Continuous Improvement Project Manager

Nadr W. Elias

Cypress, TX *****

**********@*****.*** 248-***-****

Lead Engineer, Process – Power Generation

Lead and manage construction projects from initiation to completion. Possess significant and diverse experience with instrumentation and controls in the chemical processing industry. Experience involving continuous improvement of plant equipment, Monitor and improve energy use within the plant to save the company a minimum of 20% and up to 40% of the utility bill. start-up, and troubleshooting. Pro-active approach to maintenance, using production data to distribute resources and drive funding for process improvements. Skilled in project scoping, developing and deployment of projects for execution with experience in operations and maintenance of a wide spectrum of equipment and components. Proven ability to train staff to follow instructions and company policies while enhancing workflow and process improvement.

Professional Experience

OCEAN EDGE SERVICES, HOUSTON, TEXAS Jan 2025 – May 2025

Controls Electrical Engineer

Design and implementation of control strategies based on plant manufacturing processes needs and company vision.

Experience with ISA-95 Framework & layers and control system architecture design.

Development and interpretation of P&IDs drawing. Create the I/O list based on customer documents.

Experience with PLC/DCS redundant systems. (Communication, Processor, IO blocks, AC/DC power).

Review client specifications and design Electrical/PLC based controls solutions, including component selections, wiring diagrams, communication interfaces, enclosure general arrangement drawings, etc.

Provide the Design team with the necessary information and support to generate the drawings package.

Develop software applications for PLC/HMI Studio 5000 AB. Create project-related documents, including Functional design specifications, controls narrative, test procedures, interfaces documents, user manuals, and commissioning and start-up procedures

System commissioning, troubleshooting, and start-up at client locations: onshore and offshore. collaborate and effectively communicate with the project team (Project Manager, Engineers, Technicians, etc.), clients, and suppliers.

Knowledge of hazardous area design requirement to NEC, NEMA, IEC, OSHA, ATEX.

Plant level experience and understanding of electrical one-lines, breaker control schematics, motor control schematics, and Industry Standards (NEC, NFPA, API, etc.)

Experience with 480 V, 2300 V, 4160 V, and 13.8 KV systems with 138 KV systems experience being a plus.

CEMEX USA, HOUSTON, TEXAS April 2023 – Oct 2024

Engineer Electrical & Automation (Remote)

Design and implementation of control strategies based on plant manufacturing processes needs and company vision.

Specify, evaluate and select electrical equipment for operations and CAP EX projects.

Maintain close contact with operations, maintenance, engineering, and project development to identify and implement electrical equipment repairs and reliability improvements.

Design and specify electrical equipment such as motors, breakers, relays, generators, substations, buses, starters, transformers, and other industrial electrical equipment (480V to 230kV).

Review and/or negotiate utility contracts with outside vendors.

Review the existing hardware architecture for PLC-based control systems Allen Bradley/Rockwell, Siemens, Modicon, SCADA, analog and digital I/O systems and hardware, supporting equipment, and design improvements as needed (programming, start-ups and debug).

Monitors Engineering Quality Control and leads contractor’s electrical work to ensure consistency with project specifications and guidelines.

Mentor & coach new graduate engineers and internships.

Prepare and review projects technical drawings (Electrical and P&ID).

Calculate power requirements, CB ratings, Starter sizes, cable sizes, field disconnect ratings for MCC and control panels.

Coordinate control system startup, checkout, and commissioning activities with the project manager or team leader.

Update documentation and backup all the control system applications.

Travel to attend project meetings and executions to multiple USA plants.

MATERIAL HANDLING SYSTEM (FORTNA) (MT. WASHINGTON, KY) May 2023– March 2024

System Engineer (Remote)

Utilize the existing toolsets to generate electrical equipment and labor costs for new material handling systems as well as modifications to existing systems and change orders.

Collaborate with internal departments as required to estimate costs for controls engineering, electrical installation etc.

Analyze system layouts and sequence of operations as required to ensure proper system operation.

Attended estimate review meeting with upper management.

Review and quality check of our estimate tools.

MATERIAL HANDLING SYSTEM (FORTNA) (MT. WASHINGTON, KY) April. 2022 – May 2023

Robot Electrical & Commissioning Design Engineer (Remote)

Responsible for commissioning manual and Robot lanes in various USPS national distribution centers.

Commissioning servers, Thin Clients, VMs, Vision system (Allen Bradley/Rockwell, Schneider, activating Windows licenses and configuring Cisco switches.

Design, fabricate and install industrial control panels, Pallet conveyor and sortation system.

