Instrument Engineer Instrumentation

KARUPPIAH VAIRAVAN

*****************@*****.*** Chennai, Tamil Nadu +91-960*******

A detail-oriented Senior Instrumentation and Control Engineer skilled in design, development, installation, maintenance, and repair operations,PLC Programming.

Competencies

PLC Programming, PLC Module, FAT/SAT Procedures

Systems Managed

ABB 800XA DCS Commissioning Honeywell EPKS C300 Controller Honeywell Safety Manager Yokogawa Centum VP DCS Yokogawa Prosafe- RS Emerson Delta V DCS V13.3 ABB 800 xA Schneider Electric Foxboro Evo and I/A Series EcoStruxure Triconex Safety Systems Siemens Simatic PCS7

Achievements

Executed

oField Engineering for DS1, DS2 (Brownfield Project) of Shell Iraq

oDebottlenecking Study of Kothari Petrochemicals Ltd

oSulphur Recovery and Acid Gas Recovery Project for Qatar Petroleum and SaudiAramco

oFire and Gas Line Expansion project of Chemplast Sanmar Ltd

oCentral Processing Facility (Greenfield Project) and 23 Wellpad Engineering of Shell Iraq

oADCO ASAB Full Field Development Project of M/s Petrofac Engineering Services Pvt Ltd

o50 KL Inverter Battery Automated Capacity Plant Project Commissioning

oCommissioned Rockwell Automation Control Logix System in Niobium NFC Project”

oPrecommissioning carried out for “LNG Jetty Topside and Offshore Facilities Project”

Estimated Project Cost for new instrument addition and prepared engineering documents for procurement

Key Projects

Project of LOIL-EthylAcetate Unit,Acetic Acid,Acetaldehyde INR 52 Crore

Commissioning Reliance GrassRoot Refinery INR 14,250 Crore

Bayer Dryer Coagulation Project(ABS-Acrylonitrile -Butadiene-Styrene resins & derivatives INR 250 Crore

ITC Bhadrachalam Paper Boards INR 640 Crore

Ashuganj power complex project Tk 14.73 Billion

Jamnagar Loni Pipeline Project INR 195 Crore

BMWD Water Treatment Project INR 1033 Crore

PET Flakes Project with replacement of Oligomer INR 245 Crore

NTPC Sipat First stage 3 trains of 660MW Power Project INR 9456 Crore

Kafco MAA New Fuel Depot Project INR 581 Crore

BORL Refinery Crude Expansion Project-6 MMTPA INR 2519 Crore

15MW Captive Power Plant Project INR 100 Crore

Supercritical Sipat Power Project 1st stage 3x660MW INR 3028 Crore

ONGC Fire Fighting System Project INR 672 Crore

Polypropylene Derivate Chemical Project INR 6000 crore

3 Tonnes of NiobiumThermit Production Unit of NFC INR 277 Crore

Fadhili Gas Plant Project of SRU-6 Trains $13.3 Billion

Kothari Petrochemicals Debottlenecking Project INR 3.5 Crore

IOCL C4H Raffinate Project INR 29,000 Crore

LNG Jetty Topside and Offshore Facilities Project INR 5600 Crore

Work Experience

Commissioning Engineer Ecojet Powertech Private Limited Oct 2021 - Dec 2021

Freelance Engineering Consultant Consultant Nov 2020 - Aug 2021

Hindustan Dorr Oliver Ltd Instrument Engineer Dec 2017 - Apr 2019

Konstelec Engineers Private Ltd Senior Engineer Nov 2016 - Oct 2017

Seametric Engineering Private Ltd Senior Instrument Design Engineer Nov 2010 - Jan 2011

Contracts

Indczech Engineering Private Ltd Senior Instrument Engineer Oct 2019 - Oct 2020

Petrofac Engineering Services Instruments Engineer May 2019 - Jul 2019

Indus Projects Private Ltd Senior Electrical and Instrument Engineer Apr 2016 - Sept 2016

