Control Systems Technical Support
Resume:
ALI AHMED
Seeking a challenging and dynamic work environment where I can collaborate with cross-functional teams to identify and address automation needs and continually enhance my skills in the latest automation technologies and tools.
SKILLS:
Expertise in programming and configuring various PLCs including Siemens S7-200, S7-1200, S7-300, S7- 400, Allen Bradley MicroLogix, PLC5, ControlLogix and CompactLogix, GE 90-30, 90-70, Versamax, Versamax, GE-IP Rx3i, Rx7i, Kinco HMI's, LS PLC, Fatek FB's 60 MA and Vipa PLC 315-SN.
Experience working with OPC Kepware, WinCC Scada, Cimplicity 8.2, Easy Builder, HMI Wonderware, XP Builder, WinCCFlexible, GT-Works.
Proficient in programming software such as Proficy Machine Edition, Step-7, Microwin, Proficy Process system, TIA Portal V13, Winpro Ladder, Unity Pro, RS-Logix 500, GX Developer.
PLC programming, I/O wiring, Panel designing and BOM designing for hardware supply and installation.
Good knowledge of communication protocols such as Modbus RTU, Modbus TCP/IP, Profibus-DP, Profinet, DH-485, DF1, SNP, EGD, SRTP.
Experience with programming languages such as C and VB scripting.
Good knowledge of Redlion, Banner, MaxStream wireless systems & Interfacing Festo Pneumatic Blocks on Ethernet/IP, Kepware OPC servers.
Control Logix integration with Point I/O’s and Power flex 750 drives via Ethernet IP.
Developing and implementing Wonderware HMI applications.
Configuring Prosoft Modbus cards MVI56-MCRM & Prosoft gateway PLX31-MBS to enable communication between Control Logix and E&H ATG control system.
Configuring Control Logix redundancy for improved system reliability
Proficient in configuring industrial communication networks such as Ethernet IP, ControlNet, Device Net using RsNetworks Software.
PROFESSIONAL EXPERIENCE:
I am currently working as a PLC Engineer with Sankyu Arabia, where we manage the operation & maintenance contract for the solid handling system at the OQ8 refinery Oman.
• Conduct root cause analysis and troubleshoot PLC-related issues to minimize downtime.
• Perform hardware and software diagnostics on PLCs, HMIs, and networked automation systems.
• Review and modify electrical schematics, P&IDs, Cause & Effect diagrams, and control narratives for accuracy and alignment with project specifications.
• Perform preventive and corrective maintenance of PLC system Allen Bradley, Siemens and Stahl HMIs automation networks.
• Oversee Plant maintenance activities for critical equipment, including the bridge crane, reclaimer, coke cutting unit & weigh bridge package.
• Maintain and Manage spare PLC modules to ensure system availability and reliability.
• Submit Kaizen Proposals for the process improvements and operational efficiency.
• Analyze system performance trends and Alarms to predict failures and implement proactive solutions.
• Provide technical support to maintenance teams, improving the system’s uptime and reliability.
CAREER OBJECTIVES:
Sankyu Arabia Duqm Oman (Working as a PLC Engineer since Jan 2025 --- Currently) Contact : +968-****-****
As a Technical Lead in the AMS department, I have successfully provided solutions and troubleshooted root causes for various tasks across multiple sites. My responsibilities include:
• Develop and modify PLC and SCADA logic to meet evolving process requirements, ensuring optimal system performance.
• Provide on-site and remote support for start-up, troubleshooting, and maintenance of automation systems under SLAs.
• Identify outdated control systems and propose cost-effective replacements to improve reliability and reduce downtime risks.
• Conduct preventive maintenance on automation systems, submitting detailed reports with recommendations for performance improvements.
• Organize and conduct training sessions for SLA and non-SLA customers, ensuring teams are proficient in system operation and maintenance.
• Build accurate BOMs & WBS for system upgrades, conduct site evaluations to assess conditions, ensure task allocation, define timeline for smooth project execution.
• Implement cybersecurity measures on OT networks, protecting critical industrial control systems from potential threats.
• Design, modify, and maintain PLC programs across platforms like Allen Bradley, Siemens, GE, and Redlion to enhance system reliability.
• Troubleshoot PLC, HMI, and SCADA systems, minimizing downtime and ensuring continuous operation.
• Implement, optimize, and integrate automation solutions for production lines to enhance system efficiency and communication.
• Ensure all systems comply with industry safety standards and regulations for a secure automation environment.
• Lead project activities, overseeing upgrades, maintenance, and modifications while maintaining high standards.
• Lead FAT and SAT procedures, including loop, HMI, and logic checks, ensuring control systems meet performance criteria.
• Configure alarm events, trend logs, and database integration for real-time monitoring and historical data analysis to improve system performance visibility. As a Technical Lead in the Engineering department, I had several responsibilities:
• Allen Bradley control systems integration by implementing CPU to CPU communication via Ethernet IP.
• Interfacing of Wonderware Intouch with S7-300 and S7-1200.
• Installation of Brainchild recorders.
• Logic Development for Burner Management System of Heating unit on Micro Logix 1400 and Local Panel Designing.
• Troubleshooting common issues with Allen Bradley Radiolinx modems, including connectivity issues, signal interference, and other problems that can arise when using wireless communication solutions in industrial environments.
• Conducted site visits prior to proposal preparation.
• Proficient in PLC programming and HMI designing.
• Executed Factory Acceptance Tests (FAT), Site Acceptance Test and managed project execution Activities.
• Developed comprehensive execution plans for projects.
Installed instruments in accordance with project requirements. Strong analytical and problem-solving skills, and the ability to work independently as well as in a team environment.
