Ajay Jacob Varghese
Bangalore
Summary
Dynamic Senior Digital Solution Engineering Specialist with ABB Global, adept at driving innovative software product development and enhancing Instrumentation Asset Performance Management. Proven track record in leading agile projects and mentoring teams, while excelling in maintenance and reliability improvement. Recognized for conceptualizing impactful solutions that elevate customer value and operational efficiency, based on strong foundation built on core industrial field experience as Instrumentation & Control Engineer.
Overview
17
17
years of professional experience
1
1
Certification
Work History
Senior Digital Solution Engineering Specialist
ABB Global
Bangalore
09.2023 - Current
- Served as Functional Subject Matter Expert for development of Instrumentation and Process Automation Solutions, as part of ABB Genix APM Suite
- Conceptualized and developed strategies for Software Developers, Testing teams, Solution Architects, and DevOps teams.
- Conducted functional reviews for UI/UX team to validate customer user journeys in software applications.
- Specialized in Instrumentation Remote Condition Monitoring, Asset Performance Management, and Asset Strategy Management.
R&D Senior Engineer
ABB Global
Bangalore
01.2020 - Current
- Conceptualize designs for value engineering scenarios to incorporate in digital transformation solutions in the Asset performance management, Reliability, RCM, CBM, Predictive maintenance etc.
- Work closely with Customers and Business Units to architect and develop customer centric solutions tailored to their requirements
- Agile development of digital solution ‘Proof of Concepts’ to effectively articulate the Customer Value Proposition
- Provide industry specific domain insights for rich proposal responses by articulating customer value proposition
Lead Engineer
Reliance Industries Ltd
Patalganga
07.2014 - 12.2019
- Handling team of 7 people consisting of Maintenance Executives and Junior Engineers
- Planning, co-ordination & execution of shutdowns and turnarounds tasks related to Instrumentation of all equipment in plant.
- Project Manager for 3 major Instrumentation Brown field projects in Captive Power Plant.
- Maintaining critical spares of all equipment in plant, creation & approval of all Purchase Requisitions, material follow up with Buyer & vendor
- Discipline lead - Incident investigation & Root Cause Analysis of Instrumentation failures in Captive Power Plant
- Preparing and releasing Monthly report of all plant Instrumentation activities
- Monitoring safety norms for execution of plant jobs on daily basis through Toolbox talk, review of Risk Assessment sheets for planned daily jobs
- Preparing annual job plan & Annual Budget for Instrumentation department of CPP and suggest forward path for implementing the same.
- Review of new changes in plant instrumentation through MOC (Management of Change) and technical review of proposed changes in co-ordination with inter-discipline maintenance and operations teams.
- Internal Auditor for ISO 9001/18001/45001 Audits in CPP plant
- Conducting ReSOP (Reliance Safety Observation Procedure) & CFA (Contractor Field Audits) on a monthly basis
- Successfully mentored 9 Trainee Engineers, awarded Best Trainer award – CPP Plant, for 3 consecutive years
- Involved in developing Annual Training Plans for new engineers & technicians, through Competency Assurance System
Manager
Reliance Industries Ltd
Patalganga
05.2010 - 06.2014
- Planning & Execution of Daily Instrumentation maintenance jobs in CPP Plant
- Active involvement in execution of Brown field projects
- Material & manpower management for Instrumentation jobs in CPP Plant
- Instrumentation Maintenance Jobs (MI, HGPI, CI & Opportunity Shutdowns) of GE Gas Turbines: Planning and execution of shutdown Jobs of 2
- 30 MW Frame-6 Gas turbines, HRSGs of capacity 2
- 125 TPH. Supervision of Calibration of Instruments, maintenance of all associated instrumentation. Adherence to standard maintenance practices for instruments, keeping in view the duration of equipment outage as per process requirement.
- Auxiliary Boilers: Planning & execution of preventive & predictive maintenance of capacity 3
- 70 TPH Borsig make Steam Boilers, Pre-Start Boiler Management System (BMS) Checks & Interlock Testing and Basic Troubleshooting
- DM Water Plant, Effluent Treatment Plant: Maintenance of analytical instruments like pH, conductivity meters and Silica & Turbidity meter, etc.
