Sr Engineer Control Systems

Job title

Snr/ Engineer Control System

Grade

Stream

Commercial & Downstream – RPI

Function

Maintenance – Central Maintenance – Central & System Planning

Location

Oman – Suhar

Budget control

Reporting to

TL Central & System Planning

Direct reports

0

Job purpose

Designs, analyzes, implements and maintain control systems to regulate and optimize various processes in the RPI areas, under Team Leader Control Systems scope, acting as team player and part of the site’s management team using his/her technical expertise to develop solutions regarding quality problems of control system, including all aspects of maintaining control system asset installed based, supporting on new automation projects, and leading the troubleshooting/repair/ and maintaining control system equipment by:  (1) manage and ensure the availability of the site’s Emergency Shutdown System (ESD), the Distributed Control System (DCS), and PLC-based control loops while proactively promote process safety initiatives, (2)  Develop solutions to maintenance and quality problems of control systems in Suhar plants (AP, PP, SR1, SR2, LPIC-1 and LPIC-2),(3) supporting on new automation projects, and (4) Interact with Operations, Engineering, Maintenance, Safety, Environmental personnel, and third-party contractors – Control Systems works at RPI in designated areas, (5) Providing professional technical advice, guidance and support to the team, (6) Identify opportunities of improvement, as well as assess and support improvement proposals from others, and (7)  Guide young engineers in related Control System matters;  in order to ensure that the assets and equipment are available at all times, minimizing the down time and meeting the operational targets that support the gross margin / profitability with a sufficient organizational capability for business continuity while identifying & developing talent people to as feeder for OQ talent pipeline.

The position will act in accordance with the Group’s Mission, Vision, Values & Strategies, as well as, policies, guidelines, and standards, supported by an IT Technology platform, HSE standards, Omani’s government & other legal justifications, and best international practices in consonance with national objectives.

Main tasks and responsibilities

Scope

Areas of application

RPI & Plastic Assets (SR/AP, MAF, Plastics & NGLE)
Designs, analyzes, implements, and maintain control systems

Designs, algorithms, selecting the appropriate sensors and actuators, and maintain control systems
Testing and validating control systems

running simulations and performing experiments to verify the performance of the control system.
Troubleshooting and maintaining control systems

Monitoring the performance of the system and identifying and fixing any problems that arise with control systems and related equipment to ensure the continue and correct operation
Availability of the systems

Ensure the availability of the site’s Emergency Shutdown System (ESD), the Distributed Control System (DCS), and PLC-based control loops while proactively promote process safety initiatives in Suhar plants (AP, PP, SR1, SR2, LPIC-1 and LPIC-2),
Projects

Leading projects to upgrade or replace existing control systems, ensuring that new systems are integrated with the existing infrastructure and meet the refinery's requirements for safety, reliability, and performance.
Automation projects, new opportunities of improvement
Stakeholders & Main interactions

collaborating with other professionals such as Operations, Engineering, Maintenance, Safety, Environmental personnel, and third-party contractors to design and implement complex control systems & ensure that the control systems are integrated with the existing processes and equipment
Professional Advise / Support

Guidance and mentorship to junior engineers and technicians, helping to develop their skills and knowledge in control systems engineering.

Principal Accountabilities:

HSE and Process Safety

Provides a well-resourced source of expertise and advise in process safety by engaging consistently and transparent with stakeholders where dealings with duty-holders and informing the developments in process safety topics.
Support the policy of HSE for the control of major accident hazards.
Participate as part of a multidisciplinary team in safety case assessment, inspection, and investigation.
Stimulate the research and development for the prevention of major accident hazards.
Maintain awareness of current developments in process safety
Instrumentation and Control Maintenance Strategies

Set maintenance strategies encompassing preventive, predictive, and corrective measures for instrumentation and control equipment and systems.
Ensure that the implemented strategies maximize the optimal performance and reliability of instrumentation and control assets.
Develop and manage Control Systems lifecycle plan.
Develop templates and guidelines to assist with Control Systems design standardization.
Work closely with the IT/ICS group on cyber security initiatives and adhere to ICS Network Security Policy.
Develop and maintain guidelines and procedures for effective configuring of control systems / PLCs.
Provide technical support for troubleshooting, and configuration of control systems installed based to ensure they are operating to at optimal levels.
Identify opportunities and delivers solutions for increasing the uptime of DCS, and PLCs and improving the control systems.
Execute in-house new enhancements and optimization related to the control systems across RPI Assets.
Establish standardized maintenance procedure aligned with the competency requirement resulting from close collaboration and coordination with ITQAN (Competency Assurance Program) team.
Maintenance Service Contract

Collaborate with end-users, contract, and procurement teams (including legal, if necessary) to create detailed maintenance service contracts for external service providers.
Ensure that the contracts provide fit-for-purpose coverage and align with industry standards and best practices.
Maintenance Performance Monitoring and Optimization

Monitor the performance of instrumentation and control assets on a predefined frequency.
Analyse data collected during monitoring to identify trends, anomalies, and opportunities for improvement within the maintenance context. Recommend optimization strategies that enhance operational efficiency and minimize unplanned downtime.
Within the context of maintenance, proactively identify equipment/system that frequently require attention or exhibit recurring issues. Collaborate with the reliability/maintenance team to address these specific concerns and implement targeted interventions that improve their performance and reliability.
Root Cause Analysis

