ASHOK KUMAR

Operations Associate

New Delhi, Delhi, India7 yrs 7 mos experience
Most Likely To SwitchHighly Stable

Key Highlights

  • Led digital transformation initiatives in petrochemical environments.
  • Developed predictive maintenance models using AI/ML.
  • Strengthened cybersecurity posture for critical control networks.
Stackforce AI infers this person is a Cybersecurity and Automation Specialist in the Petrochemical industry.

Contact

Skills

Core Skills

Ot CybersecurityDigital TransformationEnvironmental MonitoringPolymer Production

Other Skills

ABB 800xAAI/ML-based solutionsAlarm ManagementAnalog Signal ProcessingArduinoAtmel AVRBattery Electric Vehicle (BEV)CCSCoDeSysContract ManagementControl EngineeringControl System IntegrationControl logixCyber OperationsCyber Threat Intelligence (CTI)

About

Process Automation Manager at GAIL (India) Limited with over a decade of experience driving digital transformation in complex petrochemical environments. I specialize in control engineering, IIoT architectures, and Industry 4.0 implementations—leading projects that integrate smart instrumentation, distributed control systems, and real-time data platforms to boost operational efficiency, safety, and reliability. I manage cross-functional teams and oversee automation initiatives from requirements gathering to system commissioning. My hands-on expertise spans DCS/PLC configuration, SCADA integration, and network segmentation for cyber-secure architectures. Passionate about AI/ML and generative AI, I have developed predictive maintenance models using Python, implemented anomaly-detection algorithms with high accuracy, and deployed process optimization tools that reduced energy consumption. I collaborate with data scientists and field technicians to translate real-time sensor data into actionable insights, supporting proactive decisions and reducing unplanned downtime. With certifications in CompTIA Security+ and CAP-ISA, I champion “security-by-design”—conducting risk assessments, vulnerability analyses, and embedding access controls to safeguard critical control networks. My initiatives have strengthened GAIL’s cybersecurity posture, ensuring compliance with IEC 62443 standards. An active thought leader, I have presented at India Energy Week and industry forums on topics such as Digital Twin development, advanced data analytics, and autonomous process adjustments driven by self-learning algorithms. I have authored white papers on integrating cloud-based analytics platforms with on-premises control systems. Collaborating with academic institutions and industry consortia, I explore advances in edge computing, next-generation sensor technologies, and resilient automation strategies. My recent work includes piloting an edge-to-cloud predictive quality control system, which improved gas purity consistency. Committed to mentoring future engineers, I lead workshops on cybersecurity awareness, automation best practices, and data-driven operations. Outside of work, I volunteer with local STEM education initiatives and contribute to open-source automation toolkits. Let’s connect to discuss process automation best practices, cybersecurity for critical infrastructure, or applying AI/ML in industrial settings. I’m open to knowledge-sharing and collaborative opportunities that drive innovation and sustainability.

Experience

Gail (india) limited

2 roles

Manager

Promoted

Apr 2023Present · 2 yrs 11 mos · New Delhi, Delhi, India · On-site

  • In my current role at GAIL, I am actively involved in driving operational technology (OT) cybersecurity, digital transformation, and critical infrastructure management at one of India’s premier petrochemical complexes. My key contributions include:
  • 🔐 OT Cybersecurity
  • Conducting OT Cybersecurity Risk Assessments and Vulnerability Assessment & Penetration Testing (VAPT) across the GAIL PATA Petrochemical complex.
  • Contributing to the development of GAIL’s OT Security Policies, Procedures, and the Cybersecurity Governance Framework, aligning with industry standards for robust protection of critical OT assets.
  • 💻 Digital Transformation – SANCHAY 2.0
  • Supporting the execution of SANCHAY 2.0, GAIL’s digital transformation initiative in collaboration with KPMG, aimed at enhancing IT-OT maturity across petrochemical sites.
  • Involved in evaluating and implementing AI/ML-based solutions for process optimization, operational efficiency, and cost reduction.
  • Contributing to the rollout of real-time KPI/KRA dashboards to drive data-driven decision-making for plant operations.
  • ⚙️ Operations & Maintenance (O&M) – Critical Utility Units
  • Overseeing the O&M of the Tank Farm Management System (TFMS) for hydrocarbon storage (Ethylene, Ethane, Propane, LPG, and Hydrogen),
  • N2 & Instrument Air Generation Units, Automatic LPG Loading Terminal, and the Gas-Fired Boiler Power Plant at GAIL PATA.
  • 🌿 Statutory Compliance – Environmental Monitoring Systems
  • Managing the O&M of the statutory compliance-based reporting systems for CPCB and UPPCB, involving IoT-based real-time monitoring of environmental parameters:
  • AAQMS – SOx, NOx, PM, CO₂, CO
  • EQMS – BOD, COD, TSS, pH, Treated Water Flow
  • 📑 Public Procurement & Contract Management
  • Leading procurement activities for O&M requirements, including specification preparation, vendor management, and contract lifecycle oversight for all major utility systems under my purview.
OT CybersecurityDigital TransformationAI/ML-based solutionsReal-time KPI/KRA dashboardsOperations & MaintenanceEnvironmental Monitoring Systems+2

Senior Engineer

Aug 2018Apr 2023 · 4 yrs 8 mos · New Delhi, Delhi, India · On-site

  • As a Senior Engineer at GAIL, I was responsible for the operations and maintenance (O&M) of key polymer production and packaging facilities at the PATA Petrochemical Complex, overseeing advanced international technologies and ensuring reliable, high-efficiency operations. My core responsibilities included:
  • 🏭 Polymer Packaging & Palletizing Systems
  • Managed the O&M of 13 high-capacity polymer packaging and palletizing lines from world-class OEMs:
  • STATEC BINDER, Austria
  • PAYPER, Spain
  • 🔬 Polymer Production Units – LLDPE & HDPE
  • Oversaw the Gas Phase-based LLDPE (Linear Low-Density Polyethylene) production unit licensed by UNIPOL™ Univation Technologies, USA.
  • Supervised the Slurry Phase-based HDPE (High-Density Polyethylene) production unit licensed by MITSUI CHEMICALS, Japan.
  • 📦 Polymer Pelletizing & Conveying Systems
  • Led the O&M of Pneumatic Conveying Systems by COPERION GmbH, Germany, integrated into both LLDPE and HDPE production lines.
  • Handled the O&M of LLDPE Polymer Pelletizing Units (COPERION GmbH, Germany) and HDPE Pelletizing Units (JSW, Japan) to ensure optimal throughput and pellet quality.
Polymer PackagingPolymer ProductionPneumatic Conveying SystemsHigh-capacity production lines

Gaia smart cities

Intern

Jun 2017Jul 2017 · 1 mo · Mumbai Area, India

  • Gained professional experience on the things like; Internet of things (IOT) and industrial need of iot , industrial automation, technological and analytical way to build a smart city and gained hands on experience on different type communication and embedded system technology needed to implement IOT.
Internet of ThingsIndustrial AutomationEmbedded Systems

Education

Dr B R Ambedkar National Institute of Technology, Jalandhar

Bachelor of Technology - BTech — Instrumentation and control

Jul 2014Jun 2018

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