Zafar Ali
Industrial Automation & Control Systems Specialist | PLC, SCADA, DCS & Instrumentation
Control System Specialist
Strategic Vision & Expertise
Design and Application Engineer with 13 years of experience in industrial automation, control systems, instrumentation, and commissioning, with extensive project experience across the oil and gas sector in Nigeria, Angola, and Saudi Arabia. Highly experienced in the design, development, integration, commissioning, troubleshooting, and upgrading of PLC, DCS, SCADA, HMI, Safety Shutdown, and Fire & Gas systems. Proficient in platforms including Allen-Bradley ControlLogix, Siemens, GE PAC, Wonderware, FactoryTalk, Emerson DeltaV, Yokogawa Centum, and Foxboro. Experienced in industrial networking, OPC, Modbus, ControlNet, DeviceNet, instrumentation, alarm management, system upgrades, FAT/SAT, project engineering, and technical documentation, with proven experience leading complex control-system projects for major international energy companies.
Services Offered
Industrial Automation & Control Systems
Design, development, integration, troubleshooting, and optimization of industrial automation and control systems for process industries.
PLC Programming & Engineering
PLC programming, logic development, system modifications, hardware configuration, and application engineering using major industrial PLC platforms.
SCADA & HMI Development
Design, development, configuration, upgrading, and testing of SCADA and HMI applications for industrial process monitoring and control.
DCS Engineering & Integration
Engineering, configuration, integration, modification, and commissioning of Distributed Control Systems including DeltaV, Yokogawa, and Foxboro platforms.
Safety & Fire and Gas Systems
Engineering, integration, testing, and commissioning support for Safety Shutdown Systems and Fire & Gas detection and control systems.
Control System Upgrades & Migration
Planning and execution of control system upgrades, platform migrations, hardware replacements, software upgrades, and system optimization.
Industrial Network Integration
Configuration and troubleshooting of industrial communication networks including Modbus, OPC, ControlNet, DeviceNet, Ethernet, and fiber optic networks.
Instrumentation Engineering
Engineering and troubleshooting support for pressure, flow, and temperature transmitters, valve controllers, HART devices, and industrial field instrumentation.
Control Loop Assessment & Optimization
Assessment, configuration, troubleshooting, and performance optimization of simple and complex PID and cascade control loops.
Alarm Management & Optimization
Industrial alarm analysis, KPI reporting, diagnostic implementation, alarm management configuration, and performance improvement.
Commissioning & Pre-Commissioning
Site commissioning, pre-commissioning, loop checks, functional testing, system integration, and startup support for industrial control systems.
FAT & SAT Services
Factory Acceptance Testing and Site Acceptance Testing for PLC, SCADA, DCS, safety, instrumentation, and control system projects.
Control Panel Design
Design of control system cabinets, panel interfaces, terminal wiring, system architecture, and related engineering documentation.
Control System Troubleshooting
Technical troubleshooting, failure analysis, root-cause investigation, and corrective action planning for industrial control and instrumentation systems.
Project Engineering & Technical Management
Technical project planning, resource management, scope coordination, contractor supervision, documentation, and execution of automation projects.
Work Experience
Control System Specialist
Responsible for safety logic and Fire & Gas matrix validation, control system maintenance strategies, KPI development, troubleshooting and failure analysis, contractor supervision, ICS documentation, spare-parts management, and control system upgrade planning and execution for two FPSOs.
Project / Commissioning Engineer
Worked on the ControlNet Network Upgrade, including site assessment, network problem resolution, system architecture, cabinet and loop drawings, cable schedules, execution planning, migration philosophy, resource management, scope management, and technical project support.
Lead Project / Commissioning Engineer
Led the upgrade from ControlLogix SLC-5 to a redundant ControlLogix system, Wonderware InTouch HMI upgrade, FAT, Modbus serial to TCP/IP conversion, Kepware configuration, loop and functional checks, system transfer, and implementation of metering reports.
Project Lead
Led development of a Cause and Effect simulator using CAPE VPLink, including simulation of Cause and Effect charts, pump and SDV feedbacks, test laboratory setup, discrepancy testing, and preparation of detailed results and reports.
