Mahmoud Atef

Control Systems Engineer

Mahmoud Atef

I modernise the control systems that keep process plants safe, reliable and productive.

Instrumentation & Control Engineer specialising in automation and control systems, with oil and gas experience since 2014, combining PLC and DCS logic, HMI development, field instrumentation, system integration, FAT/SAT, commissioning and live-plant troubleshooting.

Allen-Bradley ControlLogix · Foxboro I/A Series · PLC/DCS · SCADA/HMI · Industrial Instrumentation · FAT, SAT & Commissioning

View selected projects LinkedIn profile
  • 01Automation & control engineering
    since 2014
  • 02Oil & gas and LPG
    processing experience
  • 03Based in Cairo, Egypt
    Open to international relocation

Professional profile 01

Control systems from field signal to operator screen

Portrait of Mahmoud Atef

I work on brownfield automation and control-system projects in operating oil and gas facilities, combining control logic, field instrumentation and practical plant execution.

My strongest hands-on platforms are Allen-Bradley ControlLogix and Foxboro I/A Series. My work covers relay-to-PLC migrations, PLC and DCS logic, HMI development, I/O integration, alarms, permissives, interlocks, trips, loop checking, FAT/SAT, commissioning, start-up and plant troubleshooting.

I combine field-instrumentation knowledge with control logic and practical project execution. I collaborate with operations, maintenance, process and electrical teams, as well as contractors and vendors, to implement modifications safely and with minimal disruption to production.

I also use Python for engineering data analysis and repetitive technical tasks. For a Foxboro DCS expansion, I developed a utility to analyse configuration exports, identify unused I/O channels and validate the results against field wiring and engineering records.

Bridging field instrumentation, control logic and practical plant execution.

Core engineering capabilities 02

Engineering capability across the control-system lifecycle

From design requirements and field signals through control logic, operator interfaces, testing and commissioned operation.

01 / Core discipline

Control Systems Engineering

  • PLC Programming
  • DCS Configuration and Modification
  • Control Logic and Operating Sequences
  • HMI and SCADA Development
  • Alarms, Permissives and interlocks
  • Trips and shutdown logic
  • Cause-and-effect analysis
  • PID configuration and tuning
  • Control-System Modernisation
  • Control-System Troubleshooting
02 / Platforms

PLC, DCS and HMI

  • Allen-Bradley ControlLogix 5570/5580
  • Studio 5000 Logix Designer
  • FactoryTalk View
  • PanelView Plus 7
  • Foxboro I/A Series
  • IACC
  • FoxDraw
  • SCADA and HMI development
03 / Field to system

Instrumentation and Integration

  • Field Instrumentation
  • I/O Integration
  • Analog and digital signals
  • RTD and thermocouple signals
  • HART instruments
  • Radar level instruments
  • Intelligent valve positioners
  • Marshalling cabinets
  • Intrinsic-safety barriers
  • Industrial Ethernet
  • Loop Checking
  • Packaged-equipment integration
04 / Execution

Engineering Delivery

  • Control Systems Design
  • Control philosophies
  • P&ID and schematic review
  • I/O lists
  • Cause-and-effect matrices
  • Panel arrangements
  • Wiring and loop diagrams
  • Technical Documentation
  • FAT and SAT
  • Project Commissioning
  • Installation and Start-Up
  • Root-cause analysis
  • Maintenance and Lifecycle Planning
  • Safety and Risk Assessment
  • Technical Leadership
  • Vendor and contractor coordination
05 / Supporting tools

Engineering Data & Automation Tools

  • Python for engineering-data analysis
  • SQL as a supporting data skill
  • Technical reporting and documentation
  • Workflow automation

Selected project case studies 03

Brownfield control projects with practical outcomes

Three examples spanning relay-to-PLC migration, DCS expansion and owner-side furnace safeguard verification.

Case study 01

PLC modernisation · Compressor control

CompAir BroomWade Compressor Control-System Upgrade

Modernisation of an obsolete relay-based compressor control system while retaining the existing mechanical package and maintaining the plant air supply.

7-day cutoverNo plant shutdown

My role

Responsible for the internal control-system engineering scope, including relay-to-PLC logic conversion, HMI development, I/O definition, testing and installation supervision.

Challenge

The old control panel had to be replaced without shutting down the plant or losing the lead/lag/standby function of the compressor system.

Result

Completed the control-panel replacement in seven days without a plant shutdown, while improving system maintainability, diagnostics and future integration capability.

Engineering contribution

  • Prepared the detailed I/O list and selected the PLC, I/O modules and system power requirements.
  • Prepared control-panel layout and arrangement drawings and converted relay operating logic to PLC logic in Studio 5000.
  • Developed operator displays in FactoryTalk View and improved the lead/lag/standby operating sequence.
  • Developed a temporary pressure-band operating strategy to maintain the plant air supply during the cutover.
  • Performed I/O simulation, loop testing and cause-and-effect verification.
  • Led final installation, commissioning and start-up.
ControlLogix 55701756-L71Studio 5000FactoryTalk View MEPanelView Plus 7AI / DI / DO / RTDEtherNet/IPPLC migration
Case study 02

DCS expansion · LPG processing

LPG Plant Foxboro DCS Expansion and Loop Digitalisation

Brownfield expansion of the existing Foxboro I/A Series DCS to increase I/O capacity, integrate new equipment and convert pneumatic control loops to digital DCS control.

loops digitalisedPython-assisted I/O analysis

My role

Led the in-house DCS engineering and implementation activities for the expansion.