Support or participate in investigations into instrumentation and control equipment failures and incidents.
Support root cause analyses and recommend corrective actions to prevent recurrence.
Maintenance Excellence

Oversee condition monitoring, trending, and analysis of critical instrumentation and control equipment.
Ensure that resultant actions from analysis are incorporated into the SAP and CM notification systems. Engage with site maintenance engineers and drive for the closure of action items.
Regularly review maintenance data quality in SAP and drive continuous improvements.
Maintenance Expertise

Demonstrate expertise in instrumentation and control equipment, including sensors, transmitters, final elements, SIF, SIL, DCS, ESD, PLC, and SCADA systems.
Provide specialized maintenance support to the Instrumentation and Control Plant Maintenance team, including troubleshooting, investigations, and OEM support. Recommend and follow up to bridge the competency gap of the Instrumentation and Control Plant Maintenance team.
Collaborate on implementing maintenance business improvement projects and MOCs for the discipline.
Business Plan

Provide support and challenge to end-users in incorporating accurate maintenance input into the business plan.
Assist in developing fit-for-purpose OPEX budget proposals for instrumentation and control equipment maintenance and inspection.
Technology Adoption

Keep abreast of the latest advancements in instrumentation and control maintenance technologies.
Propose their integration into maintenance strategies.
Collaborate with the instrumentation and control technical authority team to ensure access to up-to-date information and company experience.
Safety and Compliance

Perform regular audits to ensure that all instrumentation and control maintenance activities adhere to maintenance strategies, relevant safety regulations, industry codes, and company policies.
Training and Development

Provide in-house specific maintenance training and mentorship to enhance the expertise of the maintenance team in instrumentation and control maintenance aligned with the competency requirement outline by ITQAN (Competency Assurance Program) team.
Facilitate the transfer of learning and best practices across the Maintenance function and other departments.
Stakeholder Management

Work closely with TSD, plant maintenance, operations, HSSE, and central maintenance personnel/team to ensure systems, people, processes, and resources required to manage integrity are in place and fit for purpose throughout the lifecycle of the asset.

Key Competencies

Discipline Competency

Competence Level Required

Develop and Implement Instrumentation Maintenance Strategies

Skill

Troubleshoot Instrumentation and Control Systems

Skill

Root Cause Analysis for Control System Failures

Skill

Coordinate and Supervise Maintenance Activities

Skill

Perform Preventive and Corrective Maintenance

Skill

Instrumentation Documentation Management

Skill

Commissioning and Testing of Control Systems

Skill

Instrumentation Modification and Upgrades

Skill

Ensure Compliance with Industry Codes and Standards

Skill

Functional Safety and Safety Instrumented System (SIS)

Skill

Instrumentation and Control Protocols

Skill

Project Management for Instrumentation Maintenance Projects

Skill

Process Safety and Environmental Regulations

Knowledge

Industry Best Practices and Standards

Knowledge

Distributed Control Systems (DCS)

Skill

Programmable Logic Control (PLC)

Skill

Key interactions

Internal: Maintenance – RPI & Plastics Maintenance, Operations & TSD.

External: Contractors, Vendors & Suppliers

Notable Working Conditions. Field Operations and office environment, Moderate to extensive computer screen use.

Education requirements

Minimum Qualifications for this position is a Bachelor degree in Electrical / Electronic or Instrumentation Engineering or similar.

Language requirements 

Excellent knowledge of written, read, and spoken English (required)  Arabic - Native (desirable)

Background and experience

Competencies and skills

Sr. Engineer 8+ years of relevant experience

Engineer 5-8 years of relevant experience 
Relevant experience in similar role Control System in refinery & petrochemical plants maintenance or proven merit on the required competency.
Relevant experience in maintenance role within the Oil & Gas / Refinery / Petrochemical industry, preferably with experience in the area/assets associated with this position. 
Knowledge of the refinery process and plant equipment.
Experience in Developing/reviewing maintenance work instruction
Sound judgment in technical matters with good skills in engineering field.
Proven experience with Personal Safety Management.
Good knowledge in HSE / SCE QA/QC, equipment & plans/ standards
Skill either in Yokogawa, Honeywell, or Schneider DCS and ESD is required.
Skill either in Siemens, Triconex or Allen Bradley PLC is required.
Skill in machine monitoring system such as Bently Nevada or Emerson CSI
Knowledgeable on machine protection system such as Woodward, and CCC.
Sound understanding of IEC62443 specifically focusing on maintenance of the OT equipment’s.
Experience in bids evaluation and knowledge of contracts management & spare parts optimization.
Soft: 

Strong analytical and problem-solving skill
Result oriented.
Analytical thinking.
Time management

Technical

Computer literacy including MS Office
Process automation protocols, such as (HART, Profibus, SDS).
Maintaining and troubleshooting of Distributed Control System.
Maintaining and troubleshooting PLCs.
Develop/review maintenance work instruction.
Writing technical reports and documentation,
Use of mathematical models and computer simulations to analyze system behavior and make design decisions
Full awareness of MOC “Management of change procedure and implementation” 
Familiar to SAP system transactions & reports.  
Participate/Lead RCA & HAZOP study. 
Develop/review Lifecycle Management Plan to overcome the obsolescence and support issues.
Understanding of international standards related to control systems.
Bids evaluation.