeywell Experion DCS R310)

Education

2005 - 2009
NUST

Bachelor of Science in Electrical Engineering

Expertise

Project Management

  • Develop project management plans and project schedules using Microsoft Project
  • Project management including resource management and project reporting
  • Budget and schedule estimation, development, management, and control throughout the project life cycle
  • Extensive client communication and stakeholder management
  • Oversee the activities of contractors, vendors, and other support staff in execution of project activities.

Control Systems Engineering

  • Complete hardware and software system design for industrial automation projects
  • Create, review, redline, and modify P&IDs, cause & effects, control narratives, FAT and SAT procedures, motor control schematics, and maintenance manuals
  • Develop and implement complex process control loops and advance process control strategies
  • Loop turning for traditional PID and MPC based process controllers
  • On-site loop checks, commissioning, and start-up support
  • Knowledge of industry codes and regulations ISA / IEC / NFPA / Class and Zone classifications
  • Technical leadership of process control and process safety system projects

Control Systems Platforms & Technologies

  • Honeywell Experion PKS DCS R200 / R300 / R400 / R500
  • Honeywell TDC 2000 / 3000
  • Honeywell Safety Manager
  • Rockwell RSLogix Studio 5000 / FactoryTalk View Studio Site Edition / Machine Edition
  • Rockwell Micrologix, CompactLogix, and ControlLogix PLCs
  • Siemens S5 and S7 PLCs
  • Foxboro I/A DCS
  • DeltaV DCS
  • Schneider Electric Triconex TriStation
  • Inductive Automation Ignition
  • Codesys Automation Software
  • Communication protocols including OPC, Modbus TCP-IP/RS-232/RS-485, ControlNet, etc.

Programming

  • Software development best practices including separation of concerns, object-oriented design, suitable design patterns, and test-driven development
  • Good understanding of agile software development management including revision control (git), branch and release management, continuous development, and continuous integration
  • Good understanding of database design, performance considerations and other design aspects including suitability of indexes, stored procedures, CTEs, etc.
  • Good understanding of software architecture best practices including the use of ORMs, APIs, separation of front ends/back ends, containerization, and microservices
  • Good understanding of DevOps and software developments management tools and methodologies including Scrum and Kanban frameworks
  • C# application development experience with desktop (WPF) and web applications (.NET core)
    SQL Database development and maintenance experience (Microsoft SQL Server)
  • Experience with Microsoft Azure and Amazon AWS platforms
  • Proficient with Excel VBA programming and Access databases

Certifications & Qualifications

  • PMI Certified Project Management Professional (PMP) – Credential ID: 2794113
  • Scrum.org Professional Scrum Master I (PSM-I)
  • Scrum.org Professional Scrum Product Owner I (PSPO-I)
  • International Society of Automation (ISA) Certified Automation Professional (CAP) 2015-2018 – Credential ID: 100234
  • Certified Associate Honeywell Safety Manager Fundamentals Implementation – Honeywell Automation College, Houston, USA
  • Honeywell Advance Process Control Fundamentals, Profit Controller Implementation – Honeywell Automation College, Calgary, Canada
  • Courses taken at University of Alberta, Canada: SMO-500 Managing People, BUEC-503 Economic Foundations, and MARK-502 Principles of Marketing Management
  • Georgia Institute of Technology: ISYE6501x Introduction to Analytics Modeling