Directing High-Capacity
Electrical & Automation in Heavy Metallurgy & DI Pipe Mills.
Deputy General Manager (DGM) – Electrical & Automation at M/S Welspun DI Pipe (Base: Anjar, Gujarat | Currently on-site in Dammam, Saudi Arabia directing electrical & automation erection for Welspun's new greenfield DI pipe plant) and formerly Assistant General Manager (AGM) at Electrosteel Group (19 years). Over 28 years commanding heavy plant electrical systems, process automation, Allen-Bradley & Siemens PLCs, DeltaV DCS, transmitters, instrumentation loops, and continuous lehr casting lines.
Murali Talikkal
Deputy General Manager (DGM) – Electrical & Automation
M/S Welspun DI Pipe • Anjar, Gujarat
Ex-AGM Electrosteel Group (19 Yrs) • The KCP Ltd • Lanco
Years Total Industry Tenure
From 1996 in instrumentation & automation to DGM
Senior Leadership Milestones
Promoted to DGM at Welspun DI Pipe (ex-AGM)
Electrosteel Group Tenure
Sri Kalahasti, AP • AGM & Sr. Manager
Complete Process Stack
DeltaV, Allen-Bradley, S7, Rosemount 3051
Career Timeline & Industrial Roles
Detailed 28-year trajectory from frontline instrumentation engineering to Senior Manager, Assistant General Manager (AGM), and Deputy General Manager (DGM) – Electrical & Automation at Welspun DI Pipe.
Deputy General Manager – Electrical & Automation
M/S Welspun DI PIPE • Full-time
Directing plant-wide electrical distribution, instrumentation infrastructure, and automated process control systems for Welspun's Ductile Iron (DI) Pipe manufacturing operations. Currently deployed on-site in Dammam, Kingdom of Saudi Arabia (KSA), spearheading the electrical erection, high-voltage substation commissioning, field instrumentation integration, and automated centrifugal casting control architecture for Welspun's state-of-the-art new Greenfield DI Pipe facility.
Concurrently governing electrical and automation engineering frameworks established across Welspun's flagship manufacturing complex at Anjar, Gujarat – orchestrating PLC/SCADA automated loops, high-voltage substations, centrifugal die drive synchronization, DeltaV DCS integration, and predictive maintenance protocols for continuous high-tonnage pipe production.
Electrosteel Group
Sri Kalahasti, Andhra Pradesh, India • Full-time
Sri Kalahasti, Andhra Pradesh, India
Steered plant operations, electrical systems, and process automation across ductile iron pipe centrifugal casting lines, cupola smelting, annealing lehr furnaces, and finishing bays. Governed multi-shift engineering crews and cross-functional maintenance with consistent high machine uptime.
Srikalahasti, Andhra Pradesh, India
Led automation and instrumentation teams in continuous process optimization, Siemens S7 PLC & WinCC SCADA architecture, instrumentation loop calibrations, and zero-defect quality management. Recognized for driving high plant reliability and successful automation upgrades.
Assistant Manager – Electrical & Instrumentation
THE KCP LIMITED • KCP Ltd (Cement Unit)
- Installation & Commissioning: Directly commanded the installation and commissioning of heavy plant machinery, electrical equipment, and utilities, conducting rigorous tests and inspections to ensure 100% operational effectiveness.
- Predictive & Preventive Maintenance: Planned and effected predictive and preventive maintenance schedules of critical equipment, significantly increasing machine uptime.
- Breakdown Trend Analysis: Proactively identified areas of obstruction and recurrent breakdowns through trend analysis, implementing systematic troubleshooting tools to rectify plant issues.
Senior Engineer – Instrumentation
LANCO INDUSTRIES LTD
Managed complete plant instrumentation, sensor loops, control valves, and process telemetry across heavy industrial operations. Maintained continuous operational readiness, calibration benches, and breakdown troubleshooting for high-temperature and high-pressure process lines.
