Control Systems Engineer - PLC/SCADA/BMS/EPMS

Dileep Reddy

Control Systems Engineer

984-***-**** — **************@*****.*** — https://www.linkedin.com/in/dilip59/ PROFESSIONAL SUMMARY

Controls Engineer BMS EPMS Data Center Controls PLC/SCADA Industrial Automation Manufacturing Automation Controls Engineer with hands-on experience delivering PLC/SCADA automation, BMS/EPMS integration, and commissioning support across data center, critical infrastructure, facility automation, and manufacturing environments. Experienced with Allen-Bradley RSLogix 500/Studio 5000, Siemens TIA Portal, Ignition SCADA, FactoryTalk View, and Siemens WinCC for PLC logic development, safety interlocks, permissives, SCADA/HMI configuration, alarm management, operator control, diagnostics, and troubleshooting. Strong background supporting BMS, BAS, and EPMS platforms for critical electrical and mechanical infrastructure including switchgear, UPS systems, generators, PDUs, HVAC equipment, VFDs, and power meters. Hands-on manufacturing automation experience includes production-line controls, motor controls, VFD-controlled equipment, conveyor and material-handling systems, PID loops, field instrumentation, equipment sequencing, and production troubleshooting. Skilled in BACnet, Modbus TCP/RTU, Ethernet/IP, LON, and Profibus for controller, drive, meter, and field-device integration. Experienced in FAT, SAT, Functional Performance Testing, point-to-point verification, I/O validation, loop checks, alarm validation, alarm rationalization, redundancy/failover verification, RCA, startup support, SCADA historian trend analysis, and commissioning documentation including control narratives, SOOs, BOMs, as-built drawings, and commissioning reports.

• U.S. Work Authorized Open to Travel (~75%).

TECHNICAL SKILLS

Controls & Automation Platforms: Allen-Bradley (RSLogix 500, Studio 5000), Siemens TIA Portal, CodeSys (WAGO), Ignition SCADA (Core Certified), FactoryTalk View, WinCC, PLC Programming, HMI Development, Ladder Logic Development, Permissives, Safety Interlocks, Alarm Configuration, Alarm Rationalization, Alarm Management, SCADA Tag Configuration, SCADA Historian, Historian Trend Analysis

Building & Power Systems: BMS, BAS, EPMS (Electrical Power Monitoring Systems), Data Center Controls, Critical Infrastructure Monitoring, HVAC Controls, Generators, UPS Systems, Switchgear, PDUs, Power Distribution Monitoring, Power Meters, Electrical Infrastructure Monitoring, VFD Integration

Manufacturing Automation & Process Controls:Production-Line Controls, Conveyor and Material-Handling Automation, Motor Controls, VFD applications, PID Control, PID Loop Tuning, Machine and Equipment Sequencing, Sensors, Actuators, Field Instrumentation, Process Instrumentation

Industrial Communication Protocols: Modbus TCP/IP, Modbus RTU, BACnet, EtherNet/IP, LON, Profibus, TCP/IP Networking, VLAN, Industrial Ethernet Communication

Testing, Commissioning & Troubleshooting: Functional Performance Testing (FPT), Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), Point-to-Point Testing, I/O Verification, PLC Logic Troubleshooting, Loop Checks, Alarm Validation, Redundancy Testing, Failover Verification, Root Cause Analysis (RCA), System Startup & Commissioning, Device Communication Troubleshooting

Electrical & Control Systems: Control Panels, PLC I/O Systems, Electrical Distribution Monitoring, Power Meter Integration, Grounding & Shielding Practices, UL 508A Standards, Control Panel Wiring Validation

Design, Documentation & Project Tools: AutoCAD, AutoCAD Electrical, MEP Drawing Review, Wiring Diagrams, Sequence of Operations (SOO), SOW Development, BOM Preparation, Control Narratives, As-Built Documentation, Commissioning Reports, Vendor Scope Review, Procore, Microsoft Project

IT & Networking Fundamentals: IP Addressing, Network Switch Configuration, Industrial Network Architecture, SCADA-PLC Communication Diagnostics

EDUCATION

Master of Science in Computer and information Sciences - Concordia University Wisconsin - 2022 to 2024 Bachelors in Electronics and communication Engineering - St. Peter’s Engineering College - 2013 to 2017 PROFESSIONAL EXPERIENCE

Client: General Motors USA Aug 2024 - Present

Role: Control Systems Engineer

Responsibilities:

Supported BMS and EPMS platforms used to monitor and control critical electrical and mechanical infrastructure in large-scale data center environments.

