PLC, HMI & SCADA
Allen-Bradley ControlLogix and CompactLogix, Siemens S7, OMRON, WinCC, IEC 61131-3 programming and ISA-88 control strategies.
Automation engineering
Amal Suresh Kumar.
Automation engineer.
Five years of PLC and HMI/SCADA experience, with work spanning control architecture, industrial networks, commissioning and OT cybersecurity practices.
Senior Automation Engineer · Automation ConsultantKerala, India · Open to employment and consulting
PLC & SCADA SYSTEMSINDUSTRIAL NETWORKSFAT / SAT & COMMISSIONINGOT CYBERSECURITY
Technical expertise
From logic to live operation.
Hands-on engineering across control systems, plant connectivity, validation and secure operations.
Architecture & industrial networks
PLC–HMI–SCADA integration, centralized control architectures, EtherNet/IP, ControlNet, Profibus, Profinet and Modbus.
Commissioning & validation
FAT/SAT, control logic verification, I/O checks, loop testing, tuning, parameterization, troubleshooting and performance verification.
OT cybersecurity
IEC 62443 principles, segmentation, defense-in-depth, secure remote access, RBAC, hardening, risk assessment, backup and disaster recovery.
Engineering documentation
Functional Design Specifications, control narratives, P&IDs, I/O lists, electrical schematics and vendor documentation reviews.
Engineering & programming tools
AutoCAD, MATLAB, MathCAD, Java and Python for engineering, modelling, calculations and application development.
Selected work areas
Practical industrial applications.
International commissioning leadership, supported by project documentation and photographs, alongside machine and utility automation experience.
Featured commissioning project / Algeria
Plaster plant commissioning
Commissioning work at SARL Plâtrière d’Oggaz, Algeria, with a documented plant design rating of 1,000 tonnes/day.
I led a 20-person multidisciplinary team during commissioning. The project has been handed over.
- Plant design rating
- 1,000 tonnes/day
- Team led
- 20 personnel
- Project outcome
- Handed over
My responsibility
Multidisciplinary team leadership during plant commissioning, coordinating 4 electrical personnel, 2 mechanical personnel and 14 workmen.
Plant process scope
Storage and crushing, grinding/calcination, homogenization, rotary drum cooling and material transfer.
Documented controls
Siemens S7-300 systems serving quarry handling, the circular stockyard and grinding/calcination.
Explore the documented control architecture
Quarry handling
CPU 314C-2 PN/DP; crusher, feeder and conveyor sequencing, motor control and HMI status/alarm functions.
Circular stockyard
CPU 315-2 PN/DP; stacker/reclaimer sequences, motor calls and encoder management.
Grinding / calcination
CPU 317-2 PN/DP; motor/VSD control, analog processing, PID, alarms and PROFIBUS functions.
Architecture summarized from project documentation. The design rating is not a claim of achieved production. System scope does not imply personal authorship of every control program.
From the project site
Additional engineering experience
Hydraulic presses & tire building machines
Development, commissioning and optimization of machine control applications, including multi-axis servo control.
Oil distribution & cooling water systems
Control engineering for centralized oil distribution, cooling-water management and process-control applications.
OEM controls & connected architectures
Modernized OEM control programs, developed centralized architectures and integrated MES data acquisition.
Consulting focus
Engineering support for your next project.
Open to consulting enquiries across the following areas. Scope, deliverables and site requirements can be discussed for each engagement.
PLC, HMI & SCADA engineering
Control application development, machine sequencing, visualization and integration with industrial networks.
Commissioning & troubleshooting
Control system validation, FAT/SAT support, fault investigation, I/O and loop checks, and multidisciplinary commissioning coordination.
Architecture & engineering reviews
Control philosophies, FDS, network designs, I/O documentation and practical OT cybersecurity considerations.
A clear path from requirements to handover
Requirements review → Scope and deliverables → Engineering → Testing and commissioning → Documentation and handover
Professional experience
Engineering across the lifecycle.
Experience spanning engineering design, development, integration, testing and site delivery.
2026 — Present
Automation Consultant
Plant Supervision India Pvt Ltd
- Led a 20-person multidisciplinary team during plaster plant commissioning in Algeria; project handed over.
- Lead engineering and design for PLC and SCADA architectures and application development.
- Review control philosophies, FDS, network designs, I/O databases and vendor documentation.
More about this role
Develop and integrate PLC, HMI and SCADA applications using IEC 61131-3 practices. Coordinate multidisciplinary engineering and support schematic design, calculations and modelling with MATLAB, MathCAD and AutoCAD.
2023 — 2026
Automation Engineer
Aleb Automation
- Led projects and developed control architectures from initial design through commissioning.
- Delivered machine and utility applications with PLC, HMI, SCADA and industrial network integration.
More about this role
Designed and validated Profibus, Profinet and Modbus architectures. Developed ISA-88-aligned applications, performed tuning and validation, and prepared schematics, P&IDs, I/O lists and project documentation.
2022 — 2023
Project Engineer (Deputed)
Diligent Automation Pvt Ltd
- Programmed and commissioned ControlLogix, CompactLogix and Siemens S7 systems.
- Supported OEM modernization, MES data acquisition and IEC 62443-aligned OT practices.
More about this role
Worked on sequencing, motion control and recipe management. Supported FAT/SAT by verifying logic, communications, redundancy, alarms, secure configurations and recovery procedures.
2021 — 2022
Technical Apprentice — Automation & Process Control
NLC India Limited
- Received hands-on training in control systems, DCS fundamentals and power and utilities automation.
- Assisted with PLC logic, commissioning, I/O checking, loop testing and field instrument validation.
About
A systems approach.
A practical mindset.
I am a Senior Automation Engineer and Automation Consultant with hands-on experience in industrial control systems, automation architecture and engineering delivery.
My work connects control logic, industrial networks, field equipment and documentation, with a focus on commissioning, validation and OT cybersecurity practices.
Diploma in Instrumentation EngineeringState Board of Kerala
LanguagesEnglish · Malayalam · Hindi
French — intermediate
Tamil — spoken
French — intermediate
Tamil — spoken
Current roleAutomation Consultant
Plant Supervision India Pvt Ltd
Plant Supervision India Pvt Ltd
Employment & consulting
Let’s talk about your requirements.
Based in Kerala, India. Open to employment opportunities and consulting enquiries in automation and control systems.
Full professional profile
Take a closer look at my experience.
Download my CV for employment history, technical skills and education.