Senior Maintenance Engineer - Instrumentation & Controls

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Main Responsibility/Accountabilities

• The function of the I&C Maintenance Lead Engineer is to provide front line maintenance leadership and maintenance related technical support for the Power Block facility and act as the primary contact for I&C maintenance related issues in the area of responsibility.
• Work closely with the Maintenance I&C Section Head, Technical/Engineering support groups, Plant Management, facility maintenance team and contractors, with a focus on improving equipment integrity and plant reliability at the lowest sustainable cost to JIGPC, consistent with the facility’s asset management plan.
• Work closely with the Maintenance Section Head and Planner, to help ensure planning and execution of the planned and un-planned (emergency) plant shutdowns are executed safely, efficiently, within budget and on schedule.
• Responsible for ensuring the day-to-day maintenance of the facility is completed according to the appropriate JIGPC systems and procedures, to maximize the facility reliability, whilst ensuring compliance with the JIGPC maintenance program and the plant maintenance budget.
• Responsible for the site-based maintenance personnel, including joint responsibility for their personal development and mentoring, as well as effective utilization of their skills and workmanship.

Safety

• Comply with JIGPC safety rules and regulations.
• Ensure all maintenance work is carried out according to JIGPC safety procedures, ensuring KPIs are met or exceeded.
• Actively promote and drive safety excellence for contractors and JIGPC staff, through active participation and compliance with JIGP’s safety procedures.
• Awareness of Quality, Occupational Health & Safety and Environment Management system principles.
• Ensure proper isolations are carried out before starting the maintenance activity on the respective equipment released for maintenance in coordination with maintenance supervisor and executing technicians and local operator.

Leadership

• Offer front line leadership to contractors and the maintenance team in all situations, pulling together and coordinating the appropriate resources to deal with all maintenance related issues.
• Give directions to and ensure the productivity and capability of any maintenance work force in the area of responsibility.
• Initiate and drive improvement projects. Lead the continuing effort to raise standards for plant maintenance.

Reliability

• Ensure that effective predictive and integrity-based maintenance programs are followed that are consistent with regional programs, reducing unplanned shutdowns and ultimately enhancing overall plant profitability and reliability.
• Make timely and correct decisions based on fact and sound judgement, in order to keep plant downtime to a minimum, in both planned and un-planned situations.
• Trouble-shoot and diagnose problems and perform maintenance on equipment under his jurisdiction.
• Locate and develop local resources (contractors, vendors, etc.) for improved plant support.
• Liaise on a daily basis with Production and maintenance staff, to ensure that potential issues are identified, and plans created to rectify the issues in an appropriate and timely manner.

Preventative Maintenance

• Ensure the PM system is appropriate for the equipment and periodically evaluate the program’s effectiveness and modify accordingly to ensure that optimum reliability/cost benefits are maintained.
• Put systems in place to ensure the maintenance is carried out in accordance with the PM system requirements, ensuring that PM compliance KPIs are met.
• Work with the Maintenance Manager and Planners to actively develop and take responsibility for short- and long-range planning and execution of essential programs, shutdowns, and equipment maintenance schedules.
• To perform preventive maintenance of plant equipment, repair, lubrication and cleaning of machines and tools, mechanical, I&C, and hydraulic systems as per the direction of Maintenance Supervisor.

Planned Maintenance

• Perform all the maintenance activities in the plant in a timely and safe manner with strict adherence to the maintenance procedures and work instructions applicable for the respective activities. Document maintenance concerns/history for the equipment.
• Installs, adjusts, inspects, services, and repairs a variety of static and rotating I&C equipment utilized in power plants.
• Responsible and accountable for proper care of tools, lifting equipment or any other related devices which are required to carry out his assigned jobs.
• Carry out all necessary preparation required for I&C maintenance to equipment of assigned area.
• To perform routine, corrective maintenance of plant equipment, repair, lubrication and cleaning of machines and tools, mechanical, I&C, and hydraulic systems as per the direction of Maintenance Supervisor.

Un-planned Maintenance

• Have systems in place such that un-planned (emergency) breakdown situations are dealt with in a safe, efficient and cost-effective manner in order to get the equipment operational with minimal disruption to plant on-streams.

Dimensions

• All equipment at the Power Block Cogen I & II.
• Geographical Scope: Power Block.
• Budget Impact: Approx. $78MM in FY 2024.
• Replacement investment of facility > $3.0BB.
• Number of Reports:
• 1 Direct Reports.
• 4/6 Indirect Reports.

Skills

• Practical experience and know-how of I&C engineering.
• Knowledge of downtime analysis and practical knowledge of problem-solving tools.
• Knowledge of maintenance management methods, of predictive inspection tools and of CMMS (Computer Maintenance Management System, good knowledge of SAP Template desirable).
• Hands-on experience with Siemens and Honeywell control systems are of added advantage.
• Detailed understanding of preventative/predictive maintenance methods.
• Knowledge of the operations in combined cycle power plants, Siemens Gas and Steam turbine experiences are an added advantage.
• Be able to work both independently and in a team, environment completing objectives efficiently with a sense of responsibility.
• Be able and willing to work in non-ideal environments such as: confined spaces, working at heights and around chemicals.
• Understand, practice, and enforce safe work practices related to the following: respiratory protection, elevated work platforms, fall protection, control of hazardous energy (Lockout/Tag-out procedure), fire protection systems, I&C safety, forklift/hoist operation, welding, cutting, brazing, confined space entry, PPE etc.
• Knowledge of identification, classification, and disposal of waste.
• Knowledge of Power plant/IGCC/CCPP Operations and Control Philosophy.
• Working knowledge with CMMS maintenance tools (SAP/Maximo etc.).

Qualifications & Experience

• Postgraduate / Graduation in I&C Engineering.
• Minimum of 8 to 10 years of Maintenance experience in Power plants/ IGCC/CCPP Plants.
• Strong Knowledge of the Maintenance work process.
• Knowledge of Maintenance software – preferably SAP.
• The successful candidate must be a self-starter with a solid work history and excellent references along with the ability to work in a team-oriented environment.
• Must be knowledgeable and experienced in Refining, Chemical, Petro Chemical equipment and specifications.

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