Balasubramanian S
Summary
Managed maintenance operations for process instrumentation and control systems, focusing on routine, preventive, and breakdown maintenance. Prepared procurement specifications and maintained essential systems such as DCS, PLC, and ESD. Demonstrated proficiency in troubleshooting alarms and creating cost-effective maintenance strategies. Leveraged SAP PM for streamlined work planning and vendor coordination, ensuring efficient material tracking and requisition handling.
Overview
12
12
years of professional experience
1
1
Certification
Work History
Instrument & Controls Engineer
Exxonmobil
Bengaluru
10.2025 - Current
- Executed risk-based work selection for control valves and developed equipment strategies.
- Reviewed maintenance plans for control valves, recommending changes to enhance reliability.
- Utilized Conval software extensively to evaluate controllability and reliability of valves.
- Reviewed and approved instrument-related documentation for upcoming seawater treatment project.
Manager - Maintenance Instrumentation
Bharat Petroleum Corporation Limited - BPCL Kochi Refinery
Kochi
06.2014 - 09.2025
- Coordinated instrument maintenance for Diesel Hydro Desulfurization Unit, Vacuum Gas Oil Hydro-desulfurization unit, and Sulphur Recovery Units 2 and 3.
- Developed PM Plan procedures for instrument equipment to ensure compliance through documentation.
- Executed troubleshooting strategies to identify and eliminate root causes of equipment trips.
- Collaborated with Central Maintenance Reliability Organization to enhance instrument reliability.
Education
Bachelor of Engineering - Electronics & Instrumentation
Anna University - MIT Campus
Chennai, India04-2014
Skills
- Control Valve Selection & reliability assessment
- Root cause analysis (RCA) - Trips & Incidents
- SIL Verification
- Efficient Material Tracking
- Preparation of SMPs
- Presenting & Communication
- Turnaround co-ordination
Affiliations
Major Shutdown Experience 1:
Year 2020 - 2022
Planning: 2020 Q4 to 2022 Q1
Execution: 2022 Q3
Planned & Executed for Instrument shutdown activity of Sulphur Recovery Unit - during major plant turnaround
Critical Jobs: 156 Number of valve servicing (up to 40 inches), New Instruments installation & Commissioning, DCS & ESD Maintenance Jobs, PST commissioning, Converter multi point thermocouple inspection, Pelletizer Instrument shutdown maintenance jobs, FF Loops diagnostics check, Air Blower reliability improvements etc.,
Year 2020 - 2022
Planning: 2020 Q4 to 2022 Q1
Execution: 2022 Q3
Planned & Executed for Instrument shutdown activity of Sulphur Recovery Unit - during major plant turnaround
Critical Jobs: 156 Number of valve servicing (up to 40 inches), New Instruments installation & Commissioning, DCS & ESD Maintenance Jobs, PST commissioning, Converter multi point thermocouple inspection, Pelletizer Instrument shutdown maintenance jobs, FF Loops diagnostics check, Air Blower reliability improvements etc.,
Commissioning Experiences
- Year 2020 - 2021 : MSB Unit Commissioning - Commissioning of Multiple Field Instruments, Bently MMS systems, Screw compressor CO2 Flooding system, Logic Modifications in Schneider PLC.
- Year 2024 Q1 : Cyclemax PLC Upgradation - Obsolescence Management - Retrofit of Cyclemax Schneider Triconex PLC (200+ IO Loop Testing)
- Year 2022 Q1 & 2024 Q3: Woodward Micronet Upgradation & Peak 200 - Reliability Improvement
- Year 2024 : Honeywell FSC Upgradation & Front End Upgradation - Replacement of FSC Cozi Type PLC into FSC cum SM system. Front end upgradation to comply with cybersecurity recommendations
Significant Professional Contributions
- Placement of contract and execution of Clean agent panel PM and Functionality test.
- Revolutionized Bently proximity sensor health assessments with custom built excel tool.
- Developed SMPs for Several critical instrument system.
- Successfully implemented modified MMS logics for Centrifugal compressor in Bently 3500 system to avoid spurious trips.
- Contributed for SIL Study completion and execution of SIL Study recommendations at VGOHDS & NHTCCR Units
- Contributed for finalizing OT system architecture in line with cybersecurity standards, OISD & CDAC Audit Points
Languages
English
Proficient (C2)
C2
Tamil
Native
Native
Malayalam
Intermediate (B1)
B1
Certification
• TUV SUD - Functional Safety Engineer (FSEr) : Level 01 (IEC 61508/61511)
• Scaffold Supervisor Course
• Introduction to Gen AI Course
• Automation & Robotics for Smart Manufacturing & Quality Control
• Scaffold Supervisor Course
• Introduction to Gen AI Course
• Automation & Robotics for Smart Manufacturing & Quality Control
Control System & Softwares
- Honeywell C300 (DCS), FSC & SM (PLC)
- Woodward Peak 150, Peak 200, Micronet TMR, CCC Reliant Anti surge system
- Emerson Delta V DCS & PLC, Schneider Triconex PLC
- Siemens S7-400 PLC, Bently 3500 Monitoring system
- Conval Software (Control valve sizing, Orifice plate sizing, Thermowell Wake frequency calculation & Actuator sizing)
- SAP PM Module
- Seeq Software for trend analysis and Honeywell CPM Analytics for process loop performance monitoring.
- Exsilentia for SIL Verification.
Timeline
Instrument & Controls Engineer
Exxonmobil
10.2025 - Current
Manager - Maintenance Instrumentation
Bharat Petroleum Corporation Limited - BPCL Kochi Refinery
06.2014 - 09.2025
Bachelor of Engineering - Electronics & Instrumentation
Anna University - MIT Campus