Results-driven Systems Engineer with expertise in PLC programming, BMS, and automation systems for industrial and data-center environments. Proven ability to enhance system reliability and compliance.
Expertise in designing, implementing, and maintaining PLC-based control systems for HVAC and facility automation.
Proficient in programming and configuring Siemens TIA Portal and Allen-Bradley Studio 5000 platforms.
Experience in managing BMS and HVAC automation for mission-critical environments to ensure uptime and environmental control.
Skilled in integrating various automation components to optimize building and facility operations.
Toyota Motor North America
Supported PLC-based control development for HVAC and facility automation systems using Siemens TIA Portal and Allen-Bradley Studio 5000, ensuring compliance with Toyota engineering standards and high-reliability operational requirements.. Implemented structured diagnostics, modular logic blocks, and fail-safe sequences to enhance system maintainability and align with Toyota’s Jidoka principles.. Integrated multi-vendor HVAC equipment and field controllers using BACnet/IP, BACnet MSTP, Modbus TCP/RTU, and EtherNet/IP to ensure seamless interoperability across plant systems.. Developed operator-focused HMI graphics, alarm dashboards, and trend interfaces in WinCC, Wonderware, and FactoryTalk View SE to improve visibility and reduce response time.. Executed commissioning workflows including I/O validation, loop tuning, SOO verification, FAT/SAT, and system bring-up to ensure readiness for production and facility operations.. Performed root-cause analysis on PLC logic, communication networks, VFDs, sensors, and field devices to minimize downtime and support high-availability environments.. Conducted trend-based performance reviews and alarm analytics to identify inefficiencies, optimize HVAC sequences, and support Toyota’s continuous improvement initiatives.. Maintained as-built documentation, firmware revisions, backups, and change-control records in alignment with Toyota’s quality and compliance processes.. Collaborated with mechanical, electrical, IT/OT, facilities, and vendor teams to resolve integration issues and deliver stable, scalable automation solutions.
Reliance Industries Limited (RIL)
Supported BMS and HVAC automation operations for mission-critical data-center environments, ensuring continuous uptime, environmental stability, and compliance with reliability standards.. Developed, modified, and optimized PLC logic for AHUs, CRAC/CRAH units, chilled-water plants, exhaust systems, and hydronic loops using Siemens Step 7 and Allen-Bradley platforms.. Engineered HMI graphics, alarm frameworks, and trend dashboards in Wonderware InTouch and Siemens WinCC to enhance operator visibility and support proactive maintenance.. Integrated multi-vendor HVAC and facility systems using BACnet/IP, BACnet MSTP, and Modbus RTU, ensuring deterministic communication and accurate point mapping.. Executed commissioning workflows including I/O validation, loop tuning, SOO verification, redundancy checks, and system bring-up for new installations and retrofits.. Performed root-cause analysis on PLC logic, communication networks, field wiring, and instrumentation failures, restoring system functionality and preventing recurrence.. Conducted alarm rationalization, trend analysis, and performance tuning to improve energy efficiency and environmental control stability.. Prepared and maintained engineering documentation including I/O lists, SOOs, wiring diagrams, network layouts, and commissioning reports.
Master of Science
In my PLC programming work, I make compliance with industry standards a priority from the beginning of every project. I follow the required sequence of operation, safety rules on site standards, I could say, and I verify that the logic, alarms, interlocks, and documentation all matches those requirements before commissioning. I also make sure the program is structured clearly, uses consistent naming, and is easy for other engineers too, for technicians to understand and maintain. For example, on a previous controls project, I worked on, you know, PLC control system where I had, you know, to make sure the logic aligned with the expected startup sequence and safety requirements. I reviewed the drawings and input-output list and the functional requirements before making changes. And I checked that all field devices were mapped correctly during testing. I validated the interlocks and alarms behavior step-by-step so the system would, you know, behave on the output safely and consistently. If I found anything that did not match the standard, I corrected it and, you know, retested before moving forward. What I learned from that experience is, what compliance is not just about following a document, it is about following it, you know, it is about building quality into the program, you know, verifying it in the field, and making sure the final system is safe, reliable, and maintainable. So this is how my approach is gonna be when, you know, How I ensure the compliance in industry standards in my PLC programming projects.
