Automation & Controls Engineer - Welspun Tubular - Arkansas, USA
(2024-06)
Designed, developed, and commissioned PLC-based control systems using Siemens (TIA Portal, STEP 7) and Allen-Bradley (ControlLogix/CompactLogix), implementing IEC 61131-3 programming languages (LAD, FBD, ST, SFC) for complex industrial processes.
- Engineered and configured HMI/SCADA systems including WinCC, FactoryTalk View SE/ME, Ignition, and Wonderware InTouch for real-time monitoring, data visualization, alarm management, and operator control.
- Integrated industrial communication networks such as EtherNet/IP, PROFINET, Modbus TCP/RTU, OPC-UA, and DeviceNet to enable seamless data exchange between PLCs, field devices, and enterprise systems.
- Performed instrumentation design and calibration including PID loop tuning, configuration of flow, pressure, and temperature transmitters, and commissioning of VFDs, servo drives, and control valves for optimized process performance.
- Developed electrical schematics, panel layouts, and control cabinet designs using AutoCAD Electrical and EPLAN, ensuring compliance with NEC, IEC, NFPA, and GMP/FDA standards.
- End-to-end project execution including FAT/SAT, system testing, commissioning, startup support, and integration with historian systems (OSIsoft PI, FactoryTalk Historian) for data analytics and reporting.
Controls Engineer - Infosys Engineering Services – Automation Division - Pune, India
(2021-08 - 2022-11)
- Programmed Siemens S7-1200/1500 PLCs using TIA Portal V16/V17 for automotive body shop assembly line automation; delivered 3 projects on schedule with zero critical defects at FAT.
- Developed WinCC SCADA screens and alarm management system for paint shop conveyor control, cutting mean time to resolve (MTTR) alarms by 35% through improved operator guidance.
- Configured and commissioned PROFINET and Modbus TCP networks for 30+ field instruments and robot interface panels; performed point-to-point loop checks and termination verification.
- Created detailed P&IDs, electrical schematics, and I/O lists using AutoCAD Electrical for 4 greenfield automation projects with aggregate control panel count of 22 units.
- Supported SAT and commissioning activities at client sites across India and Germany; resolved 150+ punch list items within agreed timelines, achieving on-time project handovers.
Junior Automation Engineer - Electrotek Systems Pvt. Ltd. - Gujarat, India
(2020-06 - 2021-07)
- Assisted senior engineers in programming Allen Bradley MicroLogix 1100 and CompactLogix PLCs for material handling and packaging line automation in FMCG sector.
- Built HMI screens using Rockwell FactoryTalk View ME and Panelview Plus terminals for 5 production lines, incorporating real-time process visualization and operator controls.
- Performed wiring, I/O checkout, and pre-commissioning testing on 8 MCC panels; documented as-built drawings and updated loop diagrams post-installation.
- Configured Modbus RTU and DeviceNet communication between PLCs and third-party drives (ABB ACS880, Danfoss FC302), resolving fieldbus issues under senior supervision.
- Participated in FAT and SAT activities for 4 packaging automation projects; created test protocols and recorded results to support client sign-off and project closure.
