Instrumentation Manager

Summary of the Role:

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

Responsibilities / Accountabilities:  

• Lead instrumentation and control system & automation installations maintenance to ensure the dependable, efficient & 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 & classroom Training, awareness and development of instrumentation team & 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 & certificates and continuous improvements.
• Plan as well as track & 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 & 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 & 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 & 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 & 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 & 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 & 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 & risk management.
• Must have experience on Capex & 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 & 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.