Programmed and configured PLC and SCADA systems including Allen-Bradley, Siemens, and WAGO for real-time monitoring, alarm management, and operational control of facility equipment.

Integrated power and mechanical systems including switchgear, UPS systems, generators, PDUs, HVAC equipment, and field instrumentation into centralized monitoring platforms.

Implemented and maintained industrial communication networks using BACnet, Modbus TCP/RTU, LON, and Ethernet/IP to ensure reliable connectivity between controllers, meters, and field devices.

Reviewed MEP drawings, electrical schematics, wiring diagrams, and sequences of operation to validate controls installation and confirm alignment with design intent.

Supported control system deployment and commissioning, including PLC configuration, firmware updates, device mapping, and automation sequence validation.

Performed point-to-point verification, I/O validation, and functional testing to confirm correct signal flow and system readiness prior to operational handover.

Troubleshot BMS/EPMS alarms, device communication issues, control logic discrepancies, and field integration issues to improve system reliability and monitoring accuracy.

Collaborated with electrical, mechanical, commissioning, construction, vendor, and operations teams during device installation, control panel validation, control sequence testing, and startup readiness for critical facility infrastructure.

Updated SCADA/HMI interfaces and dashboards to improve operational visibility, alarm response, and system monitoring capabilities.

Executed FAT, SAT, alarm validation, functional performance testing, redundancy testing, and failover verification for mission- critical power and mechanical monitoring systems.

Prepared and maintained technical documentation including control narratives, BOMs, network diagrams, commissioning records, turnover documentation, and lifecycle maintenance records.

Followed strict data center safety standards, LOTO procedures, and site compliance requirements while working in energized and high-availability environments.

Client: Bastian Solutions India Jan 2020 – Jul 2022 Role: Controls Engineer

Responsibilities

Designed, configured, and supported Allen-Bradley and Siemens PLC-based automation systems using Studio 5000 and TIA Portal for facility equipment, motor-driven systems, VFD applications, and field control devices.

Developed, optimized, tuned, and validated PLC logic for equipment sequencing, motor start/stop control, permissives, safety interlocks, alarm handling and priorities, fault handling and reset conditions, and operator reset functions.

Configured and supported FactoryTalk View and SCADA/HMI screens for equipment status, operator commands, alarm visibility, fault reset, and real-time troubleshooting support for operations and maintenance teams.

Integrated VFDs, motors, sensors, actuators, power meters, gateways, control panels, and other field devices with PLC and SCADA systems using EtherNet/IP, Modbus TCP/IP, BACnet, and Profibus.

Validated communication between PLCs, drives, gateways, meters, and field devices, resolving protocol, addressing, device- status, and connectivity issues during integration and startup.

Performed I/O checkout, point-to-point verification, signal testing, device-status validation, terminal checks, device wiring validation, grounding and shielding review, and field-signal confirmation during startup and commissioning.

Troubleshot PLC logic faults, VFD trips, motor-control issues, sensor and actuator failures, communication faults, HMI alarms, and control-panel wiring discrepancies to restore equipment operation and reduce recurring downtime.

Supported manufacturing and material-handling automation equipment by validating operating sequences, motor and VFD response, sensor feedback, safety interlocks, operator reset behavior, and startup readiness during commissioning and troubleshooting activities.

Reviewed electrical schematics, wiring diagrams, panel layouts, I/O lists, and sequences of operation to verify controls installation against project requirements and support PLC/SCADA deployment.

