Sr. System Analyst - Control and Automation

MADHUKAR BONKURI

Mobile: +1-832-***-**** Email: ************@*****.***

EXPERIENCE SUMMARY

Experience in Industrial Automation and controls systems development including design, engineering, project management, documentation, commissioning and operator training.

Increasingly responsible project management skills, self-motivated.

Experience in SCADA, PLC and HMIs (Rockwell,Siemens,Intouch,Wonderware Archestra system platform etc)

Good exposure on Database management system and entity relationships.

Very effective interpersonal, oral and written communication skills. Great ability to consult with senior management, project personnel and customers.

Participate in mentoring team to ensure effective growth technology members for organization.

Proposed and lead Implementation of process improvement initiatives for cost reduction and defects elimination.

Change Requests - Analyze impacts on scope, resources, and schedules.Communicating findings with team members in a timely manner.

EDUCATION

B.E (Instrumentation) in 2004 from Osmania University, Hyderabad, India.

TECHNICAL EXPERTISE

PLC /SCADA software’s : Rockwell –Control Logix, GuardLogix, Factory Talk ME

Siemens – S7-300, S7-400, WinCC, WinCC Flex, Starter

Wonderware –System platform2017, 2014 R2,Intouch 8.0,7

Yokogowa –Centum VP, ABB-800xA

Protocols / Standards :Ethernet/IP, Profinet, DAServer, Kepware,Modbus, Serial.

Electrical Design : Electrical AutoCAD 2011, 12, Panel Design

Software Skills :C#,.Net, Windows services,WCF,WPF and Std SQL database.

CERTIFICATIONS

Wonderware Application Developer – System Platform 2017,2014R2.

Wonderware Application Developer – Historian 2017,2014 R2

GM CCRW

PROJECT DETAILS #1

Project Name : Oil well maintenance and upgradation

Duration : April 2017 to Till date

Environment : Rockwell – ControlLogix L63, System platform 2014R2

Location : Houston,TX

Role : Sr. Systems Analyst/ Controls and Automation Engr.

Company : PLCs Plus International Inc

Responsibilities:

Working on Wonderware System Platform 2014 R2 and communication with the Rockwell PLCs using DA Server configuration.

Trouble shooting on the issues with connectivity and problem solving with servers, .net functions,window services and SQL database.

Interacting with the field analyst and resolving the issues related to the field including Intouch screen and historians

To offer technical help to customers both external and internal.

Working with IoT to integrate in SCADA.

On call production support.

PROJECT DETAILS #2

Project Name : Terminals – Transmission and Storage

Duration : August 2016 to April 2017

Environment : Rockwell – PLC 5, ControlLogix L63, System platform 2014R2

Location : Houston,TX

Role : Scada Systems Engineer – Automation & Controls

Company : Parijat Controlware Inc

Responsibilities:

Converting the Intouch application into Wonderware System Platform and communication with the Rockwell PLCs using DA Server configuration.

Trouble shooting on the issues with connectivity and problem solving with servers,.net functions,window services and SQL database.

Conducting FAT with the Client and resolving the discrepancies of the screen with the Field Supervisors.

To offer technical help to customers both external and internal.

On call production support.

Weekly review presentations on operations and application enhancements status.

PROJECT DETAILS #3

Project Name : Midstream Services – Booster Station

Duration : November 2014 to July 2016

Environment : Rockwell – PLC 5, ControlLogix L63, System platform 2014

Location : San Angelo,TX

Role : Automation Specialist

Company : Pondhop Automation and Controls Inc

Responsibilities:

Converting the IFix application into Wonderware System Platform and communication with the remote PLCs using Kepware configuration.

To assist remotely and visiting plants for operational issues with SCADA and ControlLogix PLCs .

Trouble shooting on the issues with connectivity and problem solving with servers, .net functions,window services and SQL database.

Weekly review presentations on operations and application enhancements status.

PROJECT DETAILS #4

Project Name : Blow and Injection Molder machine

Duration : August 2014 to November 2014

Environment : Rockwell – PLC 5, ControlLogix L63, System platform 2014

Location : Manchester,MI

Role : Automation Systems Engineer

Company : Amcor Rigid Plastics Limited

Responsibilities:

Involved in the development of the objects on Wonderware System Platform as per the standards.

To assist remotely and visiting plants for operational issues with SCADA and ControlLogix PLC using DA server configuration, .net functions,window services and SQL database.

Develop SQL queries to generate reconciliation reports.

Coordination with other Application interface teams on reconciliation data loads.

Weekly review presentations on operations and application enhancements status.

PROJECT DETAILS #5

Project Name : Heat Recovery Steam Generator

Duration : June 2013 to August 2014

Environment : Siemens S7-300, Yokogawa Centum VP, MarkVI

Location : Amal,Oman

Role : Systems Integration Manager

Company : Al-Hassan Engineering Co.SAOG

Responsibilities:

Integrate resource policies and specification to determine the procedures related to pre-commissioning, Commissioning and handover of Amal HRSG as per the standards.

To assist with the design, installation and commissioning of systems in conjunction with the System Engineering and Technical Projects Department.

Assist Senior Service Personnel in developing / maintaining all necessary procedures & documentation associated with IEC61508 certification.

Establishing DCS communication interface between HRSG OEM and third party controls including BOP, Mark VIie GTG system with the requirement of Petroleum development Oman.

To offer technical help to customers both external and internal.

PROJECT DETAILS #6

Project Name : Automotive – Skid Conveyor

Duration : February 2012 to June 2013

Environment : Rockwell - ControlLogix, GuardLogix, WinCC

Location : Silao, Mexico

Role : Project Leader – Control and Automation Systems

Company : Kasa Anlagen India Pvt Ltd.