Rainbow Controls Private Ltd Principal Instrument Engineer May 2015 - Jul 2015

DOPET Lead Commissioning Instrument Engineer Nov 2014 - Feb 2015

Petrofac Engineering Services Senior Instrumentation Engineer Feb 2011 - Jun 2014

Black and Veatch Senior Instrument Engineer July 2025- Aug 2025

Led a team of 40 for electrical and instrumentation works

Framed and managed,Designed

oExisting plant details study and preparation of design documents.

oPlant operating manuals, procurement engineering services such as RFQ, TBE, PR

oDatasheets, Energy Saving Calculation, and Ametek Stabilizers/UPS Design Specifications,L&T Yaskawa Drives

oLogic up-gradation/programming of BCH PLCs, HIMA PLC's and L&T Yaskawa, ABB Variable Frequency Drives

o Revamp details for the Project "Shifting of Local Control Room into Main Control Room" 100 Tonnes per day Ammonia Plant of Kuwait National Petrochemical Industries Corporation

oParticipated in FAT,SAT and Hazop during EPC contracts Reviewed Safety Plan and Risk Assessment for Lifting Study – EPC for process control, System upgrade,SIL determination using RISK Graph Method and LOPA Method,SIL Study Report, SIL Implementation, SIF List Generation, SRS Preparation, SIL Verification, SIL Validation, and testing

oConducted FEED (Front End Engineering Design) documentation review, design calculations, and analysis. Organised datasheets,Ffabrication drawings, Equipment layouts, Piping general arrangements, Area classification drawings, instrumentation system architecture, logic diagrams, loop diagrams, technical specifications, and Instrument MTO’s

Controlled design,erection and commissioning of

oDCS System

oRMU Erection in PDPL Project

oNaptha Hydrotreating /Isomerization Project of BPCLh

oAddition of Fire and Gas Line in Chemplast Sanmar Limited,Karaikal Unit

oKOC Dhukan Automation Project -Replacement of existing DCS with a new FF DCS, existing DCS field Instruments with new FF instruments, existing ESD and F&G systems with TUV Certified SIL-3 redundant systems and integrated to new FF DCS.

oIOCL Panipat C4H Raffinate Project

oIFIX 32 Scada in Ethyl Acetate Plant

oPolypropylene Derivative Petrochemical Complex Project

oFinal Commissioning of 6 Trains of Sulphur Recovery Project

oSystem Automation of Micrologix1200 Input-Output of Allen Bradley System

oField Instruments and DCS Installation in 32.4 million litres per day effluent treatment plant of Jamnagar.

oDesign of Super Critical Thermal Power Project of 3 Trains of 660-Megawatt Power Project

oFibre Optic Cable Connectivity, Satellite Connectivity to System via Fibre Optic Cabinet in GAIL Loni Pipeline Project.

oAluminium Bath Handling System, Anode Grouping and Cleaning System, Rodding Shop Automation

oProcess Instrumentation in Municipal Corporation for 4,55,000 cubic meter/day draining water plant

oErection and Commissioning of Instruments in Aromatics Tatoray Area, Tankage Area, Norsk Hydro Electrolysers Package, Mini Hydrogen Plant, and Hydrogen Plant

oOverhauling of 3 units of Boilers, under IHI Corporation of Japan. Revamped instruments with Latest Smart Instruments and Configuration via HART Held Configurators

oAsh Handling System, Coal Handling System, Thermax Boiler Related Instrumentation, Coal Feeder, Conveyor Proximity Switches, DG Synchronization Indications in 15-Megawatt Captive Power Plant of Technocraft Industries.

oTerminal Automation of Kandla Despatch Terminal and Jaipur Intermediate Pumping Station containing redundant PLCs, I/O servers, operator workstations, and LANs; 3051 Model Rosemount Transmitter and 600T 2 wire ABB Transmitter in the 1355 KM long LPG Pipeline producing 2.5MMTPA LPG