Site Engineer
Performed control loop assessment using PAS Control Wizard and Loop Tune Wizard, including PID and cascade loop configuration, performance assessment, reporting, failure diagnosis, and coordination with process engineers.
ICSS Commissioning Lead
Led offshore integration and pre-commissioning of Process Control, Safety Shutdown, and Fire & Gas systems. Performed hardware and software modifications, safety logic updates, Modbus configuration, instrumentation checks, HART partial stroke testing, loop checks, Cause & Effect verification, and system integration during a short shutdown window.
Site Engineer
Configured alarm analysis, reports, KPI metrics, diagnostic logic, PSS web client access, and automated diagnostic email notifications for multiple sites.
Lead Design Engineer
Designed and implemented ControlLogix and Wonderware InTouch systems for Process Control, Safety Shutdown, and Fire & Gas applications. Designed PCS, SIS and F&G cabinets, supervised fabrication, developed PLC and HMI applications, configured Modbus and DeviceNet, supported commissioning, and prepared as-built documentation.
Lead Design Engineer
Designed and implemented ControlLogix and Wonderware InTouch systems for Process Control, Safety Shutdown, and Fire & Gas applications. Developed PLC and HMI applications, designed control cabinets, performed loop and functional checks, supported commissioning, and prepared as-built documentation.
Project Engineer
Reviewed technical documentation and plant control philosophy, designed control cabinets and engineering drawings, developed RSLogix 5000 control logic and FactoryTalk ME graphics, prepared sequence of operations, and performed internal testing.
Project Lead
Reviewed customer specifications and designed and implemented complete HMI and PLC applications using GE PAC8000, Workbench, and Proficy HMI SCADA iFIX. Configured alarm groups and trends, managed project documentation, and supported FAT.
Project Lead
Led HMI upgrade from PME 6.0 to PME 9.0, integrated testing, SQL alarm logging configuration, hardware compatibility analysis, FAT, SAT, and site activities using GE Proficy Machine Edition and Cimplicity.
Project Engineer
Maintained the extended I/O list, developed DeltaV HMI statics, supported software functional design specifications and hardware design for RIO and junction box panels, and participated in FAT.
Project Engineer
Developed transfer concepts and pre-commissioning procedures and provided engineering support for the OML 100 control system upgrade project using Yokogawa Centum CS 3000.
Project Engineer
Performed PLC logic modifications using Schneider ScadaWorks to resolve automatic valve closure issues, prepared functional specification documentation, and conducted internal testing and FAT.
Project Engineer
Responsible for preparing commissioning procedures and supporting commissioning planning activities for the project.
Skills & Competencies
// HMI / SCADA
// Panel Interfaces
// PLC / DCS Programming
// PLC Systems
// DCS Systems
// Industrial Historian
// OPC Servers
// Industrial Networks
// Asset Management
// Simulation & Testing
// Instrumentation
Projects & Initiatives
Control System Upgrade Planning & Execution – Two FPSOs
Agbami FPSO ControlNet Network Upgrade
Escravos Metering Upgrade Project
Cause and Effect Simulator Using CAPE VPLink
PAS Loop Assessment
OKAN PRP Control System Integration
PAS Alarm Management System
DLT Control System Integrator – Phase I
DLT Control System Integrator – Phase II
Compressor Control Design – Saudi Aramco
Diesel Supply Control & Emergency Shutdown System
Dalia LP/EXP Compressor Upgrade
ICSS for Pan Ocean LPG & Propane Loading Pumps
OML 100 Upgrade – Total Nigeria
CALM Buoy PLC Modification – BP Angola
UEC Commissioning Planning – Chevron Nigeria
Education
BE Electronics
NUST Islamabad
Certifications
Basic Offshore Safety Induction and Emergency Training (BOSIET)
PAS PSS Control Wizard and Tune Wizard
Schneider Electric System Advisor
Trainings & Workshops
PAS PSS Control Wizard and Tune Wizard Training
PAS USAQMS, HSE, Policies and Procedures Orientation
INTECH Process AutomationProject Management and Quality Assurance
INTECH Process AutomationInstrumentation and Control Codes & Standards
INTECH Process AutomationHSE Management System
INTECH Process AutomationBinder Database (BDB)
INTECH Process AutomationPanel Designing and Terminal Block Selection
INTECH Process AutomationYokogawa Centum CS3000
INTECH Process AutomationAllen-Bradley ControlLogix and RSLogix 5000