Direct and coordinate manufacturing, construction, installation, quality inspection, maintenance, support, documentation, and testing activities to ensure compliance with specifications, codes, and customer requirements.

Prepare specifications for the purchase of materials and equipment.

Experience with Indusoft, AVEVA (Wonderware), SoMachine Motion Logic Builder, Allen Bradley /Rockwell and, Siemens and Controller Assistant software’s (Schneider Electric).

Provides verbal and written reports to communicate project status as required and contribute to project review meetings.

Attend Site Acceptance Test to make sure the equipment is reliable and running with minimal issues/interventions and high-performance statics.

Operational/Maintenance training for customer personnel.

INSIGHT GLOBAL, CHICAGO, IL Jul. 2021 – Mar 2022

Electrical Engineer (Contract/Remote)

Responsible for design and/or specification of equipment and process.

Project Management skills, including the ability to manage multiple projects simultaneously.

Familiar with IEC61508 and IEC61511 standards.

Modeling power system by ETAP.

Mentor & coach new graduate engineers and internships.

Responsible for generating costs for electrical power/controls engineering and electrical installation of

chemical plant equipment based on mechanical AutoCAD layouts, equipment lists, customer

specifications and sequence of operation documents.

Experience with Indusoft, AVEVA (Wonderware), Allen Bradley /Rockwell and, Siemens and Modicon.

Oversee the preparation of bid documents, cost estimates, responses to requests for proposal.

Evaluate customer Request for Quote (“RFQ”) documents and ensure that our costing is inclusive of their requirements and specifications.

Generate RFQ documentation for external material and labor suppliers.

Calculate power requirements, CB ratings, Starter sizes, cable sizes, field disconnect ratings for MCC and control panels.

Develop and release bill of materials for panels and field devices.

Develop overall architecture drawing including different communication protocols like Fiber Optics, Ethernet IP and Profibus.

Experience using AutoCAD Electrical and Vault to create\store electrical drawings and schematics.

Review and approve supplier/manufacturer calculations and specified data for control, measurement, monitoring, and electrical equipment to be purchased.

Develop/validate control, measurement, monitoring, and electrical equipment parameters on instrument datasheets.

Complete the Technical Bid Evaluation for instrumentation, control, and electrical equipment.

Visits internal/external panel manufacturing facilities to assess progress, provide technical assistance and for final inspection and sign off.

Provides verbal and written reports to communicate project status as required and contribute to project review meetings.

Proactively contributes to the continuous improvement effort and eliminate the bad actor/bottle neck in the process.

Provide detailed Power and Controls Engineering design.

Review and approve engineering drawings (PFD, PID, Control panels, MCC and SLD) and plans.

Provide troubleshooting and technical assistance to manufacturing plants.

Development of project scope and Material Take off.

Working with Rockwell PLC’s and Motion controls (hardware and software).

JTAM ENGINEERING, Houston, TX Oct. 2020 – April 2021

Senior Principal Engineer I/E

Responsible for generating costs for electrical controls engineering and electrical installation of

chemical plant equipment based on mechanical AutoCAD layouts, equipment lists, customer

specifications and sequence of operation documents.

Evaluate customer Request for Quote (“RFQ”) documents and ensure that our costing is inclusive of their requirements and specifications.

Modeling power system by ETAP.

Generate RFQ documentation for external material and labor suppliers.

Designed an overall Architecture drawing for new Sunoco terminal in Brownsville, Texas. Includes servers, switches, Rockwell Controllogix PLC, and Top Tech system.

Support MRU-1 replacement in DOW Freeport terminal.

Support few upgrade projects and Activities for VOPAK / DOW terminals (Freeport, St Charles and Plaquemine).

ODFJELL TERMINALS, Seabrook, TX Dec 2015 – Aug 2020

I/E Engineer

Provide leadership in safe implementation of work and perform activities with due diligence for safety.

Strong understanding with ERCOT protocols and market rules.

Establish the overall project execution strategy considering the risks evaluation and mitigation.

Mentor & coach new graduate engineers and internships.

Knowledge of hazardous area design requirements to NEC, IEC, ATEX.

Strong knowledge of electrical power distribution OHTL, UGC, power transformers, switchgear and Protection system for different power equipment.

Support LPG plants and related equipment.

Update plant electrical drawing using ACAD Electrical.

Prepare the key project deliverables such as technical solution, scope, budget, schedule, risks and staffing plan.

Experience with Indusoft, AVEVA (Wonderware), Ignition, Allen Bradley /Rockwelland, Siemens.

Ensure the technical integrity of the proposal and consistency between the commercial & contractual offer and the project definition.

