Hassan Ali

Experience

• 

  Packages Group, Pakistan

  Mar 2012 - Apr 2015

  • Step 7- 400 PLC: Assisted in commissioning and implemented 37 logic changes for 1800 IOs High speed winder project.• WinCC Flexible 2008 SP2: Configured and displayed 240 Alarms on HMI of winder project through data blocks (DB) linkage• Simatic Step 7 Manager v5.4: Configured and commissioned 11 drives including Siemens Micromaster 440, ABB DCS 800 in S7-400 PLC Profibus network. The project scope included implementing master/ slave configuration of drives for tension control for high speed winder project.• Step 7- 200 PLC: Added extra feature of oscillation around static position in 40 bar cleaning shower by bringing about changes in OEM supplied logic for machine which led to $ 27,000 savings annually• Led project team of 4, while simultaneously managing maintenance activities to timely completion and commissioning of 7 standalone projects (field and HMI) on Step 7 PLCs with a net worth of $1.2 million• Step 7- 400 PLC: Implemented position control through Siemens Micro master drive on conveyer system leading to $ 4,800 savings per month• ABB DCS 800xA: Led to successful commissioning (field and HMI) of $2.8 million turbo washer comprising of 15 VFDs, 6 Direct Online (DOL) motors, 21 control valves, 4 level transmitters, 7 flow transmitters and 13 on-off valves• Focused on increased self-reliance resulting in 1 incident of support from OEM (Siemens and ABB) as compared to 7 incidents previous year• Convinced management for the need of electronic card repairing and troubleshooting equipment, procured equipment which was used to repair cards with a net worth of $ 43,500 within a year• Designed thorough alarming and event logging system on paper machine, leading to efficient machine control and surveillance• ABB DCS 800xA: Added redundant connectivity servers in DCS for enhanced machine reliability• Implemented OSHAS 14001 standards in maintenance, resulting in zero observations and zero non-conformances during external audits Show less

  • Assistant Manager

    Jan 2013 - Apr 2015

  • Electrical Engineer

    Mar 2012 - Jan 2013
• 

  Sadara Chemical Company

  Apr 2015 - Jul 2016

  Control System Engineer

  Control System Engineer IPCS 07/08 -ABB DCS 800xA v5.0 revEResponsibilities included commissioning of plants in close coordination with EPC (FLUOR, DAELIM), working with EPCs to ensure time schedules for IO testing and test runs are met, designing plant control logics through functional descriptions provided by EPCs• FLUOR Chem2 ISS: Designed and Created HSE subnets based on P&IDs from EPC in foundation fieldbus and commissioned 938 H1 devices such as vortex, coriolis, magnetic FTs, guided and free space radar LTs, differential PTs and control valves from Rosemount, Vega, Endress Hauser, Fisher, Krohne and Magnetrol.• FLUOR Chem2 ISS: Configured and Commissioned 3 Chiller Units with 500 IOs by establishing communication and data exchange between ABB DCS OPC Client and Quantum PLC of Chiller Units through Modbus. Designed the architecture of communication and HMIs for Chiller Units in DCS• DAELIM Chem2 HNO3: Based of functional description by EPC designed SIS ( Safety Instrumented System) Logic for HNO3 Plant• DAELIM Chem 2 HNO3: Designed and programmed foundation fieldbus redundant network and developed documentation for EPC• DAELIM Chem 2 HNO3 & DNT: Supported Loop check activities as Loop Check Engineer role for conventional, HART and FF devices for HNO3 and DNT Plant. Updated the documentation from EPC based on feedbacks in loop checks• DAELIM Chem2: Performed SAT representing EPC with project management team (PMT) for 19 IO, Marshalling and Controller cabinets of project.• DAELIM Chem2: Did configuration of 16 Client server switches & control network switchesDAELIM Chem2: Performed validation and correction of 2500 IO assignment in controllers Show less

• 

  Packages Group, Pakistan

  Aug 2016 - Feb 2022

  Engineering Manager

  • Commissioning Engineer Starch System PM6: Successfully performed commissioning and code acceptance test (CAT) of 560 IO sub-system in absence of programmer due to COVID-19. FBD was used as programming language.• Lead Engineer Roll Transfer System: Led a team of 12 to successfully commission Siemens S7 1500 based 1478 IO system to fully automatic conveying of finished product• Automation Engineer Rewinder Machine: Successfully implemented code acceptance test (CAT) with OEM and commissioned Siemens S7 1500 based 890 IO rewinder machine through a team of 27 people. ST and FBD was employed. • Project Manager ABB QCS: Led to successful and timely installation and commissioning of nuclear source based quality control system ( QCS ) along with its integration in ABB DCS 800xA• Programmer ABB 800xA Starch Oxidization Plant: Designed the control system logics and motor control centers for the ABB 800xa based 670 IO system . Designed HMIs in Process Graphics 2. FBD was employed• Automation Manager PM6 Rebuild: Led a team of 48 people to successful and timely commissioning of complete E & I and Hydraulic scope of $ 13 million PM6 Rebuild• Led integration of $ 0.5 million Web Inspection System, capable of detecting defects as small as 0.11mm2 • Led to successful commissioning of $ 260,000 Siemens S7-200 based automatic bailing press system Show less

• 

  ABB

  Mar 2022 - now

  Senior Project Engineer

  Development of Standards for Customers on Hardware and Software front. Implementation of customized solutions in ABB 800xA