Maintained PLC program backups, control-logic revisions, I/O list updates, and change records to preserve configuration traceability through automation modifications, commissioning, and maintenance handover.

Prepared and updated control narratives, network diagrams, commissioning checklists, as-built markups, and troubleshooting documentation, while validating operator display behavior before system turnover.

Coordinated with electrical, mechanical, maintenance, vendor, and commissioning teams during PLC/SCADA deployment, device installation, panel validation, testing, startup, commissioning, and BMS/SCADA integration for facility monitoring points while maintaining PLC-based control as the primary automation layer. Client: Honeywell India APR 2018 – Dec 2019

Role: Automation Engineer

Responsibilities:

Supported PLC/HMI-based automation systems across manufacturing equipment, production lines, motor-driven systems, VFD-controlled equipment, and utility/process support systems.

Programmed, modified, and validated Allen-Bradley and Siemens PLC logic for equipment sequencing, alarms, permissives, safety interlocks, motor control, fault handling, and operator reset conditions.

Developed, tuned, and validated PID control loops, machine sequences, interlocks, alarm limits, and operator display behavior to maintain stable process and equipment operation.

Configured and supported FactoryTalk View and SCADA/HMI screens for machine status, process values, operator commands, alarms, fault messages, and real-time troubleshooting visibility during production support.

Troubleshot production equipment faults involving VFDs, motors, sensors, actuators, field instruments, control panels, PLC I/O signals, and HMI alarms to restore line operation and minimize downtime.

Investigated recurring machine stoppages, PLC faults, alarm conditions, and abnormal equipment behavior using SCADA historian trends to analyze alarm patterns, PID loop response, recurring faults, and production interruptions.

Leveraged SQL-based alarm/event queries and Python-based analysis of exported fault logs to identify root causes, support control-logic tuning, and implement corrective actions, helping reduce recurring downtime by 15% and improve equipment reliability and uptime.

Supported conveyor, assembly, and material-movement equipment by diagnosing sensor-alignment issues, motor and VFD faults, safety-circuit conditions, operator-station alarms, and PLC sequence interruptions affecting production flow.

Performed I/O verification, loop checks, signal validation, and functional testing during equipment startup, modification, and commissioning, working with pressure, temperature, flow, and level instruments, proximity and photoelectric sensors, limit switches, and control devices to ensure accurate process and equipment monitoring.

Reviewed and updated electrical drawings, wiring diagrams, I/O lists, loop diagrams, control narratives, and system configuration records to support troubleshooting, equipment modifications, and configuration traceability.

Supported control-system upgrades, PLC/HMI modifications, and equipment-improvement projects while minimizing disruption to active production and ensuring automation changes, testing activities, and equipment startup work followed plant safety practices, electrical safety procedures, and change-control requirements.

Collaborated with maintenance, production, process, mechanical, and electrical teams during breakdown support, startup testing, and corrective-action implementation, while providing hands-on support to operators and maintenance technicians on alarm-response steps, equipment-sequence behavior, and basic troubleshooting procedures.

Worked with IT and plant teams to maintain reliable communication between PLCs, HMIs, operator stations, historian systems, and plant network infrastructure.

PROJECTS

Alarm Rationalization and Fault-Pattern Analysis

Analyzed recurring PLC fault patterns and alarm-flood conditions across motor-driven and VFD-controlled manufacturing equipment using SCADA historian trends and alarm-event data.

Audited more than 200 configured alarms and identified nuisance alarms, duplicate triggers, stale setpoints, and ineffective priority assignments contributing to operator alarm fatigue.

Reconfigured alarm priorities, deadbands, delays, and suppression logic within the PLC/HMI environment, reducing nuisance and recurring alarm volume by 35% while preserving all safety-critical and process-critical alerts.

Documented the revised alarm philosophy, configuration changes, and operator-response guidance following structured alarm-management principles.

Improved critical-fault visibility, reduced repeated alarm acknowledgments, and enabled faster troubleshooting to support equipment uptime and production continuity.

Contact this candidate