Karthikeyan Sadasivam
Principal Engineer
Chennai
Summary
Results-driven Instrumentation & Control Systems Engineer with over 22 years of experience in industrial automation across Oil & Gas, Petrochemical, Power, and Data Center industries. Specialized in ABB 800xA DCS systems, control logic development, and library engineering aligned with Dow Good Engineering Practices and industry standards. Strong background in developing and testing control function blocks using IEC 61131-3, implementing SIL-rated logic, and executing MOD5 to ABB 800xA migration projects. Experienced in functional safety (IEC 61508/61511), HMI and faceplate development, FAT/SAT, and system integration via Modbus, OPC, and Profibus protocols. Familiar with ABB Batch Management libraries and ISA S88 concepts, with limited hands-on experience. Committed to delivering quality automation solutions with a focus on structured engineering and long-term reliability.
Overview
22
22
years of professional experience
6
6
Certifications
Work History
Principal Engineer
Randstad India Pvt Ltd
01.2021 - Current
- Project: LHC8 Freeport
- Deputed to CEC-India (Dow Chemical Int
- Pvt Ltd) as a Senior Process Automation Engineer
- Involved in MOD5 to ABB 800xA system migration projects
- Handled migration of Light Hydrocarbons Cracker 8 (Freeport, USA)
Senior Process Automation Engineer
Randstad India Pvt Ltd / KBR Engineering & Construction India Pvt Ltd
07.2018 - 12.2022
- Project: LHC7 Freeport
- Deputed to CEC-India (Dow Chemical Int
- Pvt Ltd)
- Involved in MOD5 to ABB 800xA system migration for Light Hydrocarbons Cracker 7 (Freeport, USA)
Engineer to Senior Engineer - Operation Center
ABB GISL
06.2015 - 06.2018
- Project: Asta Hansteen (Statoil, Norway) at HHI Shipyard, Ulsan | Linde Bremen Graphics Development
- Development and testing of Pg2 Graphics displays and Modbus applications
- Development of graphics displays, faceplates, and graphic elements for Building Management Systems (BMS)
- Implementation of PCS and ESD application logic based on SCDs
- Basic and detail engineering: IO list preparation, system architecture, hardware panel design
- Review and testing of Pg2 faceplates and graphic elements based on VB graphics and project guidelines
- Commissioning document support and collaboration with hardware and software teams
- System: 800xA system, AC800M, 800xA Rev 5.1 & 6.0
- Duration: 2 years (combined)
Engineer - Operation Center
ABB GISL
03.2016 - 11.2016
- Project: Zenith Data Center Automation (Obashi, Singapore)
- Development of BMS Graphics display, faceplates, and elements
- Library and Application logic development for BMS
- IO List preparation, System Architecture, Hardware Panel Design
- Kepware configuration for electrical and 3rd-party device integration via TCP/IP, BACnet
- Commissioning/SAT of mechanical and electrical equipment in BMS
- Hardware/software FAT, Janitza Power Meter Integration, Modbus programming
- System: 800xA 6.0.1, AC800M-PM866, Profibus DP, Modbus RTU/TCP, BACNet IP, OPC, Janitza Power Meters, Kepware
- Duration: 8 months
Domain Developer to Domain Lead Developer – Development Center
ABB GISL
05.2006 - 01.2015
- Project: REUSE Solution Library (SIL 3), DOW DPA Migration to 800xA, Harmony INFI 90 Evolution
- Led development of REUSE SIL 3 Library for Oil & Gas projects, aligned with NORSOK I-005 standards
- Designed and tested Control Module Types and Functional Blocks for process safety applications
- Developed and supported safety logic for ESD and FGS systems using HI Controller, REUSELib, and Vote Loop objects in compliance with IEC 61508
- Engineered and validated PCS Objects, managed documentation and code reviews to ABB quality standards
- Spearheaded function block development for DOW
- Hands-on experience with PCDeviceLib for application programming, logic structuring, and testing using Control Builder M
- Defined version control processes and acted as Configuration Manager for multiple releases
- Developed diagnostics, control graphics, and C&E displays for Harmony system migration, using tools like Harmony Composer and Engineering Studio
- Systems & Tools Used: ABB 800xA Rev 5.0 / 5.1, AC800M / AC800 HI Controllers, Control Builder M, PCDeviceLib, REUSELib, Infi90Lib, Harmony Composer
- Duration: 8 years 8 months (combined)
Engineer / Trainee - Operation Center
Invensys India Private Limited
10.2003 - 04.2006
- Project: CPP, PRU, Grasim Industries, VVF Limited
- Project engineering from IO list and P&ID to database generation using IACC/FOXCAE
- Front-end FAT/SAT coordination, commissioning of Foxboro systems
- Graphics development, interlock strategies, and report generation using Report Writer Package
- Loop checking, system hardware QA, historian and reporting setup
- Configuration and testing of Modbus and Nodebus communications
- Interface testing and integration with Triconex and Allen Bradley PLCs
- Client coordination, documentation, and HMI symbol development
- System installation and logic modifications during commissioning support
- System: Foxboro DCS, IACC, ICC, I/A Series CP 60
- Duration: 2.5 years (combined)
Education
Bachelor of Engineering - Electronics & Instrumentation
"Bachelor of Engineering" (B.E. ) - Electrical, Electronics And Communications Engineering
S.R.M Engineering College
Chennai 04.2001 -
Skills
- ABB 800xA DCS Development & Configuration
- Control Function Block Design
- Faceplate & Graphics Engineering
- Application Engineering
- FAT/SAT Execution
- Library Configuration
- System Integration
Roles
- Principal Engineer (Current)
- Senior Process Automation Engineer
- Senior Technical Professional
- Domain Lead Developer
- Senior Domain Developer
- Domain Developer
- Project Engineer
Market Sectors
- Oil and Gas
- Petrochemical
- BMS Data Center
- Power Plant
Personal Qualifications
Bachelor of Engineering, Electronics & Instrumentation
Certification
T309 HI System training and Certification by ABB Limited.
Timeline
Principal Engineer
Randstad India Pvt Ltd
01.2021 - Current
Senior Process Automation Engineer
Randstad India Pvt Ltd / KBR Engineering & Construction India Pvt Ltd
07.2018 - 12.2022
Engineer - Operation Center
ABB GISL
03.2016 - 11.2016
Engineer to Senior Engineer - Operation Center
ABB GISL
06.2015 - 06.2018
T309 HI System training and Certification by ABB Limited.
01-2012
Reuse Library and Certification by ABB Limited
01-2012
TUV certified Functional Safety Engineer (ID #8460/14) – Valid till Jan 2022
01-2012
Training in T315 800xA System engineering and AC 800M controller.
01-2008
Reuse Library and Certification by ABB Limited
01-2007
Domain Developer to Domain Lead Developer – Development Center
ABB GISL
05.2006 - 01.2015
Engineer / Trainee - Operation Center
Invensys India Private Limited
10.2003 - 04.2006
"Bachelor of Engineering" (B.E. ) - Electrical, Electronics And Communications Engineering
S.R.M Engineering College
04.2001 -
I/A Series DCS System
01-2001
Bachelor of Engineering - Electronics & Instrumentation
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