Summary
Overview
Work History
Education
Skills
Accomplishments
Visas
Timeline
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Karan Kumar Upadhyay

Karan Kumar Upadhyay

Executive Officer
Jamshedpur

Summary

Results-driven Instrumentation and Automation Engineer with 5 years of experience optimizing sinter plant operations at Tata Steel. Proficient in PLC programming (Siemens S7 400H), DCS systems (ABB AC 800M), and SCADA integration to improve process efficiency and reliability. Skilled at troubleshooting control systems, executing automation projects, and using data analysis to reduce downtime and enhance operational performance.

Overview

8
8
years of professional experience
6
6
years of post-secondary education
2
2
Languages

Work History

Executive Officer

Tata Steel Ltd.
Angul
02.2021 - Current
  • Maintaining project baselines while monitoring and controlling projects with respect to cost, resource deployment, time overruns and quality compliance to ensure its satisfactory execution.
  • Demonstrated expertise in troubleshooting, calibration, and maintenance of Process instrumentation systems of Sinter Plant.
  • Developed and implemented control logic for DCS of ABB AC 800M and Siemens Hybrid PLC S7 400H, ensuring seamless integration with existing systems.
  • Conducted troubleshooting and maintenance of ABB DCS AC 800 M & Siemens Hybrid DCS/PLC S7 400H, identifying and rectifying control loop issues to reduce downtime.
  • Collaborated with cross-functional teams to integrate new instrumentation system.
  • Planning and procurement of complete plant using SAP-S4 HANA - SAP-MM, SAP-PM, and handling E-billing processes, material management, and Easybuy system.
  • Financial Year Budget Allocation planning for projects: Apex/Non-Apex, Capital Projects, Improvement Projects (Kiezens), logistic plans, and implementation of 5S and TPM/TQM in the workplace.
  • Knowledge of reading all types of hook-ups, P&ID.

Engineer

Uttam Galva Metallics
Wardha
10.2020 - 02.2021
  • Erection & commissioning of all types of instrumentation & establish DCS control loop like MND water control system, Furnace auto ignition system, Furnace fuel to air ration control with temperature .
  • Profibus networking & communication establishment with intelligent motor feeder with DCS
  • Analyzed process data and provided recommendations for process optimization, leading to a 15% increase in throughput.
  • Kick off meeting with the scope of work. Front readiness & execution of instrumentation work referring with P&ID

Junior Executive

Jindal Steel & Power
Odisha
12.2016 - 12.2017
  • Carried out commissioning of Burner Management System by Andritz.
  • Installation and commissioning of Sinter Plant, ESP pneumatic conveying system, and smart instrumentation.
  • Conducted preventive maintenance, calibration, and troubleshooting of instruments, reducing equipment failures by 20%.
  • Used QuickBooks to produce monthly invoices, reports, and other deliverables.

Education

Bachelor of Technology - Electronics And Communication Engineering

Biju Patnaik University of Technology
Odisha
08.2017 - 08.2020

Diploma - Electronics And Communication Engineering

AL- Kabir Polytechnic, Mango
Jamshedpur, India
07.2013 - 12.2016

Skills

Process Automation and Control Logic Development

Project Planning and Procurement

Project Management - Green Field and Brown Field Projects

Safety Health and Environment

Communication Protocols: MODBUS, PROFIBUS, Ethernet/IP

Process Optimization - Data Analysis & Reporting

HMI Development: Siemens WinCC

Instrumentation Drawings

Field Instruments & Control Systems Design

Total quality management

Accomplishments

  • Gas Mixing Station system erection & commissioning at SP 2&3 at Tata steel Meramanadali one of the milestone projects duly acknowledged by TATA Management towards the improvisation of calorific value and reduce specific fuel consumption.
  • Carried out commissioning of Burner Management System by Andritz at Sinter Plant.
  • Gold Medalist & Awarded Excellence award in National level NCQC 2024.
  • Erection & commissioning of Pneumatic conveying system for ESP & Bag filter dust handling.
  • All water tank level auto control & using BOD water at MND to reduce wastage of clean water.
  • Enhanced Maintenance KPIs viz MTTR (Mean Time to Repair from 10.6 hrs to 2.5 hrs) for all recurring breakdowns), and improved MTBF (Mean Time Between Failure ), through measures such as elimination of forced deterioration, TBM policies, continuous improvement initiatives and completion of horizontal deployment activity

Visas

  • Valid USA B1/B2, 01/34

Timeline

Executive Officer

Tata Steel Ltd.
02.2021 - Current

Engineer

Uttam Galva Metallics
10.2020 - 02.2021

Bachelor of Technology - Electronics And Communication Engineering

Biju Patnaik University of Technology
08.2017 - 08.2020

Junior Executive

Jindal Steel & Power
12.2016 - 12.2017

Diploma - Electronics And Communication Engineering

AL- Kabir Polytechnic, Mango
07.2013 - 12.2016

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Karan Kumar UpadhyayExecutive Officer