Gary — Senior Controls Engineer

Modicon Quantum

Des Moines, IA I worked as the technical lead engineer on Chevron REG projects. Performed system commissioning, software development, HMI development, and electrical troubleshooting for various customers.

Omaha, NE Executing projects for customers in the US and Canada. The projects that I work on are on the Rockwell platform as well as Yokogawa DCS. Performed re-start activities on 2 ethanol plants in Nebraska and North Carolina on the Yokogawa platform. Performed controls start-up of a wood pellet plant in Canada and executed several projects for a large baby wipes manufacturer located in Arkansas on the Rockwell platform.

Based out of my home in Omaha, NE working on system design and software design for customers in food, beverage, household and personal care division. Performed digital bus network (AS-I and Foundation Fieldbus) design. Lead a checkout and commissioning team for a large potato processing plant. Designed and implemented system sequencing based on a functional specification and implementing S88 batch control standards. Performed Factory Talk View SE HMI design.

Omaha, NE Working to reverse engineer a DOW Mod5 system to be re-deployed on a Novatech D3 DCS platform. Provided remote support for Yokogawa CS3000 customers in Nebraska, Indiana, Illinois and South Dakota.

Marrietta, GA Based out of my home in Omaha, NE working on system design and software design mainly in the ethanol industry. Worked primarily on the Yokogawa CS3000 DCS platform. Perform project management which including system review, project design, implementation, site management and ongoing support. Managed all customers in the Midwest as well as supporting projects nationally. Participated in multiple plant startups. Designed and implemented system sequencing based on a functional specification. Configured foundation fieldbus instruments and segments, Profibus motor controls, PLC subsystem communications as well as 4-20ma and discrete instruments.

Omaha, NE Worked primarily on the Yokogawa CS3000 DCS platform. Responsible for the design of hardware architecture and software development as well as implementation and checkout for chemical, ethanol, bio-diesel production facilities. Overseeing the projects and securing resources to accomplish repairs/re-design for instrumentation and piping as needed. Startup and commissioning of new facilities and systems. Worked with and troubleshot various communications protocols including Profibus, Foundation Fieldbus, AS-i, modbus, and Ethernet. Provided training for ongoing support of the system to inside employees.

Cedar Rapids, IA Responsible for coordinating all process controls and IT related activities for a large corn milling facility with five direct reports (3 process controls engineers, 1 database administrator, 1 I/T specialist.) The system is composed of the Novatech D3 DCS, Modicon Quantum I/O, Rockwell PLC5s and SLCs, industrial Ethernet, Data highway, and Modbus. Currently in the process of modifying the current process controls methodology from manual operations with electronic interface to fully automated systems with sequential state control and enhanced messaging available with a new graphics package. Working to rollout a new data historian (Osi software's PI system) which includes the training of all users, configuration of new system, and setting up standards for tag configuration. Developing a disaster recovery program for all servers. Developing a training program for new hires that would simulate processes and allow the students to interact with the equipment in order to gain a deeper understanding of how the computer systems actually control these processes. Working on a long term project to create P&IDs for the facility and update all controls to reflect the new drawings.

Blair, NE Responsible for managing all necessary tasks associated with the DCS including project and maintenance work coordinating with contractor resources. Troubleshoot, execute and manage the maintenance/repair of hardware/software problems in all control systems for DCS, Programmable Logic Controllers, Data Historian and related equipment. Responsible for negotiating and reviewing contracts with IT, DCS and PLC related service providers on an annual basis. Write, propose and manage capital work related to the plant control systems. Serve as the primary site contact for all IT related issues. Manage all assets associated with the plant and administrative networks. Monitor and manage systems resource usage. Assure that all documentation associated with the various systems is kept current. Responsible for defining and developing training programs and manage the formalized training sessions on the process control system, data historian and related applications.

