Sujan K

DCS & Process Automation Engineer with 3+ years of hands-on experience delivering Yokogawa CENTUM VP solutions for power, refinery, and batch process industries. Expertise in P&ID interpretation, control narrative analysis, loop engineering, interlocks, sequence development (SFC/Sebol), cause & effect logic, HMI development, and FAT execution. Strong experience in subsystem and package integration using Modbus (RS232/RS485 & Ethernet), Profibus, Profinet (S2 redundancy), and Foundation Fieldbus, including VFD and IMCC systems.

Proven contributor to greenfield, upgrade, and multi-platform DCS conversion projects (Honeywell, ABB, Schneider) with strong customer and EPC (EIL) coordination.

DCS System Engineer - Yokogawa India Limited

(2023-06)

• Engineered soot blower and ammonia handling systems by translating P&IDs and control narratives into robust sequences, interlocks, and operational logics
• Designed start/stop sequences and safety interlocks validated during customer FAT
• Coordinated directly with customer for logic walkthroughs and requirement finalization
• Developed limestone slurry supply and recirculation control including cascade loops, CLCS, and sequence logic
• Ensured stable FGD operation under varying load conditions and supported FAT discussions
• Reverse-engineered Honeywell control strategies and calculations
• Converted and validated logic, loops, and interlocks in Yokogawa DCS with zero functional deviation
• Actively interacted with customer during testing and clarification sessions
• Developed and added control logics for PO tank and Styrene tank systems
• Implemented split-range loops for control valves based on process requirements
• Designed and configured interlocks and duty/standby logic for pumps
• Developed and debugged HMI graphics for operational visualization
• Coordinated with customer and FES teams during testing and commissioning activities
• Executed end-to-end batch automation using ISA-88 standards
• Designed multi-product SFC sequences across shared reactors and vessels
• Implemented ratio, split range, and duty-standby logic for pumps
• Configured Profibus communication for IMCC & VFDs
• Generated batch and daily reports as per customer requirements
• Successfully managed complex product routing and batch scheduling challenges
• Designed and configured simple, closed, and complex control loops, including drive generation, for newly added I/Os
• Implemented and configured Foundation Fieldbus for subsystem communication and integration
• Performed testing and validation of fieldbus communication and loop functionality
• Explained control philosophy, loop behavior, and subsystem communication to the customer during FAT
• Developing and validating macros, control logics, loops, cause & effect matrices, and sequence logic
• Performing HMI graphics debugging and functional validation to ensure correct operation
• Implementing and testing Modbus-based subsystem communication over Ethernet and serial interfaces
• Coordinating closely with the customer to explain logic behavior, communication status, and resolve comments
• Studied and interpreted process P&IDs and control logics provided by EIL
• Cross-verified BOM and engineering inputs to ensure completeness and correctness
• Initiated basic engineering activities, including loop generation for control and monitoring
• Configured alarm setpoints, priorities, and limits as per control philosophy
• Developed static HMI graphics based on P&IDs and process flow
• Own and execute end-to-end DCS conversion from ABB platform to Yokogawa CENTUM VP
• Interpret ABB control philosophy, logic diagrams, and calculations
• Re-engineer control logics, loops, and interlocks in Yokogawa DCS
• Ensure functional equivalence through testing, validation, and FAT support
• Coordinate with customer and internal teams to clarify requirements and close conversion comments

DCS Engineer (Project-based) - NTPC Buxar

2×660 MW (Greenfield)

• Engineered soot blower and ammonia handling systems by translating P&IDs and control narratives into robust sequences, interlocks, and operational logics
• Designed start/stop sequences and safety interlocks validated during customer FAT
• Coordinated directly with customer for logic walkthroughs and requirement finalization

DCS Engineer (Project-based) - FGD Singrauli

Power Plant (Greenfield)

• Developed limestone slurry supply and recirculation control including cascade loops, CLCS, and sequence logic
• Ensured stable FGD operation under varying load conditions and supported FAT discussions

DCS Engineer (Project-based) - IOCL Guwahati & IOCL AU3 Baroda

Honeywell to Yokogawa Conversion

• Reverse-engineered Honeywell control strategies and calculations
• Converted and validated logic, loops, and interlocks in Yokogawa DCS with zero functional deviation
• Actively interacted with customer during testing and clarification sessions

DCS Engineer (Project-based) - GCPTCL

Upgrade

• Developed and added control logics for PO tank and Styrene tank systems
• Implemented split-range loops for control valves based on process requirements
• Designed and configured interlocks and duty/standby logic for pumps
• Developed and debugged HMI graphics for operational visualization
• Coordinated with customer and FES teams during testing and commissioning activities

DCS Engineer (Project-based) - Paushak

MPP8 – Batch Process (ISA-88)

• Executed end-to-end batch automation using ISA-88 standards
• Designed multi-product SFC sequences across shared reactors and vessels
• Implemented ratio, split range, and duty-standby logic for pumps
• Configured Profibus communication for IMCC & VFDs
• Generated batch and daily reports as per customer requirements
• Successfully managed complex product routing and batch scheduling challenges

DCS Engineer (Project-based) - BCPL

HPG2 (Upgrade)

• Designed and configured simple, closed, and complex control loops, including drive generation, for newly added I/Os
• Implemented and configured Foundation Fieldbus for subsystem communication and integration
• Performed testing and validation of fieldbus communication and loop functionality
• Explained control philosophy, loop behavior, and subsystem communication to the customer during FAT

DCS Engineer (Project-based) - RIL

DMD (Greenfield) - Ongoing

• Developing and validating macros, control logics, loops, cause & effect matrices, and sequence logic
• Performing HMI graphics debugging and functional validation to ensure correct operation
• Implementing and testing Modbus-based subsystem communication over Ethernet and serial interfaces
• Coordinating closely with the customer to explain logic behavior, communication status, and resolve comments

DCS Engineer (Project-based) - BPCL - MUMBAI

MUMBAI PIPELINE (Greenfield) - Ongoing

• Studied and interpreted process P&IDs and control logics provided by EIL
• Cross-verified BOM and engineering inputs to ensure completeness and correctness
• Initiated basic engineering activities, including loop generation for control and monitoring
• Configured alarm setpoints, priorities, and limits as per control philosophy
• Developed static HMI graphics based on P&IDs and process flow

DCS Engineer (Project-based) - BPCL

ABB conversion - Ongoing

• Own and execute end-to-end DCS conversion from ABB platform to Yokogawa CENTUM VP
• Interpret ABB control philosophy, logic diagrams, and calculations
• Re-engineer control logics, loops, and interlocks in Yokogawa DCS
• Ensure functional equivalence through testing, validation, and FAT support
• Coordinate with customer and internal teams to clarify requirements and close conversion comments

B.E - Electronics and Instrumentation - Kamaraj College of Engineering and Technology (2019 - 2023)