Responsibilities:

Working closely with the customers of North America on Automobile, Grain handling projects.

Preparing Functional document specification and conduction of CFAT with the client.

Project Lead for the engineering design, project estimation, analyzing the required inputs for project, conducting technical discussions with customer, estimating time for executing each task.

Took initiative in troubleshooting and execution of the up gradation of hardware,re-programming of ControlLogix PLCs,GuardLogix PLC & re-commissioning activities.

Developing the application in ControlLogix plc with the requirement of GM motors and WinCC Open Architecture screens for HMI.

Communication with different network protocols for Drives using ControlNet, DeviceNet for Barcode scanners and EtherNet for communicating between different ControlLogix PLC.

PROJECT DETAILS #7

Project Name : Clean water project – Thames water Utilities

Duration : July 2011 to February 2012

Environment : Rockwell - CompactLogix, MicroLogix, System Platform 3.1

Location : Coventry, UK

Role : Project Leader – Controls and Automation.

Company : Sarla Technologies India (P) Ltd.

Responsibilities:

Development of application, interfacing with Rockwell PLC and Wonderware Archestra system platform3.1, .net functions,window services and SQL database.

Preparing Functional document specification and conduction of CFAT with the client.

Recording the change in the specification according to client specification and showing it to customer for approval.

Mentoring the project in the stream of HMI and effective interaction with the team across the global operations.

Work closely with the operation leaders to achieve the targets, drive improvements & transition rigor in the HMI standards

Troubleshooting issues with CompactLogix & MicroLogix PLC programmes using DA server and communicating with EtherNet and DeviceNet protocols.

PROJECT DETAILS #8

Project Name : Refinery Upgrade project of FPSO platform

Duration : December 2009 to July 2011

Environment : ABB – AC800M Controller, ABB 800xA DCS

Location : Muharraq, Bahrain

Role : Asst. Manager Projects - ESS

Company : Larsen & Toubro Ltd.

Responsibilities:

Project related activities including project engineering, project estimation, gathering the requirements from each section of the site and analyzing the required inputs for project, conducting technical discussions with customer, estimating time for executing each task.

Application Development using AC800M controller. IEC Engineering for communication of relays to the ABB DCS system 800xA v5.1.

Design & implementation of hardware, loop typical and system migration.

Internal testing of completed engineering software & its verification.

Preparing documentation for the CFAT and log the changes based on the requirements of the customer to satisfy their needs.

Commissioning the system, give training to the operator and prepare the site acceptance report.

PROJECT DETAILS #9

Project Name : Continuous Pickling and Tandem Cold Mill

Duration : February 2007 to April 2009

Environment : Converteam PLC, Wonderware – System Platform

Location : Mobile, AL

Role : Engineer- Automation

Company : Converteam EDC Pvt Ltd.

Responsibilities:

Worked on the Architecture of HMI with Thick/Thin client configuration on Archestra System platform 3.0 with SP1, .net functions,window services and SQL database.

Screens identification for PL -TCM and develop screens with reference to the engineering drawings. Wonderware SP Platform is used for both PLTCM & HDGL with Historian (Trending and log data).

Process validation, inspection and supervision.

Corrective actions based on customer complaints and non-conformities. Work in process Monitoring and control.

Identifying the screens for improvement, develop strategies and methods to enhance the process in order to ensure a competitive edge with regard to the client requirement.

Driving process risk assessments and developing mitigation plan.

PROJECT DETAILS #10

Project Name : Standardization of HMI Process for Metals

Duration : February 2007 to April 2009

Environment : Converteam PLC, Wonderware – IAS 2.1

Location : Belfort, France

Role : Engineer- Automation

Company : Converteam EDC Pvt Ltd.

Responsibilities:

Testing of HMI System (architecture and environment) exploring IAS 2.1 (Wonderware-Archestra Industrial Application server) and implement first application in a Metals project with .net functions,window services and SQL database.

Quality Analysis and product enhancement, solution development, customization approaches to meet client requirement.

Program Management (Client Management, Cost and scope management time

Management, tracking product enhancements, Building the requirement specifications and solution approaches

PROJECT DETAILS #11

Project Name : Printing and Packaging Machine

Duration : May 2005 to February 2007

Environment : Siemens – S7 300, Wonderware – Intouch 7.1, 8.0

Location : Rudrapur,Uttaranchal

Role : Engineer- Automation

Company : Cerutti Engineering Services India Ltd.

Responsibilities:

Application Development using Wonderware -Intouch v7.1, v8.0 (HMI/SCADA Software), establishing Communication with PLC (S7-400, S7-300) using Communication protocols (Ethernet, Profibus, MPI/DP), DA SERVER and Database Management through Ms-Access

Worked on the Automation of Printing and Packaging machine for the clients by Application Development using Wonderware -Intouch v8.0, (HMI/SCADA Software), importing Windows from V7.1, Creating Animation links, Scripting, Security, Developing screens, Trending, establishing Communication with PLC (S7-400, S7-300) using Communication protocols (Ethernet, Profibus, MPI/DP), DA SERVER and Database Management through Ms-Access.

Discussing and communicating with client personnel on the project requirements i.e. integration of new requirements with existing functionality.

Resolving of technical issues at client place and communicating /coordinating on the issues with the offshore team.

Teamed and coordinated with engineering team to design and manage consistent work for HMI/SCADA system.

Documentation of High level Technical Screen designs based on the parameters, specifications and process flow.

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