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Process Controls Systems Engineer
OBJECTIVE: Seeking an Engineering position working with PLC/DCS based automation systems
SUMMARY
- Instrumentation and process control systems engineer experienced with cGMP.
- Combines skills with instrumentation, software engineering, communication technologies and
controls engineering to design and build process control and monitoring systems.
- Successfully designed and built systems that reduce labor requirements, increase product
quality, improve manufacturing process monitoring and track material usage.
EXPERIENCE
PROCESS CONTROL SYSTEMS ENGINEER 2/2005-9/2008
CDI Corp, contracted to Bayer Healthcare Berkeley, CA
Experience with current Good Manufacturing Practices and change controls including; writing change
control records, writing/revising software design descriptions for DCS and PLC based control systems,
writing and execution of software validation protocols for DCS and PLC based control systems,
writing/revising periodic maintenance and equipment operations SOPs, generation and execution of
installation qualification (IQ) documents, and revising calibration record sheets.
- Engineering responsibilities include
DCS (ABB MOD 300) and PLC (Allen Bradley SLC500, SLC5/02 & SLC5/04) programming.
Redlining P&IDs, instrument loop diagrams and IO diagrams. Control strategy selection, tuning PID
controllers, control network configuration and SCADA/HMI software configuration. Leading and
participation in engineering checkouts of control systems. Specification and purchasing of
instrumentation and controls equipment including personal computer and PLC hardware. Training
operators, technicians and engineers on new equipment. Installation, configuration and trouble
shooting of instrumentation and controls equipment. Providing off hour technical support to end users.
- Types of systems worked on include
Chromatography skids, WFI distribution systems, clean room particle monitoring systems, HVAC
controls, waste treatment systems, continuous fluid blending systems, bulking and CIP/SIP systems.
*Miscellaneous
Have some experience with S88 standard batch controls software. Experienced working in clean
rooms (gowning for class E & D areas). Experienced with Intools, EDMS, and Topaz
COMPUTER SERVICES STAFF 1/2004-2/2005
ProSearch, Oakland, CA
MS Windows NT network systems administration, planning upgrades to organization software
INSTRUMENTATION AND CONTROLS INTEGRATION ENGINEER 4/2000-10/2003
Fleischmann’s Yeast Inc. Oakland, CA
Integrated both hardware and software components of instrumentation and controls systems for new
manufacturing processes and upgrades to existing systems. Programmed DCSs and PLCs, configured
HMI/SCADA software packages, designed and commissioned control panels, selected and sized
instruments and process control elements. Did cost benefit analysis and project cost estimation.
*Place separator control system on plant DCS
Designed control panel, programmed APACS DCS, Mycroadvantage(AIMAX) HMI configuration,
wrote operating manual, trained operators and performed system startup in parallel with normal
production schedule with no drop off in weekly production.
*Anhydrous to aqueous ammonia blending control system
Selected, sized and configured process instrumentation, selected control strategies, configured and
tuned controllers, designed control panels, programmed Modicon 984 PLC and participated in startup.
- Added controls to clean in place systems, allowing for recovery and reuse of cleaning chemicals.
Designed control panels, selected instruments, programmed Modicon 984, Sattcon 31-10 PLCs and
Siemens DCS. Configured Mycroadvantage HMI. Reduced annual chemical use by 35%.
INSTRUMENTATION AND CONTROLS INTEGRATION ENGINEER 1/1997-4/2000
Instrument and Control Services, San Leandro, CA
Provided instrumentation and control systems engineering services for manufacturing customers
including but not limited to DCS and PLC programming, HMI configuration, control panel design and
commissioning, selection and sizing of instruments and process control elements.
- Integration of plant process data.
Integrated previously isolated plant process data from powerhouse DCS, clean in place control system,
cold box and product holding tank temperature monitoring system with manufacturing DCS and
eventual integration with plant wide MS Access database. Used Modbus to interconnect Opto-22
thermocouple analog inputs, Modicon 984 PLC, Fischer and Porter Supervisor and APACS DCS.
- Upgrade molasses blending and sterilization controls
Moved controls from existing controllers into APACS DCS and added controls for two centrifuge
desludgers. Programmed DCS to do fluid blending, flow rate, pH, level, density and temperature
controls. Programmed DCS to sequence desludgers and operate desludging in several configurations,
tuned controllers, configured HMI and participated in system startup.
- Automate cooling tower controls
Selected instruments, designed I/O circuits and control panel, programmed DCS to operate cooling
towers fans and pumps to minimize power usage while still maintaining temperature controls of
fermentation processes. Configured HMI, trained operators and performed systems startup.
INSTRUMENTATION AND CONTROLS INTEGRATION ENGINEER 1986-2/1992, 8/1993-1/1997
Brantley Instrument Co. Hayward, CA
Instrumentation and control systems engineering for manufacturing process control and monitoring
systems; PC programming, DCS and PLC programming, HMI configuration, control panel design and
commissioning, selection and sizing of instruments.
- Extend fermentation control system
Had sole responsibility for all software aspects of fermentation control system expansion.
Programmed Allen Bradley PLC-3, wrote Fischer and Porter F-tran programs to integrate four loop
controllers with AB PLC-3, performed all Pascal programming to extend recipe management and batch
reporting software for new fermenters. Configured HMI software, and upgraded operator station PC
hardware. New fermenters increased plant capacity by 30% and weekly revenue by $300K.
- Modified fermentation control system in accordance with government air quality standards.
Programmed Allen Bradley PLC-3 to regulate process gas emissions by cascading the output of the
alcohol PID controllers to the molasses flow controllers and ratio the ammonia flow to the molasses
flow rates thus controlling the alcohol concentration of the mash. Changed recipe management and
mash batch reports to reflect process control changes and made HMI configuration changes.
SOFTWARE
Operating systems: Windows XP, Windows NT, MS Dos, UNIX, Concurrent Dos.
Languages: IEC 61131-3 Languages, Ladder logic, Visual Basic, SQL, Boolean,
Pascal, FORTRAN, F-tran, several script languages
EDUCATION AND PROFESSIONAL CERTIFICATION
California E.I.T. Certificate No. 107256
B.S. Computer Science-Engineering San Jose State University
50 Units Math and Computer Science(some grad. level) California State University Hayward
Intro. & Advanced C++, OOA/OOD/OOP with C++ U.C. Extension
10+ Professional educational seminars/classes ISA