Cargill Food and Pharma Specialities, Automation Programmer, 10/2004 – 07/2005 Blair, NE Responsible for day to day support of existing automation system. This includes control system HW/SW troubleshooting and repair, system upgrades, maintenance, control loop tuning and troubleshooting, and process optimization. Responsible for design, purchase, and implementation of system upgrade from NT 4.0 server to W2K3 server based system. Design and implement DCS control system software including SABL, master device and controller design/configuration. Working with instrumentation specifications for expansion project to better coordinate programming and commissioning efforts. Assist E/I with the troubleshooting of field instrumentation and motor controls. Cargill Crop Nutrition, Process Controls Programmer, 10/2001 – 10/2004 Riverview, FL Responsible for all issues related to a large-scale control system (DCS & PLC) supporting sulfuric acid production, phosphoric acid production, granulated fertilizer production and animal feed ingredients production. This includes control system HW/SW troubleshooting and repair, system upgrades, maintenance, control loop tuning and troubleshooting, process optimization, and the engineering and management of control system related projects. Responsible for automation projects (specification, design, purchasing, assembly, testing, installation, & start-up.) Designed and implemented extensive PLC logic using Allen Bradley Logix 5, 500, 5000 and Control Logics software. Design and implement DCS control system software including SABL, master device (Boolean logic) and controller design/configuration. Assist E/I with the troubleshooting of field instrumentation and motor controls. Performed commissioning/startup on numerous projects. Performed system administration on our PI system including archive maintenance and backup, tag configuration, and user account management. Designed and implemented several projects for network infrastructure installation. Midwest Lysine (Cargill Joint Venture), Process Controls Programmer, 02/2000-10/2001 Blair, NE Responsible for all issues related to extensive control system (primarily D/3 & some small PLCs) operating the lysine (amino acid) production facility. This includes Control System HW/SW troubleshooting, system upgrades, maintenance, control loop tuning and troubleshooting, process optimization, and the engineering and management of control system related projects. Lead process controls programmer for the startup/commissioning of the facility. Performed all aspects of checkout and commissioning including sequence design/implementation, controls design/implementation, testing, and field calibration. Designed and implemented extensive sequential state logic (SC/SA) in the DCS. Worked considerably with flexbatch, writing SABL code to support recipe batching. Wrote and maintained PLC logic using Concept programming software on Modicon PLCs. Cargill North American Sweeteners, Automation Programmer, 05/1997 – 02/2000 Blair, NE Responsible for all issues related to a large control system (DCS & PLC) controlling Cargill's wet corn-milling facility. This includes Control System HW/SW troubleshooting, system upgrades, maintenance, control loop tuning and troubleshooting, process optimization, and the engineering and management of control system related projects. Designed and implemented extensive sequential state logic (SC/SA) in the DCS. Worked primarily with SABL and continuous control package but also used Concept programming software on Modicon PLCs. Assisted with migration from VMS to Windows NT DCS version to insure Y2K compliance. Built a complete D3 DCS lab with real world instrumentation to be primarily used for operator training. Taught process controls class for operators in a skills based incentive program. Cargill North American Sweeteners, Operations Technician, 10/1994 – 05/1997 Blair, NE Responsible for plant operations related to the process area of the wet corn milling facility. This included steep house operations, starch production and dryer operation. One of the original team members for the startup/commissioning/operation of the Blair facility. Helped to write many of the original site-specific standard operating procedures (SOPs) for the department. Wrote lockout/tagout and confined space entry procedures for the process area.

Omaha, NE Responsible for electrical/mechanical maintenance and repair of equipment used in the manufacturing and packaging of sliced meat products. Wrote and maintained PLC logic on Allen Bradley PLC5s and SLCs. Designed, fabricated and programmed a rotary table used to fill, weigh, and package sliced pepperoni.

Omaha, NE Responsible for electrical/mechanical maintenance and repair of equipment associated with the bottling line and packaging of soft drinks. Wrote and maintained PLC logic on Allen Bradley and Texas Instruments PLCs. Wrote first draft of a site-specific lockout/tagout program at the facility.