Instrumentation – Engineer
M/s. Instech System and Automation • Near Chennai
Carried out complete end-to-end field and functional instrumentation domain responsibilities:
• Calibration, upgrade, and process modification in running plants.
• Shift scheduling, maintenance, and material procurement.
• ISO-9001:2000 quality policy execution and audit scheduling.
• Vendor works Factory Acceptance Tests (FAT) & operator training.
• Erection, calibration, testing & commissioning of Fisher-Rosemount, Honeywell, and Bells instruments.
• Cable tray fabrication, cable laying, dressing, tubing, and airline erection.
• Preparing order specs, enquiry technical evaluations, and manpower management.
Technical Domain & Instrumentation Arsenal
Hands-on technical mastery across heavy industrial automation, field transmitters, analytical analyzers, control valves, weighing platforms, and distributed control systems (DCS).
Allen-Bradley • Siemens • Honeywell
- • Allen-Bradley: ControlLogix 5555, SLC 500, SLC 5/03
- • Siemens: Siemens S7 Series (S7-300, S7-400)
- • Honeywell: LCS Series, Fail Safe Control (FSC 620-35)
WinCC • RSView • Intellution • Eurotherm
- • Siemens: WinCC SCADA Architecture
- • Rockwell: RSView32 / FactoryTalk
- • Eurotherm: T3500 SCADA
- • FLSmidth / GE: FLS (ECS), Intellution 7.0
Emerson DeltaV • TDC 3000
- • Emerson / Rosemount: DeltaV System Architecture
- • Honeywell: TDC 3000 DCS Architecture
- • Fieldbus: HART Protocol, Profibus-DP, Foundation Fieldbus
Rosemount • Yokogawa • Honeywell • ABB
- • Pressure / DP: Rosemount (1151, 3051 Series), Yokogawa, Honeywell, ABB, Fuji
- • Flow Instruments: Magnetic Flow Meters (Rosemount, Bells), Orifice runs, Vortex
Masoneilan • El-O-Matic • Fisher • pH • O₂
- • Control Valves: Masoneilan RK valves, El-O-Matic, Fisher, Xomox
- • Analytical: Rosemount pH, conductivity analyzers, Rosemount Oxygen (O₂) Analyzers
Schenck • Philips GWT • Avery • Eurotherm
- • Weighing Systems: GWT (Philips), Avery, Indchem, Schenck Process, IPA
- • Single/Multi-Loop: Honeywell (UDC 3000, UDC 6000), Bells (BCE 761), Eurotherm (2408, 94E, 6382)
Liquid Iron Crucible & Magnesium Treatment Rheostat
Directing cupola liquid iron holding ladles, adjusting slag viscosity, and triggering magnesium-ferrosilicon wire feeding to transform brittle gray flake iron into ductile nodular spheroidal graphite prior to centrifugal pouring.
DGM Process Discipline: Pouring temperature must remain strictly within 1,440°C – 1,480°C to prevent premature graphite flake formation and preserve tensile elongation.
Centrifugal Die Spinning & 50G Solidification
Hot metal is injected via a longitudinal pouring lance into a water-cooled cylindrical mold spinning at 1,200 RPM, forcing liquid metal against the die walls under 50G centrifugal acceleration for defect-free wall thickness.
Centrifugal Slag Floatation
Radial acceleration drives slag and lighter impurities to the internal pipe bore for easy flushing.
Uniform Wall Thickness Precision (±0.3mm)
VFD drives synchronize carriage retraction speed with molten iron teeming volume under ISO 2531 rules.
Automated Ultrasonic Testing (AUT) & Seam Sweep
API Spec 5L and ISO 10893 require 100% automated ultrasonic testing of longitudinal and helical submerged arc welds. Inspect live ultrasonic echo waveforms with interactive defect injection.
Erection, Commissioning & Instrumentation Milestones
Authenticated large-scale engineering project deliveries spanning automated continuous annealing furnaces, heavy PLC/SCADA architectures, and utility power plant commissioning.
