Senior Engineer, I-C Maintenance

Job Description

About the Job

The jobholder is responsible for providing instrument & control engineering expertise to ensure the operating condition for all respective equipment’s to support Borouge’s operations and systems in line with original equipment manufacturer’s user guide and engineering standards, and relevant ADNOC and International Standards.  This role includes; performing complex trouble shooting, root-cause failure analysis and design review to provide solutions for equipment repair; modifications to enhance equipment performance; studying equipment failure data to continually improve and implement the most appropriate maintenance strategy; advising on critical and complex jobs to ensure proper maintenance procedures are followed; and supervising the operation of instrument and control equipment in a reliable and safe manner to achieve efficient and economic performance and to meet the operations requirements.

Key Accountabilities

Maintenance Planning

• • Develop and improve predictive, preventive, and major maintenance programs for plant equipment’s & systems into the respective asset, plant, area to improve reliability based on failure history and process criticality.

  • Review preventive maintenance programs for HSECES equipment’s to ensure performance standard compliance & Minimum Assurance Task.

  • Review requirements for materials, spare parts, advice on stock levels, MRP type and material descriptions, and provide suggestions for alternatives or interchangeability to enhance reliability standard of the plant.

  • Review Bill of Material in SAP for various equipment’s for correctness and completeness.

  • Identify Obsolete systems and spare parts, plan risk mitigation & Elimination actions as per End-of-Life process and propose design changes.

• • Identify Turnaround (TA) job scope and lead major shutdown activities to ensure the timely and efficient execution of all the maintenance tasks and modification/upgrade projects related activities.

  • Display variance in Maintenance cost, control and suggest improvements in cost control.

  • Identify specific resources/services required for the reliability improvement projects. Prepare scope for placing external contracts. Support contracting and purchasing team to ensure identified resources/services are available on schedule and within the allocated budget. Monitor variance to ensure the cost incurred is in line with the approved/available budget.

  • Provide inputs for preparation of Maintenance and Capex (investment) budgets and ensure their approval by providing project scopes, project plan, estimated budget, and IRR calculations.

• • Implement reliability improvement plans and design changes in the respective plants.

  • Develop reliability improvement programs for improving MTBF of equipment’s.

  • Lead reliability improvement projects in the respective plants during Turnaround and plant operation.

  • Prepare Failure Analysis Report and recommend preventive actions for failed equipment’s.

  • Lead the root cause analysis for bad actors and recommend improvement actions to ensure plant availability & reliability.

  • Ensure all repair/modification and upgrade on all electrical equipment and system are done in accordance with international standards, relevant ADNOC policies/procedures and best practices.

  • Coordinate with procurement team to ensure spare parts are purchased as per the specifications, carry out technical evaluation of the item purchased to ensure suitability of the purchased items. Ensure workman ship in all maintenance and repair work is up to the mark and in accordance with applicable standards.

  • Coordinate all Instruments & Control System related affairs with other ADNOC Group Companies staff and within the company.

  • Develop and maintain codes of practice and ensure that the standards contained in such codes are thoroughly understood and consistently complied with.

  • Follow up and supervise the installation and commissioning of the new projects related to the instrument & control system.

  • Assist in the development of a comprehensive Maintenance Management System for all systems and equipment.

  • Ensure that operation methods and procedures are maintained by which prime consideration is given to the safety, reliability, stability, and security of the system.

• • Study equipment failure data in APMS, SAP/ ERP, or other Records to implement the most appropriate maintenance strategy.

  • Perform troubleshooting, root cause analysis and design review on equipment failures to identify corrective actions, modifications or repair required, and implement new technologies as required.

• • Provide field support and advise other Engineers, Supervisors and Technicians on critical maintenance activities to ensure proper procedures are followed.

  • Perform technical evaluation & inspection on plant equipment and spare parts to ensure it meets the pre- defined specifications.

  • Support System Engineers for maintaining DCS, ESD & MCMS system Hardware.

  • Ensure performance standard compliance and quality records generation for completed Preventive Maintenance to achieve 100% HSE.

  • Support profitability programs like Energy Optimization, flare reduction and advance process control programs.

• • Support Alarm Management and rationalization program in respective plant.

  • Supervise and control the operations of the system in close and continuous coordination with other ADNOC Group Companies’ representatives ensuring the availability according to sound Technical and Engineering Practice.

  • Follow up system constraints at all areas and coordinate with each partner for removal.

• • Develop maintenance cost improvement programs like parts refurbishment, spare parts interchangeability and in country value.

  • Identify statutory requirements coming as per the government regulation, collaborate with internal external agencies such as ADNOC, AGES, other disciplines, OEM, Suppliers, contractors, vendors, international standards /service providers to produce procedures, work instructions, checklist , lessons learnt and ensure they are followed by execution team during various maintenance activities on equipment and systems.

  • Analyze strengths and weaknesses of current maintenance approaches and develop innovative solutions to enhance reliability standards of all equipment and systems.

  • Develop marked up engineering drawings for maintenance implemented projects.

  • Provide support to EPC for implementing Minor/Medium projects in respective plant and participate in project PSSR.

  • Participate in HAZOP, SIL assessment and verification.

  • Support companies’ expansion plan and major projects, share Lesson learnt, participate in engineering reviews, FAT and SAT.

Minimum Requirements

• • Bachelor Degree in Engineering

  • Minimum 8 years of relevant experience as Instrumentation & Control Engineer.

  • Experience in the Oil & Gas or petrochemical Industry is preferred.

  • Experience in troubleshooting of Instruments & Control systems.

  • Knowledge of failure analysis and root cause analysis techniques.

  • Knowledge of international standards for Instrument & Control systems.

  • Knowledge about functional safety for process industry and prevailing standards like IEC61511 & IEC61508.

  • Knowledge of SAP maintenance related modules.

  • Knowledge of APMS software is preferred.

  • Knowledge of common control system software and communication software like MCMS, PLC/ESD, HART, DCS, AMS, Alarm Management Software, instrument calibration software’s etc.

  • Knowledge of common communicating protocols and Networking concepts.

  • Awareness about field instrument sizing techniques like valve calculations, flow sizing & DP range calculations.

  • Working knowledge on Operation & Maintenance manuals and engineering documents/drawings.

  • Knowledge of Office Software’s like Windows and Microsoft Office tools