Job description

JOB PURPOSE

The jobholder is responsible for performing I-C maintenance and repairs, ensuring safe, continuous, and reliable operation of assets, plants, and equipment, which is crucial for Borouge's operational efficiency and adherence to international standards

This role includes; leading the I-C maintenance and repair activities to ensure the safe, continuous, and reliable operation of assets, plants, and equipment; performing troubleshooting, corrective maintenance, and major repairs during shutdowns; while also conducting predictive, preventative, and proactive maintenance; while supporting commissioning activities, coordinating with contractors, and ensuring compliance with HSE standards, all of which contribute to Borouge's operational efficiency and adherence to international standards.

KEY ACCOUNTABILITIES

Instrumentation & Control System Maintenance

• Perform regular preventive and corrective maintenance on instrumentation and control systems, including sensors, transmitters, control valves, analyzers, and actuators to ensure smooth plant operations.
• Troubleshoot and resolve issues in Distributed Control Systems (DCS), Programmable Logic Controllers (PLCs), and SCADA systems to maintain operational efficiency.
• Conduct calibration, testing, and validation of field instruments (pressure, temperature, flow, and level sensors) to ensure accurate measurement and control.
• Maintain calibration records and ensure instruments are within operational tolerances to comply with industry standards.
• Diagnose and repair issues with control loops to optimize process efficiency.
• Tune control loops to maintain process stability and efficiency.

Installation & Commissioning

• Support the installation, configuration, and commissioning of new instrumentation and control systems to ensure proper integration with existing systems.
• Assist in updating and reviewing control systems to align with process changes or improvements.
• Participate in planning and scheduling preventive maintenance tasks to minimize disruption to plant operations.
• Use condition monitoring techniques and tools to predict and prevent potential equipment failures.
• Follow all HSE guidelines to ensure safety when working with hazardous materials or in potentially explosive environments.
• Ensure compliance with Lockout/Tagout (LOTO) procedures during maintenance activities to prevent accidents or equipment damage.

Maintenance Reporting

• Maintain accurate documentation of all maintenance activities, including calibration data, fault reports, and work orders to ensure traceability.
• Update Computerized Maintenance Management Systems (CMMS) such as SAP with maintenance records, equipment history, and spare part usage to support maintenance planning.
• Provide quick response to instrumentation or control system breakdowns to minimize plant downtime.
• Act as the technical expert for complex issues in instrumentation and control systems to ensure effective troubleshooting.
• Ensure proper inventory of critical spare parts for instrumentation and control systems to maintain sufficient stock levels.

I-C Maintenance Excellence

• Participate in continuous improvement initiatives by identifying and recommending upgrades or improvements to instrumentation and control systems for increased reliability and performance.
• Collaborate with process engineers to implement process optimization and control strategies to enhance operational efficiency.
• Conduct task risk assessments to maintain safety at work locations.
• Test the performance function of SIL instruments and record deviations to ensure functionality.
• Conduct and participate in risk management for interlock defeat requirements to mitigate risks.
• Perform visual, close, and detailed inspections of installed Instrument & Control equipment to ensure compliance with standards.

HSE Compliance

• Follow all HSE guidelines to ensure strict adherence to safety protocols.
• Ensure compliance with Lockout/Tagout (LOTO) procedures during maintenance activities to prevent accidents or equipment damage.
• Support System Engineers in maintaining DCS, ESD, and MCMS system hardware to ensure system integrity.
• Support maintenance requirements related to profitability programs and alarm management to enhance operational efficiency.
• Ensure HSE critical and non-HSE Instrument and Control systems operate safely and comply with regulations.
• Follow up on calibration of all IQE instruments and maintain proper records as per ISO requirements.

Spare Parts & Inventory

• Ensure proper inventory of critical spare parts for instrumentation and control systems to maintain sufficient stock levels.
• Assist in identifying the need for spare parts and new instrumentation technology to support continuous improvement.
• Segregate repairable and non-repairable items and initiate actions for refurbishment to optimize resource use.
• Raise material reservations and assist in receipt and quality check of materials to ensure availability.
• Maintain records of work performed, progress, and related data for monthly reports to support maintenance planning.
• Initiate failure reports and support engineers in root cause failure analysis to improve system reliability.

Emergency Response & Troubleshooting

• Provide quick response to instrumentation or control system breakdowns to minimize plant downtime.
• Act as the technical expert for complex issues in instrumentation and control systems to ensure effective troubleshooting.
• Perform fault analysis and corrective actions to maintain operational efficiency.
• Conduct equipment troubleshooting and decide on corrective actions to ensure proper maintenance.
• Supervise Instrument and Control maintenance jobs to minimize failures and ensure equipment reliability.
• Coordinate with different departments to ensure timely completion of maintenance jobs to support operational efficiency.

QUALIFICATIONS, EXPERIENCE, KNOWLEDGE & SKILLS

• Diploma in I-C, or any equivalent technical qualifications.
• Technical diploma or certificate in I-C Engineering, I-C Technology, or a related field from a recognized technical institute.
• Technical diploma or certificate in Instrumentation Engineering, Control Systems Engineering, Electrical Engineering, or a related field from a recognized technical institute.
• Experience in various I-C equipment and their maintenance and trouble shooting.
• Familiar with I-C plant safety procedures and maintenance of quality procedures/records.
• Effective communication and technical report writing skills in English.

• Minimum of 5 – 7 years of relevant experience in installation, repair, testing and maintenance of a wide range equipment items of production facilities in an oil/gas or petrochemical industry.
• 5–8 years of hands-on experience in instrumentation and control maintenance, ideally within the oil, gas, or petrochemical industries.
• Experience working with field instruments, control systems (PLCs, DCS), and process control loops
• Extensive experience in maintaining I-C systems, including switchgear, motors, MCCs, and transformers.