Developing a plan with ERCOT to reduce 200KW of our power usage when we receive alert email, and we get a rebate on our monthly electrical usage. (Energy Efficiency).

Building and maintaining strong relationships with different stakeholders.

Supervise two electrical supervisors and five I/E technicians.

Responsible for generating costs for electrical controls engineering and electrical installation of

chemical plant equipment based on mechanical AutoCAD layouts, equipment lists, customer

specifications and sequence of operation documents.

Evaluate customer Request for Quote (“RFQ”) documents and ensure that our costing is inclusive of their requirements and specifications.

Manage monthly client invoices, and accounts receivable process.

Ensure compliance with contract requirements and quality control standards.

Support Root Cause Failure Analysis (RCFA) & Bad Actor Program.

Develop/Review and improve required reliability process. Increase the MTBF and reduce the MTTR.

Assists in setting, tracking, and meeting department goals. Supports plant and corporate initiatives. Promote teamwork.

Provide accurate system diagrams, loop diagrams, block diagrams and network diagrams for new or existing software systems.

Experience with Backup Generators, Automatic Transfer Switches and Uninterruptable power supplies.

Provide technical and leadership to convert Automation Direct PLC to Rockwell Controllogix Studio 5000 Professional Edition.

Provide SCADA system hardware/ software support in conjunction with appropriate IT personnel as needed.

Review the modification/upgrade projects for technical compliance with the facility. Ensure all the relevant documents are revised and updated.

Supervise and coordinate the construction activities and start up and commissioning of projects.

Provide maintenance support to operations by ensuring availability and reliability of electrical and Hydraulic power packs equipment, instruments, and control system (Rockwell/Wonderware).

Converted eight Auto transformer power packs to soft start on time and within budget.

Completed Marine Vapor Control System project to obtain USCG certification for five years.

Successfully converted absolute TRL/2 Radar gauges to new Raptors Rosemount Auto Tank Gauging system. (TankMaster).

Support new Ethylene terminal FEL I, FEL II and FEL III activities.

Developed test procedure to checkout our Over Fill Prevention System. Add SIL 3 Solenoid to achieve independent configuration for the OFPS.

Serve as the subject matter expert for all electrical and process issues.

Available 24x7 to support terminal operations during unplanned outages and call ins.

ABB INC., Houston, TX Mar. 2012 – Nov. 2015

Senior Automation Engineer

Designed and provided specifications for all required Hardware for Power Management System and Server cabinet for multiple DCS Project to drive customer to approve the hardware design.

Provide technical and leadership to convert GE control system to ABB 800XA DCS platform.

Completing the Integrated Control and Safety System Upgrade over British Gas over in Trinidad &Tobago Dolphin platform.

Translate the client specifications and requirements to equipment design, cause and effect sheet.

Created all required documents for project (I/O List, Electrical Drawing, BOM, Cable schedule, Power and heat calculations and Test Procedures), ensuring complete documentation for customer and panel builder.

Executed FAT test in the staging area with the customer representative and solved all the punch list items, leading customer to sign off the test and release the cabinets’ shipment to site.

Successfully execute the FAT witnessed by the customer in ABB staging area and fly offshore to commission the BGTT rig.

Attended 800XA and Graphics training in Houston, TX and System 800xA Safety – AC800M High Integrity configuration and Maintenance training which also covered IEC 61508 and 61511.

Familiar with offshore and subsea operations.

FORUM ENERGY TECHNOLOGIES, Houston, TX Oct. 2011 – Mar. 2012

Electrical Engineer

Developed complete ACAD package for new EDR/PVT system, accurately measuring, monitoring, and displaying all drilling variables in real time include high temperature sensors for oil well monitoring.

TRELLEBORG OFFSHORE US, INC., Houston, TX Oct. 2010 – Oct. 2011

Controls Engineer

Developed PLC code (RSLogix 5000), HMI applications (Factory Talk View ME & Indusoft) for Tank Farm Project in accordance with design requirements detailed within functional and system design specifications.

Drove numerous upgrade projects and improvement initiatives to completion on time and within budget.

Arranged and coordinated Operational and Maintenance Training, system in plant check-out, installation and field start-up.

Developed & executed an energy efficiency plan to shutdown the unused oven to reduce power and save on our monthly electrical bill.

GULF CHEMICAL & METALLURGICAL CORP., Freeport, TX Mar. 2008 – Oct. 2010

Reliability Engineer

Worked with ABB DCS ADVANT OCS system AC460 controller with S800 and TRIO blocks and all aspects of dry Electrostatic Precipitators, bag houses and associated equipments (HV transformers, transformer ground switch, current limiting reactors, and rappers).

