Trenton — Controls Engineer

- Contracted to Bayer Pharmaceuticals • Lead automation projects and production support in Bayer's regulated cGMP manufacturing environment, including scope-of-work development, contractor planning, scheduling, coordination, field execution, commissioning, and validation. • Led a major packaging-line modernization that replaced a legacy iFIX SCADA system with ABB 800xA Batch control and operator graphics, receiving production data from MES and passing required data through third-party software to the packaging equipment. • Adapt DCS architecture and develop ABB 800xA control code, graphics, alarms, permissives, interlocks, and data interfaces for new packaging-line equipment and industrial printers. • Configure Kepware KEPServerEX OPC servers, channels, devices, tag mappings, and server/client connections; interface ABB 800xA with packaging-equipment OPC servers for data exchange, status, alarms, testing, startup, and troubleshooting. • Program Allen-Bradley Logix 5000 and Siemens S7 PLC applications; install and program CODESYS for bit stripping of alarm data and configure it as an OPC server for life-bit operations with third-party PLCs, creating heartbeat communications between Bayer servers and process PLCs. • Serve as lead project engineer, coordinating third-party vendors and contractors through design reviews, implementation, testing, commissioning, issue resolution, and closeout; write and execute qualification and validation protocols and document deviations, test failures, results, and change-control work.

Provide industrial automation and controls engineering services for manufacturing and process-industry clients, supporting projects from initial requirements and system design through programming, integration, commissioning and production support. Extensive experience with Allen-Bradley, Siemens, CODESYS, ABB 800M/800xA, Ignition SCADA/HMI, Kepware/OPC, instrumentation, VFDs and industrial communications. Perform PLC/DCS programming, SCADA/HMI development, control-system migrations, panel and I/O design, troubleshooting, loop checks, I/O checkout, FAT/SAT support, startup and commissioning. Experience includes pharmaceutical/cGMP, chemical and plastics manufacturing, food manufacturing, power generation and agricultural processing. Manage projects independently, coordinate with customers, vendors and other engineering disciplines, develop technical solutions and documentation, and provide ongoing troubleshooting and modernization support. SELECTED PROJECT EXPERIENCE Bayer Pharmaceuticals - DCS, PLC, Batch, MES, OPC, and Validation Projects • Led the conversion of a legacy iFIX-controlled pharmaceutical packaging line to ABB 800xA Batch and 800xA operator graphics, including MES production-data receipt and transfer of required parameters through third-party software to the packaging equipment. • Adapted the DCS architecture and developed ABB 800xA code, graphics, alarms, permissives, interlocks, and communications interfaces to support new packaging-line equipment and packaging-line printers. • Configured Kepware KEPServerEX OPC servers, channels, devices, tags, and connections; integrated ABB 800xA with third-party equipment OPC servers and clients for commands, status, alarms, production data, testing, startup, and troubleshooting. • Installed and programmed CODESYS applications to perform bit stripping of alarm data and operate as an OPC server for life-bit exchanges with third-party PLCs, establishing heartbeat monitoring between Bayer servers and process PLCs. • Completed ABB 800xA/AC460/800M changes, S800 I/O work, Allen-Bradley and Siemens PLC modifications, SAP/MES/DCS integration, scope development, vendor coordination, commissioning, cGMP validation, and project closeout as lead project engineer. Formosa Plastics - Legacy DCS Migration • Helped migrate the plant from a legacy DCS to ABB 800M/800xA by converting control logic and developing new programs. Designed I/O panels and AutoCAD drawings, installed and configured S800 I/O, assisted with panel construction, field wiring, and installation, and completed I/O checkout, loop checks, commissioning, and signal verification. Ventura Foods - Automated Batch Management Design • Helped develop an automated batch-management design that connected legacy ABB 800xA/MOD 300 and AC460/TCL controls with ABB 800M, Rockwell ControlLogix, and Ignition Perspective. The work covered recipe management, scheduling, runtime changes, revision history, sequencing, interlocks, and operator workflows. Kauai Coffee - Wireless Water and Pump Control (Fetzer Automation) • Designed and implemented an Ignition SCADA system using Modbus communications to custom radio modules for tank-level monitoring, pump control, motor feedback, alarms, trends, communications health, failsafe operation, and field troubleshooting.

• Programmed and troubleshot Allen-Bradley PLC-5, SLC 500, and MicroLogix controllers using RSLogix 5 and RSLogix 500. Also installed and troubleshot ABB 800xA DCS equipment and GE Mark IV turbine controls. • Installed, calibrated, and repaired process instrumentation from Fisher, Rosemount, Samson, Foxboro, Siemens, Honeywell, Yokogawa, and Bently Nevada, including transmitters, valve positioners, I/P transducers, ultrasonic devices, pH and flow instruments, and vibration-monitoring equipment. • Troubleshot motor-control circuits, VFDs, single- and three-phase systems, GE and Allen-Bradley MCCs, and switchgear through 13.8 kV using schematics, prints, and electrical-code practices. • Maintained and calibrated Continuous Emissions Monitoring Systems, including Thermo Electron analyzers, quarterly audits, cylinder gas audits, preventive maintenance, records, spare parts, and calibration-gas inventory.

Henderson, Nevada Short-Term Contract Analog Instruments Specialist - • Installed ABB 800xA DCS equipment, worked on Allen-Bradley Logix 5000 PLC applications in RSLogix 5000, and installed and calibrated pressure switches and Rosemount smart transmitters.

• Troubleshot and modified Emerson/Fisher Provox DCS applications and Allen-Bradley PLC-5, SLC 500, and MicroLogix control systems. • Installed, calibrated, and repaired pressure, temperature, flow, level, pH, vibration, valve-control, and discrete field devices, along with GE and MCC switchgear and plant electrical controls. • Maintained and calibrated CEMS analyzers from Teledyne, Ametek, California Analytical, and Thermo Electron; completed quarterly audits, cylinder gas audits, preventive maintenance, records, and gas inventory. • Programmed and installed a PLC/HMI system that automated cylinder gas audit testing, cutting manual test time and improving repeatability.