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Job description

Job Purpose:

The Process Control Engineer is responsible for managing and optimizing process control systems in InoChem plant producing soda ash and calcium chloride through the Solvay process. This role focuses on ensuring that the plant’s automation systems, including Distributed Control Systems (DCS), Programmable Logic Controllers (PLCs), and Human-Machine Interfaces (HMIs), operate efficiently and safely. The engineer provides technical expertise in the configuration, maintenance, and troubleshooting of control systems, contributing to the plant’s operational efficiency, product quality, and compliance with safety standards.

Key Accountabilities:

Process Control System Design & Optimization:

• Develop and implement control strategies to optimize plant performance, improve product quality, and enhance process stability.
• Analyze production data to identify areas for improvement in control systems, making necessary adjustments to achieve optimal performance.
• Collaborate with process engineers to integrate process models into control system logic to improve automation and reduce variability.

System Maintenance & Troubleshooting:

• Monitor the performance of DCS, PLC, and SCADA systems to ensure smooth and reliable operation.
• Diagnose and resolve control system issues, working with operators and maintenance teams to minimize downtime.
• Implement preventive maintenance programs to ensure control systems are operating efficiently and prevent unexpected failures.

Process Control Improvements:

• Work on continuous improvement initiatives to enhance the automation and control of processes within the plant, identifying opportunities to reduce energy consumption, improve yields, and minimize waste.
• Develop new control strategies, alarm systems, and interlock logic to improve process safety and reliability.
• Provide technical expertise for control system upgrades and expansions, ensuring that changes are implemented efficiently and in alignment with plant goals.

Project Implementation:

• Participate in the design, configuration, and commissioning of new automation and control systems, ensuring they meet plant requirements.
• Support capital projects involving control systems, ensuring integration with existing infrastructure and minimal disruption to operations.
• Work closely with external vendors and contractors during system installations and upgrades, ensuring timely and quality execution.

Compliance & Safety:

• Ensure that control systems comply with industry standards and plant safety protocols, including Process Safety Management (PSM) and OSHA regulations.
• Implement safety interlocks, alarms, and emergency shutdown systems (ESD) as necessary to protect the plant, equipment, and personnel.
• Regularly review control systems for compliance with safety standards and make necessary updates or improvements.

Data Analysis & Reporting:

• Utilize data from control systems to monitor plant performance, detect anomalies, and recommend improvements.
• Provide regular reports on control system performance, downtime, and incidents, highlighting key performance indicators (KPIs) for plant management.
• Document system changes, configurations, and troubleshooting activities to maintain accurate records for future reference.

Policies & Procedures:

• Adhere to plant safety, operational, and environmental policies, ensuring all work is carried out in compliance with company standards and regulations.
• Develop and maintain standard operating procedures (SOPs) for the operation, maintenance, and troubleshooting of control systems.
• Ensure that all system modifications and updates are documented and approved according to established change management procedures.

Budget:

• Assist in the preparation and management of the control system maintenance and project budgets.
• Track and report on expenditures related to control system upgrades, maintenance, and new installations.
• Provide cost-effective solutions for maintaining and improving control systems while staying within the allocated budget.

Leadership:

• Provide technical leadership to control system technicians and other team members, offering guidance on troubleshooting, system configuration, and maintenance.
• Lead cross-functional teams in process control improvement initiatives, coordinating with engineering, operations, and maintenance departments.
• Promote a culture of safety, continuous improvement, and teamwork within the process control team.

Reporting:

• Report on control system performance, incidents, and improvements to plant management on a regular basis.
• Maintain detailed records of control system configurations, changes, and issues for future troubleshooting and analysis.
• Provide feedback and updates to stakeholders regarding ongoing control system projects and initiatives.

Communication:

• Collaborate with operators, engineers, and maintenance teams to ensure that control systems are meeting the operational needs of the plant.
• Communicate with external vendors and contractors during the installation, maintenance, or upgrade of control systems.
• Facilitate clear communication between departments on control system-related matters, including system changes, troubleshooting efforts, and safety improvements.

Note:

Only Indian Nationals can apply

Candidates minimum 10 years of experience in Soda Ash And Calcium Chloride plants should apply.

Skills

Experience:

• 10+ years of experience in process control engineering within a chemical plant or industrial manufacturing environment.
• Extensive experience in the configuration, programming, and maintenance of DCS, PLC, and SCADA systems.
• Hands-on experience with troubleshooting and optimizing control systems in a continuous process environment, preferably in the chemical or petrochemical sector.
• Experience working with process safety systems, including safety interlocks, emergency shutdown systems (ESD), and alarm management.

Skills:

• Proficiency in control system design, configuration, and programming using DCS, PLC, and SCADA platforms (e.g., Siemens, Honeywell, Rockwell Automation).
• Strong analytical and problem-solving skills, with the ability to troubleshoot complex control system issues.
• Excellent communication and interpersonal skills, with the ability to work effectively across multiple departments and with external vendors.
• Ability to manage multiple projects simultaneously, prioritize tasks, and meet deadlines in a fast-paced environment.
• Knowledge of process engineering principles and their application to control systems in a chemical production setting.
• Familiarity with control system programming languages, such as ladder logic, function block diagrams, or HMI configuration tools.Bottom of Form