• Provided expert troubleshooting services for instrumentation and control systems.
• Monitored and controlled on-site activities to meet project schedules. As a Technical Lead in the Engineering department, I had several responsibilities including providing solutions and troubleshooting root causes for various tasks. My Experience Includes:
• Installed GE-IP RX3i Control system and Established Communication with Versamax Remote I/Os on Genius Bus.
• Upgradation of 90-70 on Versamax PLC for Boiler.
• PLC programming, HMI designing, performing FAT and project execution, installation of instruments according to requirements.
• paying visits to industries for business development, attending pre-bid meetings
• performing site visits prior to proposal preparation, preparing BOM & WBS and technical evaluation reports.
• Development of control system architecture and Designing WBS, BOM and build I/O list.
• Expertise in programming Siemens PLCs, including S7-1200, S7-1500, and S7-300 series, using programming software such as TIA Portal and Step 7.
• Ability to design, develop and maintain PLC software programs for industrial automation applications.
• Knowledge of communication protocols such as Profibus, Profinet, and Ethernet/IP, and experience in integrating PLCs with other automation components such as HMIs, SCADA systems, and sensors.
• Familiarity with Siemens PLC hardware components such as CPUs, IO modules, and communication modules, and the ability to configure and troubleshoot them.
• Experience in implementing various control strategies such as PID control, motion control, and process control using Siemens PLCs.
• Knowledge of electrical and electronic circuits, and experience in reading and interpreting electrical schematics and diagrams.
• Ability to perform hardware and software diagnostics, troubleshoot and resolve issues related to PLCs, and perform maintenance and repair activities.
• Understanding industrial automation standards and experience in following best practices for PLC programming, testing, and commissioning.
PROJECT DETAILS:
As an Automation Control Engineer, I have successfully completed various projects, some of which are listed below:
Shell LOBP:
Plant Pax DCS Preventive and Maintenance of Overfill Protection System for Blending Kettles under SLA contract. Also ensure Plant uptime, availability, and response times.
Allen Bradley redundant control system with Ftview SE.
Integrate LTMR's Motor Management Controller via Modbus RS-485 with the Prosoft PLX-31 Module.
Logic Modification to add new Level Transmitters. Mass Flow meters and Level Switches. Byco Oil Refinery:
Developed and Maintained Ftview Server Client Architecture based systems for production monitoring and control of Furnace.
Developed Logic and performed verification of Cause-and-Effect Matrix on redundant control logix 1756- L71.
Interfacing of Danfoss Drive FC-300 on Ethernet IP.
Engro Elengy Terminal:
Provide services for Control Logix redundant control system.
Developed and implemented Invensys Wonderware Scada application for monitoring.
Wireless communication between Control Logix and Compact Logix via Messaging.
Mangla Power Plant:
Provide Commissioning support for guard Logix connected with 1734 Point I/O’s.
Ftview SE server client implementation.
Polish oil and Gas Company:
Upgradation of SLC500 control system to Compact Logix.
Migration of Rsview32 to Ftview version 10.
Dewan Distillery:
Provide preventive and corrective maintenance services under SLA contract.
Allen Bradley redundant control Logix with multiple Remote I/O drops.
Scada Ftview SE is deployed on the Application layer.
K-Electric Site Gas Turbine Power Station:
Installed GE-IP RX3i Control system for the commissioning of the HRSG system.
Developed programming for redundant controllers and Cimplicity 8.2 Scada HMI.
Conducted cold testing, hot testing, and field termination. ENI Pakistan Bhit Gas Field:
Developed new HMI mimics and configured tags, animations, and alarms by decoding the old HMI backup.
Interfaced i-tech industrial Panels with 90-70 PLC for the dehydration unit and ammonia plant to upgrade obsolete HMIs.
K-Electric Bin Qasim Power Station 1:
Fetched data from M-system paperless temperature recorder through Modbus TCP on Cimplicity SCADA 8.2 and did protocol conversion using Red Lion CSMSTRSX data station.
Modified the SOE system commissioned using Rx7i PLC by adding new SOE cards and modifying the program accordingly.
Engro Polymer:
Worked on S7-200 PLC and set up communication with Red Lion G307K2 HMI.
Designed the panel and wiring for the project.
Attock Refinery Limited:
Worked on GE - Fanuc IP Rx3i IC695CRU320 redundant controllers and Versamax remote I/O.
Fetched data from AZL52 boiler monitoring device on Cimplicity based HMI by using Kepware OPC server through Modbus RTU Protocol.
Supervised the multi-core cable laying from control panel to Field JB and loop testing from control panel to field JB.
Dewan Cement:
Established wireless communication between Allen Bradley SLC 500 installed on the stacker and GE Versamax Micro PLC installed on the crusher using Maxstream32 radio frequency modems.
Maintained the reliability of data exchange between both controllers with negligible time delay. ICI Polyester Fiber Pakistan Ltd:
Upgraded the control system of the draw polyester fiber line from Siemens S5 to S7-400 PLC.
Implemented interlocks and made all ET200M stations centralized on Profibus network.
Conducted testing of all nodes with verification of each I/O, which was within the given work scope. Overall, my experience in designing and programming PLCs, developing HMI and SCADA systems, and conducting testing and commissioning will make me an asset to any organization. EDUCATION:
2009-2012: B.E in industrial electronics:
Institute of industrial electronics engineering affiliated with NED UET.Secured 3.0 GPA
2007-2008: Intermediate (Pre-Engineering)
Govt. Degree Science College Malir
Cantt.Secure B grade.
2005-2006 metric (science)
The city scholar secondary
school Secure A grade.
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