Setup a Square D Variable Frequency Drives training to improve the I/E technician programming skills.

The only chemical plants in Texas who develop VB applications hit ERCOT web page frequently to check the Electricity cost for every period. Trigger alarm to the Control room operator to back up production and reduce electricity usage on higher cost segments.

Supervise three electrical supervisors and eight I/E technicians.

Experience in ABB drives and motor testing equipment.

Installed expansion to Wastewater treatment system, enabling treatment of water from trace of metals and adjusting the PH before discharging.

KIMBERLY-CLARK, Paris, TX 2006 – 2007

Electrical Engineer

Lead Project Engineer. Upgraded old machines with Optima Stacker / Bagger. Identified process improvement opportunities and defined studies. Justified study expenditures, obtained approval, organized, managed and completed work.

ASSOCIATED SPRING (Contract), Saline, MI 2006

Controls Engineer

Modified PLC programs for a variety of assembly line machines. (Grinder, Peener, Loaders). Worked with different Allen Bradley software (programming, debugging, and troubleshooting.

AXLE ALLIANCE COMPANY (Contract), Detroit, Michigan 2005 – 2006

Controls Engineer

Worked with RSLogix 5000, Control Net, Device Net and Vorne factory information system and Indramat, VFD, Power Flex and Armor Start. Experience with Panel View Plus and RS View Studio. Updated Electrical Drawing using ACAD 2002.

Additional Experience

TOYODA MACHINERY INC., Wixom, MI

Controls Engineer

MCCOY MILLER (a Division of Warrick Industries, Inc.), Elkhart, IN

Electrical Engineer; Electrical System Designer

Using Scan Gauge tool.

NATIONAL STANDARD CORPORATION, Mishawaka, IN

Electrical System Designer

Kysor/Bangor Refrigeration, South Bend, IN

Lab Test Engineer.

EGYPTIAN ELECTRICITY AUTHORITY (Power station), Egypt

Operations Control Engineer

Performed complete design for relay protection systems, overhead transmission lines, underground cables and towers, as well as conducting load flow estimations, short circuit calculations and relay coordination studies.

Monitoring and control Alexandria power grid using SCADA to monitor loads, voltages and switching operation during regular PM or outages.

Performed detailed power flow, voltage stability and short circuit analysis to evaluate transmission system performance under various operating conditions.

Identify potential transmission issues and develop effective plans for reliable grids.

Directing the field crew to resolve faults and restore services.

Maintained and repaired high voltage equipment, including protection relays; power transformers (220KV / 66 KV / 11KV); and circuit breakers (SF6, Vacuum)

Responsible for integrating networks for 55 Power Stations, to meet fluctuating load demands of 220 KV, 66 KV and 11KV.

Worked with: DC and AC sources, AC-to-DC converters.

Worked with HV (220Kv, 66Kv, 11Kv), Power (480V, 220V, 110V) and control system (24, 48 VDC).

Worked with Single Line and Three Line with neutral and Ground diagrams.

Education

Bachelor of Science, Electrical Engineering, Alexandria University, Alexandria, Egypt

Computer Skills

Operating Systems:

WIN 10

Software:

Proficient in Microsoft 365 – Office Apps, SAP and CMMS (Maximo).

PLCs:

Processor Family of 2, 3, 5, SLC 500, Micrologix family, AB, ICOM, RSLOGIC and Studio5000 (Rockwell) software; Siemens S7, Modicon, Omron and Mitsubishi software.

DCS/SCADA:

Indusoft, Wonderware, iFix, ABB; Extended Automation System 800xA Control Builder and Human System Interface; AdvaBuild ver 3.5, MOD 300 Software (UNIX); AC 460 Controller with S800 and TRIO block I/O, SQL.

HMI Software:

AB Panel Builder, Factory Talk View, GP Pro-Face WinCC and Indusoft

Networking:

Profibus, Foundation Field bus, HART, DeviceNet, ControlNet, EtherNet / IP and Modbus

Switches:

CISCO and Hirschmann Troubleshoot and configuration

Instrument Software:

Field Care (Endress+Hauser) for Instruments set up like (Level Transmitter); AD View 6 (Emerson software) for Viscosity Meters; Tera Term for MSI scale Indicator; Adapt 300 for GSE scale Indicator

TankMaster (Auto Tank Gauging).

Conveyor Systems:

Pallet Systems, Part Loaders, Part Unloaders and Power Rollers using chain, gear, or belt; Screw Conveyor

Drawing Software:

AutoCAD 2015

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