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)