Challenge

The expansion had to fit within limited control-room space, minimise shutdown requirements and overcome poor visibility of unused channels in the existing documentation.

Result

Expanded DCS capacity, improved HART visibility and operator monitoring, modernised seven control loops and created spare capacity for future integration.

Engineering contribution

  • Defined new marshalling requirements; selected and integrated Foxboro FBMs, termination assemblies and intrinsic-safety barriers.
  • Added AI, AO, DI, DO, RTD, thermocouple, HART and Ethernet capacity.
  • Integrated three radar level gauges, two emergency diesel engines and a new gas-inlet skid.
  • Migrated existing HART transmitters and converted all old pneumatic loops within the plant to digital DCS control.
  • Configured I/O and control logic in IACC, developed FoxDraw graphics, and performed FAT, SAT and loop testing.
  • Retuned PID parameters for faster digital transmitters and intelligent valve positioners.
  • Built a Python utility to find unused FBM channels in Foxboro exports, then validated findings against documentation and field wiring.
Foxboro I/A SeriesIACCFoxDrawFBM / TAHARTMarshallingIntrinsic safetyPID tuningFAT / SATPython
Case study 03

Safety upgrade · Owner-side engineering

Hot-Oil Furnace Control and Safety Upgrade

OEM-led modernisation of an older natural-draft furnace and relay-based control system, including a new forced-purge arrangement to improve pre-start purge safety, reliability and readiness for future DCS integration.

Safeguards verifiedRedundancy & failover tested

My role

Owner-side Instrumentation & Control Engineer responsible for requirements definition, technical review, FAT/SAT participation, installation coordination and system verification.

Challenge

Modernise a legacy furnace control architecture while coordinating safety requirements, multidisciplinary installation interfaces and OEM delivery.

Result

The project delivered a safer, more maintainable furnace control architecture with forced-purge capability, improved flame detection and diagnostics, and verified safeguard and redundancy performance.

Engineering contribution

  • Defined technical and safety requirements based on operating needs and incident history.
  • Reviewed the functional design specification, P&IDs, I/O lists, cause-and-effect matrices, logic diagrams and HMI screens.
  • Coordinated electrical and civil interfaces and supported forced-purge and flame-detection modifications.
  • Verified shut-off valve position feedback and tested analog signals, alarms, interlocks, start-up and shutdown sequences.
  • Verified safeguard functions, processor redundancy and failover during FAT and SAT.
  • Supported commissioning and plant start-up.
Siemens SIMATIC S7-400FSIL 3 systemFAT / SATSafeguard testingCause & effectBurner controlPurge systemFlame detectionRedundancy

Professional experience 04

Operating-plant experience since 2014

Role

Instrumentation & Control Engineer

Belayim Petroleum Company — PETROBEL

Tenure

June 2014 — Present

Egypt

Control-systems-focused engineer delivering brownfield upgrades, PLC/DCS modifications, field integration, commissioning, maintenance support and troubleshooting in operating oil and gas facilities.

  • Design and review control-system modifications for compressors, LPG facilities, furnace systems and supporting utilities.
  • Develop, modify, test and troubleshoot PLC, DCS, SCADA and HMI applications.
  • Prepare and review control philosophies, cause-and-effect matrices, I/O lists, panel arrangements, wiring documents, loop diagrams and technical specifications.
  • Integrate analog, digital, RTD, thermocouple and HART signals.
  • Plan and coordinate FAT, SAT, loop checking, installation, commissioning, start-up and operational handover.
  • Diagnose control-system, instrumentation and industrial-communication faults and lead root-cause investigations.
  • Coordinate with operations, maintenance, process, electrical, contractors and vendors.
  • Provide technical leadership and mentor engineers and technicians where required.
  • Support system obsolescence, lifecycle and critical-spare planning.

Credentials & education 05

Qualifications grounded in control engineering

Professional assessment

Engineers Australia Migration Skills Assessment Outcome

Assessed occupation
Automation and Control Engineer
ANZSCO
233513
Occupational classification
Professional Engineer
Skill level
1
Academic qualification

Bachelor Degree in Electronics & Communication Engineering

Arab Academy for Science, Technology & Maritime Transport

Graduation project: Designed and built an internet-based home automation and monitoring prototype integrating temperature, gas, fire and motion sensors with remote control of lighting, fans and door locks.

Result
GPA 3.53 — Excellent

Selected relevant training

Selected training in PLC, DCS, HMI/SCADA and process control.

  • Studio 5000 Logix Designer: ControlLogix Fundamentals and Troubleshooting
  • Foxboro I/A Series Configuration Essentials
  • SIMATIC S7-FH
  • RSLogix 500 and FactoryTalk View SE
  • Advanced PLC
  • Advanced Process Control
  • HMI and SCADA training
  • Advanced of Vijeo Citect SCADA

Start a conversation 06

Let’s discuss your next control-systems project

I am open to international roles in control systems, industrial automation, PLC/DCS and instrumentation where practical plant experience, brownfield modernisation and troubleshooting are valued.

Based in Cairo, Egypt · Open to international relocation · Available for remote interviews

Direct contact

Email Mahmoud View LinkedIn