Pradip Balaji Sanap

Results-driven Digital Solution Specialist with over 7 years of experience in MES/MOM, SCADA, and Historian solutions for Cement, Mining, and Pharma industries. Expertise includes IT/OT architecture design aligned with ISA-95 and L1-L2-L3-L4 architecture. Led global MES upgrades, virtualization deployments, and secure OPC-based integrations while managing project execution and stakeholder coordination.

• Adani All Cement Plants Tis Upgradation, Lead Engineer (Onsite), Executed upgrade of ABB Knowledge Manager from 9.2 to 10.1, ensuring seamless migration and minimal downtime., Deployed virtual infrastructure using Hyper-V on HP Server and provisioned Windows Server 2025 environment., Integrated DCS, PLC, and laboratory systems with KM for centralized monitoring and reporting., Configured Matrikon OPC Tunneler enabling communication via OPC UA, DA, AE, and HDA protocols., Lead Oracle Database upgrade from 12c to 19c, including report migration and validation., Implemented FTP-based lab data integration and automated workflows., Directed UAT execution and end-user training, ensuring successful go-live and customer satisfaction.
• ABB MES Knowledge Manager Installation, CMS, Malaysia, Lead Engineer (Onsite), Lead end-to-end implementation of ABB Knowledge Manager across two CMS plants, integrating Siemens PLCs via Kepware., Designed and deployed Kepware OPC Server, enabling seamless PLC communication through Siemens TCP/IP Ethernet and secure data transfer using OPC UA & OPC DA., Developed advanced Operational, Production, Maintenance, and Stop Log reports to enhance plant performance monitoring., Spearheaded UAT execution and end-user training, ensuring successful project delivery and customer satisfaction.
• ABB MES Knowledge Manager Installation, DCM Sugar All Four Units, Lead Engineer (Onsite), Visited all four Sites for survey, and Prepared FDS Documents and project commissioning Planned., Implemented RAID configuration on Dell Server and installed Windows Server 2022 Standard., Deployed and configured ABB Knowledge Manager and ABB Historian in production environment., Designed IT/OT architecture in coordination with plant stakeholders and configured OT-side firewall for secure network segmentation., Designed and supported IT/OT architecture integrating SCADA, PLC, RTU, and MES systems., Configured communication between OT devices and IT systems using OPC., Managed network segmentation (VLANs, Firewalls) for secure IT-OT integration., Coordinated with IT and plant teams for secure data flow from shopfloor to enterprise systems., Architected plant-wide data acquisition by integrating DCS I/O signals into ABB Historian and synchronizing with KM database for enterprise reporting and dashboards., Developed advanced Operational, Production, Maintenance, Dashboard, and Stop Log reports to improve performance visibility and decision-making., Lead UAT execution and end-user training, ensuring smooth commissioning and customer satisfaction.
• ABB MES Knowledge Manager Upgradation, Arkan Cement, UAE, Lead Engineer (Onsite), Lead upgrade of ABB Knowledge Manager from version 9.2 to 10.0, ensuring seamless migration and system stability., Deployed virtualized infrastructure using Hyper-V on HP ProLiant servers, enhancing scalability and performance., Integrated DCS, PLC, and laboratory equipment with Knowledge Manager for centralized data management., Established secure communication between DCS and KM using OPC UA, OPC DA, OPC AE, and OPC HDA protocols., Upgraded Oracle Database from 12c to 19c, including migration of existing reports and database objects., Implemented FTP integration for laboratory data transfer., Configured SMTP services for automated report emailing and notifications., Executed UAT and delivered customer training on new features and system enhancements.
• ABB MES Knowledge Manager Upgradation, Siam City Cement, Thailand, Lead Engineer (Onsite), Lead upgrade of ABB Knowledge Manager from 9.2 to 10.0, ensuring seamless transition and system stability., Deployed virtualized infrastructure using Hyper-V on HP ProLiant servers, enhancing scalability and performance., Integrated DCS, PLC, and laboratory equipment with Knowledge Manager for centralized data acquisition and monitoring., Established DCS connectivity using OPC UA, OPC DA, OPC AE, and OPC HDA protocols., Upgraded Oracle Database from 12c to 19c, including migration of existing reports and database validation., Implemented FTP-based lab data integration and configured SMTP services for automated report emailing., Executed UAT and delivered customer training on new features and system enhancements.
• L2 Integration & Centralized Data Acquisition System Configuration, Dr Reddy, Vizag & Himachal Pradesh, Executed Level-2 (L2) integration of shop-floor machines (Injectables, Blender, Sterilizer, FBD, RMG, Ampoule, etc.) into the CDAS system., Implemented CDAS as an open, MES-agnostic solution, ensuring seamless integration with any MES platform., Centralized data acquisition from PLC/DCS/HMI via Kepware and integrated with GE Historian, GE iFIX, and GE Webspace., Developed iFIX SCADA graphics, configured Historian, and deployed Webspace for remote monitoring., Designed Batch Report templates and coordinated with the software team for customized report development as per customer requirements., Performed validation activities (IQ, PQ, SAT) and prepared comprehensive configuration and validation documentation.
• Collection of GE Historian Data to OSI PI, Dr. Reddy, Himachal Pradesh, Installed and configured GE Historian within a centralized data acquisition system, integrating shop-floor data via PTC Kepware and Kepware Collectors., Enable transfer of real-time and historical data from GE Historian to OSI PI using OPC HDA protocol., Configured OSI PI system with OPC DA (DCOM) communication settings., Created and managed comprehensive tag database in OSI PI for structured data organization and monitoring.