SAI SREEHARSHA MADINENI (CEM), (PMP)

Project 1: Gas Turbine Control System Migration (Mark V / VI / Nexus → Mark VIe)

• Led end-to-end migration of gas turbine control systems including software conversion, I/O transition, and commissioning, ensuring seamless system cutover.
• Acted as technical focal point for field engineers, resolving complex control system and turbine operational issues with strong ownership and accountability.
• Performed Root Cause Analysis (RCA) and trip investigations, defining and implementing Corrective and Preventive Actions (CAPA) to enhance system reliability.
• Managed non-conformities (NCRs) during commissioning and ensured timely resolution aligned with engineering and quality standards.
• Integrated Mark VIe, EX2100e, and LCI systems, supporting control of auxiliary and rotating equipment interfaces.
• Designed and implemented advanced control strategies using ToolboxST, Mark V Studio, and MPC techniques.
• Conducted detailed reviews of P&IDs, control philosophies, and wiring diagrams, resolving inconsistencies prior to implementation.
• Developed, validated, and presented control logic in compliance with GE engineering standards.
• Engineered and tested CIMPLICITY HMI, including alarms, trends, diagnostics, and operator interfaces.
• Executed FAT, SAT, SWAT, and site commissioning; resolved punch points and ensured smooth startup.
• Ensured compliance with commissioning KPIs, safety procedures, and quality standards, achieving zero critical incidents.
• Captured and shared lessons learned across projects to improve engineering and commissioning efficiency.

Project 2: Power Plant DCS Migration (Yokogawa → GE Mark VIe)

• Led full-scale DCS migration, integrating GE Mark VIe with Rockwell Allen-Bradley PLC systems for BOP and HRSG applications.
• Converted Yokogawa control logic into Mark VIe function blocks, ensuring alignment with multi-vendor system architecture.
• Developed multi-platform control logic using Ladder Logic, Structured Text, and FBD.
• Led a team of 5 engineers across I/O mapping, design reviews, panel verification, and testing activities.
• Designed HMI/SCADA graphics, alarm management systems, and diagnostic dashboards for improved plant visibility.
• Planned and executed FAT/SAT cycles, resolved technical issues, and achieved full customer acceptance.
• Delivered comprehensive documentation including control narratives, test procedures, commissioning reports, and validation documents.
• Coordinated with global stakeholders and engineering teams to ensure timely issue resolution and project delivery.
• Achieved zero unplanned outages during system cutover, ensuring high customer satisfaction.
• Spearheaded the use of GE Vernova AMP AI platform for plant simulation model development and I/O engineering automation, achieving 3–4 weeks reduction in project timelines and enhancing overall engineering efficiency.

Project: 180 MW Thermal Power Plant
Systems: TOSHIBA TOSMAP DCS | GE Mark VIe Turbine Control System

• Worked as DCS Engineer for a 180 MW power plant, responsible for commissioning, startup, and operational support of TOSHIBA TOSMAP DCS and GE Mark VIe TCS.
• Performed end-to-end DCS commissioning activities, including system installation checks, I/O loop checking, signal validation, interlock testing, logic verification, and functional testing.
• Executed hot, warm, and cold startups, supporting safe synchronization, load ramp-up, and stable unit operation in coordination with operations and OEM teams.
• Carried out DCS configuration, control logic verification, alarm management, and HMI validation, ensuring compliance with control philosophy and plant operating standards.
• Undertook advanced TOSMAP DCS training at Toshiba Fuchu Complex, Japan, gaining in-depth knowledge of DCS architecture, startup logic, and simulation-based testing.
• Supported field instrumentation checks, calibration verification, and signal troubleshooting during commissioning and operation phases.
• Coordinated with electrical, mechanical, and OEM teams during pre-commissioning, commissioning, and performance testing activities.
• Participated in SAT, performance guarantee tests, and reliability runs, ensuring system stability and adherence to contractual requirements.
• Provided round-the-clock DCS operational support, fault diagnosis, and corrective action during initial plant operation and stabilization period.
• Assisted in operator training, procedure development, and startup optimization, contributing to reduced startup time and improved plant availability.

Project: 2 × 350 MW | System: Harbin Steam Turbine DCS

• Led DCS commissioning and startup activities for Harbin steam turbine systems, including logic validation, interlock checks, alarm verification, and synchronization support.
• Coordinated with OEMs and site teams during pre-commissioning, commissioning, and performance trials, ensuring smooth startup and stable turbine operation.

Project: 180 MW | Systems: Emerson DCS (Boiler), Siemens PCS7

• Executed DCS commissioning, loop checking, and control logic validation for boiler and BOP systems using Emerson DCS and Siemens PCS7 platforms.
• Supported startup, tuning, troubleshooting, and field instrumentation coordination, contributing to reliable plant operation and successful project commissioning.