Instrumentation Manager

Summary of the Role

Lead and maintain plant and utilities instrumentation, control systems and improvements, ensuring plant and instrumentation upkeep to support manufacturing activities with compliance to all related legal and Lubrizol HSES policies and requirements and developing talent within team.

Responsibilities / Accountabilities:

• Lead instrumentation and control system and automation installations maintenance to ensure the dependable, efficient and cost-effective operations at site.
• Lead modification and capex processes, so as to support manufacturing in achieving production plan.
• Manage and improve Siemens PCS 7 Based DCS and other control systems company wide. Preparation and modification of master SCADA/DCS logic, follow Lubrizol standards and guidelines in installation and operation of control systems including PI server.
• Identification, planning and procurement of spares, indigenous development of spares, AMC identification and finalization to have minimum breakdown time.
• Maintenance of utility instrumentations to achieve optimum efficiency and ensuring uninterrupted supply of utilities inline to plant requirement.
• Continuous on job and classroom Training, awareness and development of instrumentation team and contractors to identify hazard, elimination / mitigation of the same, following process/plant safety policies during all work execution as well as legal compliance.
• Development of indigenous vendors, vendor management and handling.
• Adherence to ISO system and maintaining records and documents as per ISO as well as department functional requirement like calibration records, test reports and certificates and continuous improvements.
• Plan as well as track and Monitor Opex expensed vs. budgeted.
• Lead and execute activities related to detailing of control valve, relief valve, breather valve, on-off valve selection and sizing, orifice selection and sizing, loop drawing, logic diagrams, cause and effect diagrams, P&IDs, Relay logic in improvement etc.
• Maintenance of all Fire Alarm & Detection Systems at site.
• Lead the project activities for instrument engineering, installation, commissioning and trial of instrument installation on site.
• Manpower management and team development for complete plant functionality and as well as future roles.
• Ensuring 100% legal compliances applicable to department based on Factories act and other statutory bodies.
• Failure analysis and implement CAPA, Downtime control, Spares management, Equipment reliability study.
• Execution of Operational excellence projects and standardization projects at site.

Requirements (education, experience, competencies, and specific job requirements):

Education / Certification:

• Minimum qualification: B.E./B.Tech. Instrumentation and Control Engineering
• Preferred qualification/Certification: RCA

Experience and Skills:

• Minimum 10-15 years’ experience in chemical/petrochemical plants maintenance and reliability.
• Work experience of at least 2-3 years as team leader / people manager position in instrumentation function at MNC work environment.
• Exposure to detailed Control system activities DCS/PLC/SCADA basic philosophy, architecture, logic development, troubleshooting, FAT/SAT.
• Experience on Siemens PCS 7 DCS/SCADA system. Capabilities of Downloading and uploading the program on DCS, PLC systems, logic analysis and troubleshoot.
• Knowledge of instrumentation and control cabling, Manufacturing automation (various conveying and packing systems).
• Hands on experience on instrument maintenance of various global make like Emerson, E&H, Siemens.
• Knowledge of industry best practices for Preventive and Predictive maintenance related to instrument and systems.
• Well conversant with various codes, protocols, and languages for instrumentation.
• Hands on experience of working in SAP for maintenance and project management.
• Knowledge of industry best safety practices, SIL levels, HAZOP, as well as legal requirements for plant instruments.
• Knowledge of establishing and integrating OT/IT network.
• Must have experience on planning, scheduling and risk management.
• Must have experience on Capex and Opex management.
• Experience on contract manpower management / spare management.
• Effective communication and networking skills

Competencies for the Role:

• Driving success: Demonstrates a sense of urgency and strong commitment to achieving goals; creates effective plans that ensure deadlines and budgets are met.
• Collaboration: Build and maintain good relationship within teams as well as cross functional team to improve outcomes.
• Providing Leadership: Engage and develop capabilities by providing training, feedback, coaching, and guidance to enhance team performance.
• Communication: Communicate effectively and timely.

Job Segment:

Instrumentation, Compliance, CAPA, Controls Engineer, Risk Management, Engineering, Legal, Management, Finance