ANIL KUMAR GANGWAR
Fujairah,United Arab Emirates
Summary
Dynamic Electrical & Instrumentation Engineering Leader with extensive experience in delivering automation and field instrumentation solutions across large-scale industrial projects.
Specialized in ABB 800xA DCS and Siemens TIA Portal, with strong expertise in industrial networks including Profibus, Profinet, and Modbus.
Proven track record in leading end-to-end EPC project execution, including field instrumentation selection, installation, calibration, loop checking, and commissioning for cement, Steel, Oil & Gas and heavy industrial plants.
Experienced in managing cross-functional teams, contractors, and vendors within multicultural environments, ensuring compliance with international standards, HSE regulations, and project timelines. Strong capabilities in technical bid evaluation, vendor negotiations, and stakeholder coordination to achieve cost-effective and high-quality project delivery.
Demonstrated leadership in shutdown planning and execution, maintenance strategy development, and implementation of preventive and predictive maintenance programs to maximize plant availability and reliability. Expert in developing control philosophies, interlocks, and cause & effect matrices, ensuring safe, efficient, and optimized operations.
Focused on driving digital transformation and continuous improvement through advanced automation technologies, enhancing operational efficiency, reducing downtime, and delivering sustainable value to organizations.
Overview
1
1
Certification
4
4
years of post-secondary education
13
13
years of professional experience
Work history
Senior Engineer – Electrical & Instrumentation
JSW Cement FZC
Fujairah
2020.02 - 2026.04
- Lead instrumentation and automation activities for clinker and cement production facilities.
- Completed automation systems for 4000 TPD cement production line including DCS, IMCC and drives.
- Successfully commissioned Polycom mill (ThyssenKrupp) and good knowledge of hydraulic systems, including hydraulic valves and mill start/stop logic sequences.
- Successfully executed erection, testing, and commissioning of stacker and reclaimer machines; established wireless communication with plant DCS system with programming and logic development.
- Handled commissioning and maintenance of systems including gas analyzers, stack monitoring system, weigh feeders, kiln feeding system (SFM), MV VFDs (Hitachi), belt weighers, bin weighing systems, DCS controllers and I/O panels, UPS systems, coal dosing system (Pfister Panel), nucleonic gamma systems, field instruments, magnetic separator panels, metal detectors, baghouse instrumentation and PLC panels, bulk loading PLC systems, and weighbridge systems.
- Good knowledge of programming, parameterization, and troubleshooting of ABB UMC100 and Siemens SIMOCODE motor management systems.
- Proficient in PROFIBUS DP communication setup, including GSD file integration, node addressing, communication diagnostics, and troubleshooting between field devices and PLC/DCS.
- Review and approval of various project drawings IO list, I&C Cable Interconnection Drawings, cable termination schedule, UPS drawing, DCS network architecture, IMCC drawing, CCTV drawing, PLC Controller and IO panels drawing, gas analyzer drawing etc.
- Prepared BOQ, scope of work, and technical bid documents for E&I supply and erection packages; served as the single point of contact from the E&I side for the 4000 TPD Cement Clinkerization Plant Project.
- Participated in detailed engineering including review and approval of Electrical & Instrumentation drawings.
- Conduct technical evaluation and tender finalization for motors, LV&MV VFDs, transformers, UPS, Gas analyzers, CCTV, PA system, Expert optimization system, sub control system and DCS systems.
- Collaborate with the Project Manager to finalize project plans and lead technical kickoff meetings.
- Coordinate with international OEM vendors including automation suppliers and EPC contractors.
- Supervise installation, testing and commissioning of field instruments and various control systems.
- Manage plant shutdown maintenance and troubleshooting of automation and instrumentation systems.
- Create maintenance schedules at a daily, weekly and monthly basis for instrumentation maintenance activities in coordination with planning and plant maintenance teams
- Utilized SAP (PM module) for maintenance work orders, equipment history tracking, and spare parts management in plant operations.
- Ensure strict compliance with plant safety procedures and permit-to-work (PTW) system during maintenance and shutdown activities.
- Follow Lockout-Tag out (LOTO) procedures to ensure safe isolation of electrical and mechanical equipment.
- Ensure compliance with PPE requirements and safe work practices during plant operations and maintenance.
- Performed Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) of DCS, MV/LV VFDs, signal cables, UPS systems, and IMCC panels, ensuring proper integration, functionality, and compliance with project specifications.
- Finalization of control room, electrical load centers design and layouts.
Assistant Engineer – Instrumentation (Projects)
Sanghi Industries Limited
Gujarat
2018.04 - 2020.02
- Worked on 10,000 TPD cement plant expansion project including automation system design, engineering & commissioning.
- Prepared IO lists, PLC/DCS architecture, cable schedules and control system documentation.
- Commissioned ABB 800xA DCS for Cement plant & WHRS plant.
- Integrated automation networks including Profibus, Profinet, Ethernet and Modbus.
- Monitor and control instrumentation systems to minimize emissions and losses.
- Ensure compliance with environmental standards related to process monitoring.
- Implement energy efficiency initiatives to minimize resource consumption and environmental impact.
- Support continuous improvement initiatives and RCA (Root Cause Analysis).
- Maintain daily instrumentation logs and update maintenance records.
Assistant Project Engineer – Instrumentation
Engineering Projects India Ltd (EPIL)
New Delhi
2015.04 - 2018.03
- Worked on SAIL Bhilai Steel Plant 7 MTPA expansion project focusing on material handling automation and instrumentation system.
- Commissioned PLC/DCS systems including ABB, Siemens and Rockwell.
- Developed control logic and interlocking for conveyor automation systems.
- Installed and commissioned MV/LV VFD systems integrated with plant PLC systems.