INTECH Process AutomationSiemens S7-300/400
INTECH Process AutomationAllen-Bradley PLC-5 and SLC-500 (RSLogix 5 and RSLogix 500)
INTECH Process AutomationWonderware ArchestrA Platform
INTECH Process AutomationEmerson DeltaV
INTECH Process AutomationHSE and Site Work Practices
Customer PremisesKey Achievements
13 Years of Industrial Automation Experience
Control System Upgrade Planning and Execution for Two FPSOs
Offshore ICSS Integration and Commissioning Leadership
ControlLogix and Wonderware Control System Integration
ControlNet Network Upgrade – Agbami FPSO
Escravos Metering Control System Upgrade
Process Control, Safety Shutdown and Fire & Gas System Engineering
Industrial Control System Engineering for Major Energy Companies
PLC, DCS, SCADA and HMI Project Leadership
Control System Commissioning and FAT/SAT Expertise
Technical Contributions
Industrial Automation & Control System Engineering
Contributed to the design, development, integration, commissioning, troubleshooting, and optimization of industrial automation and control systems across major energy-sector projects.
PLC, HMI & SCADA Development
Designed and developed PLC, HMI, and SCADA applications using ControlLogix, Wonderware, FactoryTalk, GE Proficy, and other industrial automation platforms.
ICSS, Safety & Fire and Gas Integration
Led and supported the integration of Process Control, Safety Shutdown, and Fire & Gas systems for offshore oil and gas facilities.
Control System Upgrades & Migration
Contributed to major control system upgrades and migrations, including ControlLogix, HMI, network, and metering system modernization projects.
Industrial Communication & Network Engineering
Implemented and troubleshot industrial communication technologies including Modbus, OPC, ControlNet, DeviceNet, Ethernet, and fiber optic networks.
Control Loop Assessment & Optimization
Performed control loop assessments, PID and cascade loop configuration, performance analysis, diagnostics, and optimization in collaboration with process engineering teams.
Industrial Alarm Management
Contributed to alarm management improvements through alarm analysis, KPI reporting, diagnostic logic, web-based reporting, and automated notifications.
Offshore Commissioning & Pre-Commissioning
Led and supported offshore commissioning, pre-commissioning, loop checks, functional testing, system integration, and control system startup activities.
FAT & SAT Execution
Contributed to Factory Acceptance Testing and Site Acceptance Testing of PLC, SCADA, DCS, safety, instrumentation, and control system projects.
Control Panel & System Architecture Design
Designed control cabinets, system architectures, wiring diagrams, terminal configurations, and engineering documentation for industrial control systems.
Instrumentation & Field Integration
Performed loop checks, functional checks, transmitter and valve inspections, HART testing, and integration of field instrumentation with control and safety systems.
Technical Project Leadership
Provided technical leadership, resource planning, contractor supervision, project coordination, scope management, and execution support for complex automation projects.
Testimonials & Endorsements
"Zafar demonstrated strong expertise in industrial automation, control systems, commissioning, and troubleshooting while supporting complex energy-sector projects."
Project Stakeholder
Oil & Gas Industry Professional"His knowledge of PLC, SCADA, HMI, DCS, and industrial communication systems made him a valuable contributor to challenging control-system integration and upgrade projects."
Engineering Colleague
Control Systems Engineer"Zafar consistently demonstrated strong technical leadership, project coordination, and problem-solving skills during control system engineering, commissioning, and upgrade activities."
Project Manager
Automation Project Manager"His hands-on experience with ICSS, Safety Shutdown, Fire & Gas, instrumentation, FAT, SAT, and offshore commissioning contributed significantly to successful project execution."
Commissioning Team Member
Commissioning Engineer"Zafar brings extensive practical experience across multiple automation platforms and has demonstrated the ability to troubleshoot, optimize, and deliver control-system solutions in demanding industrial environments."
Technical Client Representative
Industrial Automation ProfessionalPublications & Reports
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Media Appearances
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