Job Description and Qualifications

Position Title: Asst. Mgr. Instrumentation

Nature and Scope The Kochi Plant is Air Products first fully owned and operated plant in India; it represents a significant investment and includes “State of the Art” technology which makes it the most advanced Hydrogen Plant within the Corporation.

The plant consists of

2x80 MMSCFD Steam Methane Reformers (SMR) with PSA’s for H2 purification.
18 MW Kawasaki Gas Turbine integrated with both reformers.
An Air Products Air Separation Unit (ASU) Producing Nitrogen and Oxygen.
Amine System for CO2 removal (aMDEA) & Cryogenic separation and purification of CO.

The scope of maintenance for the Production Plants, equipment and associated systems includes: -

Compressors, Gas Turbines, Generators, Motors, Fans, Pumps (cryogenic and other), Pressure Vessels and piping systems, Relief Valves, Control Valves, Heat exchangers, Furnaces, Burners, Computer control systems, Trip Systems, Analysis equipment, measurement, and metering system etc.

The customer is Bharat Petroleum Corporation Ltd. (BPCL), Kochi refinery and the Air Products plant is located within the customer’s site. The products from the Air Products plants go directly to the customer as part of their refinery expansion. There is a high level of integration between BPCL and Air Products with respect to feedstock’s, products and utilities. The products are critical to refinery unit operations.

The plants run on continuous basis and there is a strong emphasis of high reliability and high efficiency with contractual penalties against Air Products for underperformance.

Air Products owns, operates and maintains Hydrogen Plants and ASUs around the globe with Operations in over 50 countries, in excess of 80 hydrogen plants and 350 ASU’s. As such we have a wealth of expertise and have well established work processes in place for the reliable and efficient operation of our plants. The Plant Manger will be expected to work closely with the Global Communities of expertise and ensure consistent compliance with these work processes.

Prior to facility operation the individual will have a period of training, where they will be given training on the Air Products Safety and Work procedures, familiarization with the equipment and required internal qualifications.

Dimensions
The Kochi plant is an INR 2000 Crore asset with an annual maintenance budget of approx INR 18 Crore and INR 7 Crore direct labour budget.
Plant Products (Approximate):
H2:                              16        t/h
H2:CO:                         14        t/h
N2:                              10,000 Nm3/h
O2:                               160       Nm3/h
Power:                          18        MW
Number of Direct Reports (approximate): Nil
Responsibilities

Ensuring all planned and unplanned maintenance work is carried out according to Air Products safety procedures, ensuring KPIs are met or exceeded.

Ensure to comply with AP and local safety, health and environment standard, fulfill the mandatory safety requirement and activities: safety training, safety meeting, and all other requirements by AP EH&S and local regulation.

Troubleshooting and rectifying equipment upsets and failures in a timely and efficient manner. Monitor the serviceability of plant equipment and facilities and ensure they adhere to safety, housekeeping, and environmental requirements.

Responsible for all instrument and control system equipment regular maintenance and repairing, turnaround planning and execution for all field instrumentation, valves, flow meter, transmitter, control circuit, monitoring, DCS, PLC etc.

Response to maintenance requirements that could be scheduled or unscheduled/emergency jobs, on 24/7 base, prompt response to requests for assistance and putting in the time and effort to meet our customer’s expectations.

To be familiar with all equipment's in plants, maintain all maintenance equipments accurate documents integrity and equipment history database reachable.

Provide hand-on technical skills at the troubleshooting and all related maintenance work or supporting work responsible .

Ensure adequate spares are available in stock through SAP spares Management, identify key spares and spare part stock levels based on plant operational experience.

Coordinate or assist of supervision the contractor’s work in the facility or shop to guarantee safety and quality and reliability.

Provide technical reports through the specified datasheet or checklist.

Reporting-Time entry weekly and prepare technical reports.

POSITION REQUIREMENTS

B. Tech / BE in Control and Instrumentation engineering with minimum 12 years as a hands-on maintenance experience in refinery, ammonia, methanol, chemical process, power generation, marine industries or similar.

Will have experience in major shutdown support, project work, plant operations and maintenance efforts.

Ability to read & understand P&ID’s, single line diagrams.

Familiarity with process control and communication protocols. Experience with Siemens DCS would be preferable.

Familiarity with Analytical and Emerson Metering system would be highly desirable.

Knowledge of vendor contracts and knowledge of shop support in the region is desirable.

Must be team oriented and have a willingness to learn and further develop technical skills.

Working experience in a gas, petrochemical or chemical refinery, ammonia, methanol, chemical process, power generation, marine industries or similar for instrument/control hand on troubleshooting experience in the field at some areas of field instrumentation, valves, flow meter, transmitter, control circuit, monitoring, DCS, PLC etc with basic skills and knowledge in understanding control circuit, wiring and schematic drawing.
Favorable hand on experience at least one of below instrument equipments

Field valves: Fisher, Samson, Jamesbury/Metso, Severn Glocon, Mapag, IR valve, NELES-JBURY, VERIFLO, FOXBORO, Flowmeters; Analyzers: SICK, THERMO, TELEDYNE, SERVOMEX, DELTA F, KONTROL, XENTAUR, GE Panametrics, ABB, Angilent, SIEMENS, SYSTECH, PMS, Peak, Drager, ANALOX, Michell, UHP LOX, Sensidyne, MSA, Hartmann&Braun; DCS/PLCs: Siemens, GE, ABB, Honeywell; Metering/Measurement System : Emerson Magnetic, DP, Coriolis, Ultrasonic Flowmeters

Fluent in oral and written English language

Knowledge of Malayalam and Hindi is preferred

Knowledge in SAP