Sanatkumar Ippalpalli
Engineering Consultant | Digital Twin & Process Simulation Expert | 22+ Yrs in Oil & Gas, Refining & Petrochemicals | AI/ML & Advanced Process Control (APC) | Six Sigma Green Belt
- Role
- Principal Process Engineer at Lummus Technology
- Location
- Gurugram, HR, IN
- LinkedIn followers
- 500 followers
About Sanatkumar Ippalpalli
Strategic Engineering Consultant with over 22 years of global experience driving operational excellence for the world’s energy giants, including ExxonMobil, Shell, ADNOC, OQ and Saudi Aramco.My career has been defined by bridging the gap between complex chemical physics and digital innovation. I specialize in the architecture of High-Fidelity Process Simulation (Steady-state & Dynamic), and Advanced Process Control (APC). Having led global projects at Honeywell, Yokogawa, Schneider Electric and Lummus Technology, I bring a unique perspective on integrating legacy plant systems with modern, data-driven solutions.Current Focus: I am currently evolving the traditional process modeling landscape by integrating Artificial Intelligence and Machine Learning (AI/ML) into first-principles simulation. My goal is to deliver \"Smart\" solutions that offer predictive insights beyond standard simulation capabilities.Core Expertise:Tools: Aveva Dynsim, Aspen HYSYS, Honeywell UniSim, Yokogawa OmegaLand & KBC PetroSim.Operations: Real-time troubleshooting (Startup/Shutdown), Energy Optimization, and OTS (Operator Training Simulators).Leadership: Six Sigma Green Belt, Toastmasters Certified Communicator, and a mentor to the next generation of engineers.I am passionate about converting complex plant data into actionable profitability.Led Cross-Functional Teams in the delivery of OTS and Advanced Process Control projects for MNCs including YASREF and OQ, ensuring seamless plant startups.Spearheaded Energy Optimization studies that identified significant carbon footprint reductions and cost savings using data-driven process models.Global Technical Trainer: Delivered specialized instructor-led training for Shell and ExxonMobil, bridging the knowledge gap between complex simulation and daily operations. Personally delivered 50+ technical training sessions to multi-national teams, ensuring that local engineers could independently maintain and optimize the solutions.
Experience
Principal Process Engineer
Jan 2021 — Present · IN
India Advanced Digital Applications team with Dynamic simulation and Lummus O3S (Operator Skill Sharpening Simulator) projects inhouse for internal/external clients.Expert in building high-fidelity digital twins /Simulation Models and kinetic reactor models to optimize refinery and gas processing, petrochemical plants performance (UniSim, Aveva, KBC PetroSim, Aspen Hysys).Dynamic Simulation Projects Involved:1. Ethane Crackers Flare Study, Steam Network Optimization, Troubleshooting Study, Compressor Antisurge System & Validation Study (Aveva)2. Refining Towers Flare Study (UniSim, Aveva, Aspen Hysys)3. SHU Reactors Flare Study (Aveva)4. Developed & Validated simulation model with Data Reconciliation (Aspen Hysys)5. Experience in process/system simulation of gas processing and NGL operations.Technology based Assignments1. DUQM Oman CLG licensed OTS Training (SGP, HCU, DHT, HPU)2. Lummus Licensed O3S (OTS) Projects (Crackers, PDH)Continuously collaborated, coordinated Lummus Licensed O3S projects execution inhouse.Proven track record in technical leadership, consulting and mentoring engineering teams on advanced simulation methodologies.
Education
Savitribai Phule Pune University
B.E., Chemical Engineering
1997 — 2002
NIIT Pune
Associate's degree, Computer and Information Sciences and Support Services
Indian Institute of Technology, Guwahati
Artificial Intelligence
Bharati Vidyapeeth
Master of Engineering - MEng, Chemical Engineering
ICFAI, Hyderabad
PGDBM, Management
2006 — 2008
Indian School of Business
Certification, Organizational Leadership
2020 — 2020
Find verified contacts for anyone on LinkedIn
Unifers gives sales teams verified emails and direct dials, enriched profiles, and outreach that lands in the inbox.
Free plan included · No credit card required
This profile is compiled from publicly available professional sources. Unifers is not affiliated with or endorsed by LinkedIn. Request removal of this profile.