So one challenge, I mean, the challenge of this situation I handled is, you know, involved in a PLC controlled automated systems, you know, that was not responding consistently during the startup. So the issue showed up as, you know, intermittent faults and incorrect sequence behavior. So at first, I looked like a logic problem, but I know I had to investigate it systematically before mapping the changes. I started reviewing the PLC program, the input output list, and the sequence of operation to understand exactly how the system should behave. Then I checked the PLC signals point to point to see whether the program was in a logic, wiring, device feedback, or timing in this case. The issue turned out to be, you know, combination of an incorrect input output mapping and a logic condition that was not handling a device, you know, that state it properly, I could say. And, you know, after isolating the cause, I corrected the mapping, refined the sequence logic, and retested the alarms and interlocks step by step. I also worked with the commissioning team to verify the fix under real operating conditions. Once I validated everything, the system ran much more reliably, the faults stopped reoccurring, and startup became smoother. So the experience taught me the importance of being systematic, staying calm under pressure, and using both PLC knowledge and field troubleshooting skills to solve the real root cause instead of just, you know, treating the symptom, I could say. So, so.
Descubre otros profesionales con experiencia similar
One project I'm involved in, you know, involved in PLC programming and commissioning, you know, support for an automated system where reliable sequence of controls was critical for startup and ongoing operation, I could say. During the early phase, the system has, you know, issues with sequence timings, alarm behavior, and field device feedback. So there was a risk of extended commissioning delays and unstable operation of the handover. So my responsibility was to support the PLC side by developing and refining the control logic, validating input-output, and helping bring the system online. And, you know, it's like, you know, reliability, safety and reliability. I started by reviewing the sequence of operation and checking the PLC program against the actual field conditions. And I worked through the input-output point list, verified the input and output mapping, and tested the device responses one stage at a time, updated the sequence logic, interlocks, and, you know, alarms handling so the control behavior matched on the real process conditions more accurately during commissioning. I also coordinated with technicians, operators, and, you know, other engineers to troubleshoot issues in real time, especially, you know, when field feedback signals or device behavior did not match what I expected in the program. So that helped us to isolate whether a problem was coming from logic, wiring, instrumentation, or, you know, equipment response. As we progressed, I supported the functional testing startup, verification, and logic adjustments until the system was stable. So this is my experience.
I developed and implemented the PLC programming on a controls project where I was responsible for sequencing, interlocks, and troubleshooting input-output logic for an automated system. So I have worked with, you know, an automated system. I worked through the process in TA portal and Bradley environment, tested the logic in stages and coordinated the commissioning and operations to verify, you know, the sequence and the real conditions, I could say. The outcome was that, you know, the system ran more reliably, startup issues were reduced, and we were able to bring the equipment online with, you know, fewer troubleshooting delays. I worked on a controls project involving PLCs, logic for an, you know, automated system where I programmed the sequence, alarms, and safety interlocks, then tested and refined that, you know, code during the commissioning. I collaborated with operation, like, you know, with a few of the operators and other engineers to resolve issues quickly and validate the logic in the field. As a result, the system became more stable, downtime was reduced, and, you know, hands-on to the operations was smoother. So the good structure is, you know, I did like that, like, for the project of the controls. I have experience, you know, more than 3 plus years. So if you ask me about that, I could give you an example as well. So this is all about my experience of how I followed a structured way, like in programming, controls, troubleshooting, and commissioning work. Thank you for this opportunity.
Hey, my name is Karnakar. I have an experience of two plus years of experience in controls engineering working with, you know, in Toyota as well as Glen Industries back in India. And I'm expecting, you know, a PLC controls engineer with skills like Bachman, Modbus, Siemens, and Allen Bradley. So this is all about me.