- Air Compressors, Dryers & Chillers: Preventive & predictive maintenance of centrifugal & reciprocating compressors used in LP Air, Biogas Applications, Vapor Absorption Chilling units for Comfort Air Cooling
- PLC & DCS: Having experience in Maintenance & troubleshooting of Allen Bradley PLC systems and ABB MOD300 DCS of CPP in RIL-Patalganga.
Field Operations & Panel Engineer
Reliance Industries Ltd
Patalganga
07.2008 - 04.2010
- Planning & Execution of Daily Instrumentation maintenance jobs in Utilities Plant
- Active involvement in creation and updating Standard Maintenance procedures
- Daily field audit of Instrumentation assets in Air Compressors, Heaters, Effluent treatment plant as a part of Reliability improvement.
- Completion of Plant specific training modules and successful completion of Validation for confirmation.
Education
Bachelor of Technology (B.Tech) - Applied Electronics & Instrumentation Engineering
St. Joseph's College of Engineering & Technology
Kerala, India12.2007
Skills
- Software Product Development
- Innovative thinking
- Maintenance & Reliability Improvement
- Obsolescence Management
- Material Management & Procurement
- Brownfield Projects
- Software Product Development
- Agile development
Certification
- International Certificate in Product Management (ICPM), Institute of Product Leadership, Bangalore, 2025
- Post Graduate Program in Cloud Computing, Great Lakes Executive Learning, 2024
- TUV Functional Safety Engineer Certification, YOKOGAWA India, 11/2015
- GE MARK Vie Control System – Maintenance Training, 2017
- Yokogawa Centum VP – DCS – Fundamentals & Engineering, 2020
- Bureau Veritas certified IMS ISO:9001-2015, ISO:14001-2015 & ISO:45001-2018 Internal Auditor, 2017-2019
- Bentley Nevada 3500 Vibration Monitoring System – Maintenance, 10/2016
- Exida Functional Safety Training, 2016
- Gas Turbine Operations & maintenance training, M/s MJBI at RIL, 2015
- ABB MOD300 DCS Maintenance & Engineering Training, 2012
- Certified Automation Engineer (CAE), Prolific Automation Systems, Pune, 12/2007
Summary of Industry Projects Executed
- Upgrade of Gas Turbine Control System Mark V to Mark Vie, Project Manager
- Rockwell PLC Network upgrade and Integration – DH+ to Ethernet, Project Manager
- Installation & Commissioning of Continuous Effluent Monitoring System (CEMS) Analyzers, Team Member – CPP Instrumentation
- Installation & Commissioning of Natural Gas Custody Transfer metering skid with M/s GAIL at Reliance Patalganga. Maintenance & Calibration of skid instrumentation, Team Member – CPP Instrumentation
- Deputed in Reliance Industries, Jamnagar Refinery for conducting SIL Audits for 2 plants using ExSILENTIA software, Team Member
- Alarm Rationalization in ABB Mod300 DCS, Team Member – CPP Instrumentation
- SIL (Safety Integrity Level) Study of Feed Water Pump Logic & Boilers BMS PLC, Team Member – CPP Instrumentation
- PLC Upgrade in: Heat Recovery Steam Generator BMS (from Rockwell 5/40 to Controllogix PLC), Boiler Feed Water Pump (from MODICON PLC to Allen Bradley), Air Dryer Unit (From Mitsubishi PLC to Allen Bradley), Project Manager
Experience in Digital Product Development
- Design & Conceptualization of Digital Fleet Monitoring Solution - CEMS & PGC Analyzers
- Part of design team in development and conceptualization of Asset Performance management application Suite
Timeline
Senior Digital Solution Engineering Specialist
ABB Global
09.2023 - Current
R&D Senior Engineer
ABB Global
01.2020 - Current
Lead Engineer
Reliance Industries Ltd
07.2014 - 12.2019
Manager
Reliance Industries Ltd
05.2010 - 06.2014
Field Operations & Panel Engineer
Reliance Industries Ltd
07.2008 - 04.2010
Bachelor of Technology (B.Tech) - Applied Electronics & Instrumentation Engineering
St. Joseph's College of Engineering & Technology
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