Commissioning Engineer
GAIL India Ltd
Pata Auraiya U.P
2014.11 - 2015.04
- Executed instrumentation commissioning in GAIL gas processing unit expansion project.
- Verification of instrument installation against P&ID, hook-up drawings, and datasheets.
- Checking instrument tag numbers, ranges, and specifications.
- Inspection of impulse lines, tubing, fittings, and supports.
- Verification of instrument mounting and accessibility.
- Stroke checking of control valves and motor-operated valves.
- Verification of fail-safe positions (fail-open / fail-close).
- Testing valve response and feedback signals.
- Checking HART/Fieldbus communication where applicable.
- Configuration and parameter verification using handheld communicators.
- Calibration of transmitters (pressure, flow, level, temperature).
- Calibration of control valves, positioners, and I/P converters.
- Functional testing of switches, analyzers, and field indicators.
- Verification of alarm and trip settings.
- Knowledge of INSTRUCALC and CONVAL software for instrumentation calculations and valve sizing.
- Experience in control valve CV calculation and sizing based on process parameters.
- Preparation of field instrument datasheets as per project and process requirements.
Instrument Maintenance Engineer
Lupin Limited
2013.10 - 2014.10
- Skilled in calibration and troubleshooting of various field instruments such as pressure, temperature, flow, and level transmitters.
- Familiar with instrument loop checking, commissioning, and documentation.
Education
Bachelor of Technology (B.Tech) - Electronics & Instrumentation Engineering
Hindustan College of Science & Technology
Uttar Pradesh, India 2009.08 - 2013.08
Skills
- ABB 800xA DCS programming and graphics development
- Siemens TIA Portal programming and graphics development
- Industrial Networks: Profibus, Profinet, Modbus, Ethernet/IP, IEC61850, Foundation Fieldbus
- Erection, Testing & Commissioning of cement plant Projects
- IMCC & Intelligent Motor Control (UMC100, E300, LTMR and Simocode)
- MV/LV VFD Systems (ABB ACS880 and MV drives)
- Weighing Systems (Schenck INTECONT Weigh Feeders, SFM, Bin weighing & Belt Scales)
- Cement Plant Automation & Process Control
- Technical Tender Evaluation & Vendor Coordination
- Shutdown Planning & Maintenance Management
- EPC Project Execution & Site Supervision
- Industrial Networking & Control Architecture
- Instrument Loop Diagrams, Instrument Level Sketches
- Process & Pneumatic Hook-ups
- Interlock Logic Diagrams & Functional Schematic Diagrams
- Cable Schedule, JB Schedule & Wiring Drawings Preparation & Review
- Cable Routing Layout & Instrument Layout Preparation & Review
- Installation Drawings Review and Engineering Inputs
- ABB 800xA DCS (control builder, engineering workplace) programming and graphics development
- EcoStruxure Control Expert
- Studio 5000 Logix Designer
- SIMOCODE ES (TIA Portal)
- FIM UMC Edition software
- Industrial Communication Protocols
- INSTRUCALC and CONVAL software
- Profitrace tool
- Schenck Weighing Systems software
- ABB ACS880 Drives
- Hitachi Drives M Tool Software
- MS Office
Certification
- Completed one-month summer industrial training at Indian Farmers Fertilizer Cooperative Limited in 2012, gaining exposure to fertilizer plant operations, industrial instrumentation, process control systems, and maintenance practices.
- Successfully completed the Highfield Level 3 training on Emergency First Aider Plus Defib & CPR from Highfield Qualifications in 2026.
- Completed one-week training program on PLC and HMI systems from Sofcon India Pvt. Ltd. in 2012, including basic PLC programming, HMI configuration, and industrial automation concepts.
- Successfully completed a 10-day professional communication and soft skills development program from Sharda Group of Institutions in 2010, focused on communication, teamwork, presentation, and interpersonal skills.
PERSONAL DETAILS
Languages: English, Hindi
KEY PROJECT ACHIEVEMENTS
Completed 4000 TPD Line-2 Cement Plant Project at JSW Cement UAE including automation and instrumentation systems.
Successfully commissioned Polycom mill (ThyssenKrupp) and good knowledge of hydraulic systems, including hydraulic valves and mill start/stop logic sequences.
Led commissioning of ABB 800xA DCS with integration of IMCC, VFD and sub-PLC systems.
Completed 10,000 TPD Line-2 Cement Plant Project at Sanghi Cement Gujarat including automation and instrumentation systems.
Commissioned WHRS automation system using ABB 800xA DCS in cement plant expansion project.
Participated in Bhilai Steel Plant 7 MTPA expansion project automation system under EPIL. Commissioned multiple conveyor automation systems and material handling PLC systems.
Executed instrumentation commissioning in GAIL gas processing unit expansion project., Implemented multiple engineering initiatives to optimize power consumption and enhance plant productivity.
Participated in HAZOP, PHA studies, SIL assessment, and LOPA activities for Electrical & Instrumentation systems to ensure process safety and compliance.
TOTAL EXPERIENCE
12+ Years of Professional Experience in Electrical & Instrumentation Engineering
Timeline
Senior Engineer – Electrical & Instrumentation
JSW Cement FZC
2020.02 - 2026.04
Assistant Engineer – Instrumentation (Projects)
Sanghi Industries Limited
2018.04 - 2020.02
Assistant Project Engineer – Instrumentation
Engineering Projects India Ltd (EPIL)
2015.04 - 2018.03
Commissioning Engineer
GAIL India Ltd
2014.11 - 2015.04
Instrument Maintenance Engineer
Lupin Limited
2013.10 - 2014.10
Bachelor of Technology (B.Tech) - Electronics & Instrumentation Engineering
Hindustan College of Science & Technology
2009.08 - 2013.08