Senior Engineer, I-C Maintenance (DCS)

Job Purpose

The jobholder is responsible to provide with the DCS Expertise in the Instrumentation & Control Engineering to ensure the operating condition for all respective equipment 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 is accountable for, analysing Operation issues, suggest design changes/corrections & configure/Implement DCS modifications related to logics, graphics, hardware's, other system interfaces to ensure safe operation of the plant. Maintain the backups for DCS Systems, monitor, maintain and carry out improvements in DCS systems to achieve optimum availability. Obsolescence study and budgeting for DCS Systems maintenance and replacement/ upgrades / migration. Design and implement ICS systems improvements in the existing plant along with Tie-ups and support to Mega Projects.

Key Accountabilities

Operation Support

• Analyze operation issues, Investigate Plant events/Incidents along with Operation engineers, Identify design and configuration Issues/Improvements in DCS logics, Controls, Sequences, graphics, Operational Interfaces and hardware’s.
• Monitor & Troubleshoot system interfaces like ESD, F&G, Analyzers, IPCS, NMR, TIBCO, LIMS, Batch Tracking, SAP and Historian with DCS to ensure smooth operation across all Borouge Plants.
• Assist Operations for root cause analysis during unexpected plant disturbance and designing logics to rectify automation related issues, to enhance system reliability and support Borouge's operational efficiency.
• Collect and Organize Alarm Data to help Operation Team to measure and control the Alarm KPIs.
• Provide round-the-clock support to ensure continuous operations and minimize downtime.
  
  

Maintenance Planning and System Improvements

• Diagnose and troubleshoot the faults related to DCS operator stations, servers, controllers & I/O's, to maintain system integrity and prevent disruptions.
• Upgrade and replace the Hardware and software's for obsolete DCS system in-house without operational disturbance and minimal vendor support, to keep systems current and functional.
• Perform regular System backup and restore the DCS system during stations or server failures, to protect data integrity and support recovery processes.
• Attend operational issues related to automation systems swiftly by proposing and implementing logic, graphic, hardware, and interface modifications without causing plant disturbance, to maintain system functionality and support Borouge's operational reliability.
• Lower the downtime of the plant because of DCS system or logic issues, to enhance system reliability and support Borouge's maintenance strategy.
• Keep the DCS system secure by regularly updating and upgrading the software and hardware, and promptly attending automation issues during on-call 24/7 on rotational basis, to ensure continuous operations and minimize disruptions.
• Administer support contracts with various OEMs to obtain timely support for all the systems, to ensure operational continuity and support Borouge's maintenance strategy.
• Raise technical issues with vendors and implement recommended solutions, to address problems effectively and support Borouge's maintenance strategy.
• Coordinate routine/planned automation maintenance activities, to ensure smooth operations and support Borouge's maintenance planning.
• Prepare the purchase requests, to ensure timely procurement of necessary materials and support Borouge's operational needs.
• Support maintenance team for troubleshooting and failure investigation, to resolve issues promptly and support Borouge's maintenance response.
  
  

Reliability Support

• Ensure DCS system security from external threats by updating required software updates and patches without disturbance to plant operations, to protect Borouge's assets and maintain operational continuity.
• Review system status, diagnostic logs and troubleshoot system issues, to maintain system integrity and prevent disruptions.
• Act as DCS system focal point to ensure projects implemented by external contractors follow Borouge requirements by proper testing, to ensure project success and maintain system reliability.
• Suggest modifications for existing setup or the installation of new equipment for the improvement and modernization of the DCS system infrastructure, to enhance system capabilities and support Borouge's technological advancements.
• Review requirements for new equipment or major repairs, evaluate existing as well as new proposals and make recommendations to the section head, to ensure alignment with Borouge's strategic objectives.
• Perform obsolescence planning for upkeep of the entire system including hardware & software, to prevent outdated technology issues and ensure system effectiveness.
• Ensure operations and maintenance targets of DCS infrastructure are met, to achieve operational goals and support Borouge's safety and reliability.
  
  

Project Coordination

• Assist other engineers in solving technical issues, to facilitate collaboration and knowledge sharing and support Borouge's team efficiency.
• Coordinate with external engineers (RSI), EPC's and system vendors for major plant modifications or additions, to ensure avoiding disturbance to running plants and support project success.
• Participate in Design Workshops, Prototype/Template Validation and standardization, Testing (FAT) participation for validation of Implementation.
• Co-ordinate with Project team for document review and comments for new Project documents.
• Collaborate with HSE and Operation Teams for Success of Alarm Management Program across Sites.
• Ensure Data-sharing protocols are followed while interfacing with Project/EPC/PMC teams.
  
  

Process Control

• Assist project team as process control expert for major and minor modifications, to ensure proper implementation as per running plant Philosophies, Standards.
• Support operation/running plant in fixing problems related to ESD and DCS application software, to maintain system functionality and support Borouge's operational reliability.
• Utilize process control expertise for related modifications and problems in the existing plant, to enhance system performance and support Borouge's continuous improvement.
• Analyze end-user requirements and implement appropriate solutions, to meet operational needs and support Borouge's customer satisfaction.
• Participate and contribute to Hazard analysis of Plant modifications involving changes in Process control strategies, changes in Interlock Logics and Sequences.
  
  

Cyber Compliance and Modernisation

• Ensure Cyber Security procedures and practices are implemented and followed in day-to-day System Maintenance Activities.
• Ensure and validate Cyber checks and control are in place while interfacing to Outside OT perimeter for Business needs.
• Modernize/Upgrade existing OT/ICSS systems to ensure Security and Cyber compliance.
• Implement latest computing technologies like Cloud/Edge hardware, Virtualization Technologies to improve carbon footprint of OT/ICSS system which eventually will contribute to decarbonization drive of Company/ADNOC.
• Learning about latest trends in OT industry and manifestation of these concepts in Operation and Maintenance improvement. Like usage of Artificial Intelligence/Machine Learning algorithms for Data contextualization Or Analyzing effectiveness of maintenance strategies implemented.
• Assist and Guide Operation Teams in application of Latest Technologies securely to improve Safety and Profitability of the Plant Operation.
• Develop and review Emergency Response plans and procedures for any kind of Cyber Breach.
  
  

Qualifications, Experience, Knowledge & Skills

• University degree in Electrical or Electronic Engineering or related discipline
• Familiar with Microsoft Office and SAP system.
• Fluency in English Language; written and oral
• Minimum 8 – 12 years of total experience in Instrumentation & Control for large plants.
• Experience in Oil & Gas or Petrochemical Industries is preferred.
• Hands on and theoretical training on installation, repair, testing and maintenance of relevant systems.
• Hands on and working knowledge on relevant systems’ configuration, network administration & maintenance, programs, sequences & logic.
• Experience in Honeywell DCS system troubleshooting and modifications
• Experience in Application Logic development, Implementation & troubleshooting
• Advanced configuration and troubleshooting skills relevant to SCADA networks such as OPC / ModbusTCP/IP & RTU communications configuration
• Hands on installation, repair, testing and maintenance of a wide range of I-C Automation systems.
• Knowledge of system diagnostic capabilities, back-up routines to be followed.
• Attention to detail. Strong analytical ability. Able to troubleshoot equipment problems and perform complex system tests.
• Experience in SAP. Documents system and EDMS, know how to find work related documents.
• Certification by professional bodies like ISA / TUV is advantage
  
  

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