Senior Instrumentation and Controls Engineer
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Overall 19+ years of experience in multiple domains including MES, Control System design, Instrumentation detailed Engineering, Automation, IIOT and Project management. Completed online certifications in emerging trends. Updated in my CV
Client: Jaguar Land Rover (JLR)
Location: Wolverhampton, UK (Dec 2022 – Till date)
· Ensure day to day manufacturing plant operations are conducted as expected by virtue of daily monitoring of applications under SAP ME support project and take appropriate steps to ensure the minimize downtime
· Established the communication for real time data collection from shop floor PLC to SAP ME via OPC protocol to obtain product quality, production counts, machine runtime, downtime, material consumption
· Support for Line side part stuck, Serialization, Generation of custom reports, Monitoring production schedules and work order status
· Creating Functional requirement specification, Test case documents and Training manuals for new production lines
· Effective co-ordination & Communication with all the stakeholders. Suggest enhancements of existing applications to improve various parameters such as application performance, user experience, application reliability etc.
Location: Chennai, India (Dec 2019 – Nov 2022)
· Installation and configuration of TCS IP2 solution at customer location per IIOT architecture
· TCS IP2 solution recommends Advisories, Setpoints for implementation. Features includes Plant Twin, Process Twin, FMEA, Optimization, Report generation and Data Visualization
· Capturing historical and real time data from plant PI server. Required process parameters received for monitoring KPIs, predictive models for TCS IP2 (Digital twin) server
· Descriptive analysis was carried out and captured the insights based on 2 years of plant data
· Interacting with cross functional team includes Operations team, TCS IP2 and Analytics team
· Customer interaction to receive necessary inputs, sharing project status and receive health check. Maintain Business continuity plan, resources, documentation and focus towards continual improvement
· Monitoring daily program activities using SCRUM meeting, Managing project metrics with timeline and quality of deliverables
· Conducted steering meeting with leadership team on quarterly basis. Performed Risk assessment and mitigation plan at regular intervals
Client: Wabtec Corporation (formerly GE Transportation)
Role: Technical Leader - Controls Engineering
Location: ERIE & Fort Worth USA (from Mar2016 - Jan2019). Bangalore, India (Feb 2019 – Nov 2019)
· Strong knowledge in Locomotive Control Architecture such as CCA and ECA with experience in Validation and Verification
· Worked with multiple subsystems including Engine Control Unit, Engine Management System, Auto Engine Start Stop, Vehicle Control, Traction, HMI and Train control system
· Performed testing on Locomotive, Simulator (HITL), Virtual Simulation and Automation Platforms.
· Conducted formal design reviews during design, implementation, Validation and Verification
Client: GE Oil & Gas (Hydril Pressure Control)
Location: Houston, TX USA (from Sep2014 - Feb2016)
· Design, development and validation of SeaONYX Blow-Out Preventer MUX control system
· Hardware and Software design for GE Mark Vie control system including control panel schematics, preparation of software requirements, design specification, Control coding using ToolboxST and Cimplicity software. Conducted design reviews for control design concepts
· Validation and Verification includes creation of Test cases, Traceability matrix and Validation plan using DOORS software
· System configuration and Installation, System level testing, Unit testing for new Prototype
· Automation tool has been developed to verify the Emergency Disconnect Sequence using Proficy Historian and Workstation Alarm Viewer
Client: GE Oil & Gas (Vetcogray Subsea)
Location: Nailsea, U.K and Jandakot, Australia (from Apr2013 – Aug2014)
· Topside subsea Controls Engineer for Chevron's Gorgon and Jansz project, one of the largest natural gas projects in Western Australia
· Factory Acceptance Testing for Master Control System at Nailsea, UK for Topside controls with SEM2K including Standard Hydraulic Valve, Choke, Chemical Metering Valve, MEG Injection system and Special instruments
· Preparation of Automated Shutdown sequence, software requirements, User operator manual, Installation guide, System configuration for Simulation environment.
· Interface with Yokogawa DCS for plant control system includes communication test and functional testing
· Extended FAT has been conducted for Gorgon upstream project at Australia, verified the MCS control functions with subsea equipment as X-mas Tree, PCDM and instrument simulators
Client: GE Power & Water
Location: Chennai, India (from Feb2010 - Mar2013)
· Design, development and Validation of GE Mark Vie control system for Wind turbine NPI controls projects
· Software design includes preparation of Functional Design Specification, Simulink modeling and control coding using ToolboxST
· Conducted design reviews for new control design concepts.
· Validation of wind turbine control functions using Software-In-Loop (SIL) with MATLAB and Hardware-In-Loop (HIL) platforms
· Support for Cable scheduling and terminal connections for Hardware structuring project
Location: Chennai, India (from Sep2007 - Jan2010)
Role: Project Engineer Instrumentation and Control
Location: Chennai, India (from Dec2005 - Aug2007)
· Design, development, Testing and Commissioning of Sugar Plant Continuous Vacuum Pan Automation
· Instrumentation detailed engineering for Sugar process plant and co-generation boiler
· Preparation of P&ID, IO List, Instrument specifications and Control Loop diagrams
· Interlocking, Control Philosophy and Preparation of Loop schematics
· Hook-up drawings and BOM generation using Instrument Impulse tubing
· Cable engineering includes Cable selection, cable schedule and Interconnections
· PLC programming using RSLogix 5000 Enterprise series, Graphic Screen development using Factory Talk View and Configuration of Yokogawa Controller
· Calibration of field instruments, analyzers and control valve configuration
Location: Chennai, India (from Oct2004 - Nov2005)
· External Coal Handling System (ECHS) Electrical maintenance for Load control centers
· PLC Operations for material handling using GE Fanuc PLC and Cimplicity Software.
Bachelor of Engineering (Electronics and Instrumentation)