Annealing Furnace & Continuous Thermal Lehr Erection
Siemens S7 PLC & WinCC SCADA Architecture
Directly involved in the complete erection, instrumentation loop calibration, and cold/hot commissioning of a high-capacity continuous annealing furnace. Engineered closed-loop multi-zone thermal profiling to eliminate brittle cementite phases and guarantee pipe elongation >10%.
Erection & Commissioning of Power Plants
Associated with THE KCP LIMITED • Field of Instrumentation
Spearheaded comprehensive electrical and instrumentation erection across multi-megawatt captive thermal and utility power generation units. Governed boiler steam pressure sensors, turbine telemetry, cooling tower pumps, and high-voltage substation switchgear synchronization.
Industry 4.0 Robotics & Automated Factory Bay
Supervising continuous closed-loop automation, automated robotic SAW welding gantries, laser pipe bevel tracking, and Siemens S7 PLC / SCADA industrial architectures.
Enterprise Infrastructure & Utility Asset Management
Managing the foundation of mega metallurgical complexes—ensuring 99.8% uninterrupted power reliability, closed-circuit cooling water loops, natural gas distribution, and compressed air networks.
Captive Power & 132kV Substation
Supervising dual grid incoming feeders, high-voltage transformers, and synchronization switchgear.
Closed-Circuit Cooling Water
Governing continuous recirculating cooling water for centrifugal molds with zero liquid discharge (ZLD).
Natural Gas & BF Gas Grid
Distribution pipelines feeding continuous lehr furnaces, ladle pre-heaters, and 3LPE coating ovens.
Reinforced Yards & Rail Sidings
Reinforced high-load concrete pavement for 100-ton axle loads and dedicated gantry crane travel runways.
Plant Workforce Governance & Multi-Shift Command
Directing 1,200+ cross-functional personnel across 3 continuous shifts—uniting metallurgical engineers, certified SAW welders, crane operators, and maintenance technicians under an unbroken zero-harm culture.
Pre-Shift Line-of-Fire Stand-Downs
Mandatory hazard review and PPE certification conducted across every crew prior to machinery energization.
Multi-Skill Cross-Training Matrix
Operators certified across adjacent workstations, creating dynamic resilience against absenteeism.
Heavy Gantry Hoisting & Intermodal Freight Dispatch
Directing 35-ton dual-hoist outdoor gantry cranes, heavy C-hook lifting beams, nested pipe tier racking, and railway wagon rake loading for cross-country line pipe deliveries.
Plant-to-Port-to-Sea: Automated Pipe Dispatch Journey
Follow the automated transit cycle of 18-meter SAW and ductile iron pipes as they are mobilized from the Fabrication Bay, loaded onto Heavy Multi-Axle Flatbed Trucks, hauled over road corridors, and hoisted by Harbor Portal Cranes into ocean-going Bulk Cargo Vessels for international delivery.
DGM Intermodal Governance: Strict nesting geometries and synthetic sling padding ensure zero coating abrasion (3LPE / FBE) during long-haul highway transit and offshore oceanic roll-pitch angles.
Plant Operational Yield & Throughput Model
Simulate operational capacity, overall equipment effectiveness (OEE), and metallurgical scrap suppression to calculate bottom-line EBITDA realization and carbon abatement.
+47,600 MT
$3.81 Million
14,280 MT CO₂e
Active Industrial Shopfloor: Personnel & Autonomous Robotics
Directing collaborative human-machine operations: certified plant personnel executing quality scans, electrical calibration, and crane rigging alongside 6-axis cobots, AMR material carriers, and automated laser seam trackers.
Conducting physical ultrasonic wall thickness & circumference ovality inspections on freshly cast ductile iron pipes against ISO 2531 / EN 545 tolerances. Synchronizing live handheld readings to the central MES quality server.
Executive & Board Dialogue Desk
Inquiries are routed directly to Murali Talikkal's professional communications channel.