Directed design and frontend engineering/detailed engineering service/Field Engineering service for

oQAPCO ARU and SRU Project

oKuwait Aviation Fuel Supply Depot

o1300 TDS/D Recovery Boiler Plant in ITC Paper Mills

oBORL Refinery Coke Drum storage Project

oSaudi Kayan and Karachaganak KPO Project

oEarly Production Facility 120MBOPD of Kuwait Oil Corporation

oOnshore Asset Gas Management Project of Nigeria

oONGC Assam, Ahmedabad, and Cauvery Asset Project

Made final changes in SPI INTOOLS VERSION 8 on the database for the required updates as available in erection state

Headed installation and commissioning of Wonderware Intouch Scada for 1100 TDS/D Chemical Recovery Boiler Plant

Conducted calibration of various field instruments in SPIC Jel Project and LOIL Project.

Controlled replacement of Faulty I/O's of HIMA TMR PLCs. Installation of Operator Workstations. BCH PLC Programming modification/ PLC Troubleshooting in National Fertilizers Limited,Bhakranangal.

Supervised loop checking of 880 I/O's of Foxboro DCS in Aromatics Control Room. Reviewed instrumentation modification and selected model of Yaskawa L&T AC Drives

Governed Design Activities, Bill of Quantity, Material Availability Report, Cable Routing Layout, Instrument Location Layout, Instrument Cable Schedule, Fibre Optic Cable Schedule for the Instruments such as Automatic Radar Tank Gauging System, Petrol Automatic Dispensing Systems, Variable Frequency Drives, etc., in the 1500 Reliance Retail Outlets PAN India

Earlier Work Experience

Wevin Private Ltd Assistant Manager-Instrumentation Oct 2009 - Jan 2010

Valdel Engineers Private Ltd Principal Instrument Design Engineer Oct 2007 - May 2009

VA Tech Wabag Technologies Pvt. Ltd. Senior Instrument Engineer Jan 2007 - Sep 2007

Tricon International Senior Instrument Engineer Apr 2004 - Aug 2004

Aarvi Encon Private Ltd Instrument Design Engineer Sep 2003 - Feb 2004

Chemtrols Engineering Ltd Senior Projects Engineer Jan 2003 - Aug 2003

Ram E&I systems Private Ltd Instrumentation Engineer Apr 2001 - Oct 2002

Process Control Technology Instrumentation Engineer Oct 2000 - Mar 2001

Konstelec Engineers Private Ltd Instrumentation Engineer Sep 1998 - May 2000

Laxmi Organic Industries Instrumentation Engineer Feb 1997 - Aug 1998

Contracts

Kentz Overseas Private Ltd Senior Instrument Installation Engineer Feb 2010 - Sep 2010

OEG India Private Ltd Assistant Manager Jun 2009 - Sep 2009

Doosan Heavy Industries Senior Instrument Engineer Jun 2006 - Dec 2006

SM Aker Management services Senior Instrument Design Engineer Sep 2004 - Feb 2006

Spic Jel Engineering Private Ltd Instrument Erection and Commissioning Engineer Nov 2002 - Dec 2002

Education

•Bachelor of Engineering - Electronics and Instrumentation from Annamalai University Participated in Functional Safety Engineer (FSEr) in accordance with IEC 61508 and IEC 61511 – Level 01 (TUV SUD South Asia Private Limited)

Courses and Certifications

•PLC Course covering Allenbradley Micrologix PLC, Control Logix PLC, ABB AC500 PLC, Wonderware Intouch SCADA

•Instrumentation Software Application - Yogawas CS 3000, Centum VP Training, Wonderware SCADA Training, Siemens S7 series PLC Programming training, Emerson Delta V DCS System Training, Schneider Electric DCS training

•Training on Siemens PCS7 and, GE Intellution FIX Scada, Modicon plc, GE plc Fanuc plc, Mitsubishi plc

•Autodesk Certified Training,Autocad Training

Work Profile Feb 1997 – Jun 2021

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