Job Title: Process Control Specialist (Power Plants)

Job Summary:

The Mid-Level Process Control Specialist is responsible for independently managing the operation, optimization, and maintenance of process control systems in power generation facilities. This includes leading system commissioning, troubleshooting advanced issues, and ensuring compliance with industry standards and safety protocols. The specialist plays a critical role in optimizing the performance of systems such as turbines, generators, boilers, SCADA, and Distributed Control Systems (DCS) while mentoring junior team members and collaborating with cross-functional teams.

Key Responsibilities:

System Operation and Maintenance:

• Manage the operation, calibration, and maintenance of process control systems, including SCADA, DCS, turbines, generators, and boilers.
• Perform diagnostics, tuning, and optimization of control systems to enhance reliability and efficiency.
• Lead the implementation of system upgrades, retrofits, and performance improvements.

Troubleshooting and Problem Resolution:

• Conduct detailed root cause analysis to identify and resolve complex control system issues.
• Collaborate with vendors and contractors to troubleshoot and address technical challenges.
• Develop and implement corrective actions and preventive measures for recurring faults.

Compliance and Safety:

• Ensure all process control activities comply with industry standards (e.g., IEC, ISA) and regulatory requirements.
• Conduct risk assessments and implement mitigation strategies for critical systems.
• Oversee the testing and validation of safety and emergency shutdown systems.

Documentation and Reporting:

• Prepare and maintain comprehensive documentation, including system configurations, calibration settings, and test results.
• Develop detailed reports on system performance, diagnostics, and maintenance activities for stakeholders.
• Contribute to the creation of standard operating procedures (SOPs) and best practices for control systems.

Collaboration and Leadership:

• Work closely with operations, maintenance, and safety teams to align process control activities with organizational goals.
• Mentor and provide technical guidance to junior engineers and technicians, fostering their skill development.
• Participate in cross-functional meetings to address challenges and propose system improvements.

Project Management:

• Lead mid-sized projects related to control system commissioning, upgrades, and performance optimization.
• Develop project schedules, budgets, and resource allocation plans, ensuring timely delivery.
• Identify risks during project execution and develop mitigation strategies to ensure success.

Key Focus Areas:

• Power Generation Control Systems: Oversee operation, maintenance, and optimization of turbines, generators, and boiler control systems.
• SCADA and Distributed Control Systems (DCS): Manage configuration, troubleshooting, and optimization of SCADA/DCS platforms.
• Thermal and Nuclear Plant Control Systems: Lead commissioning and maintenance of control systems specific to thermal and nuclear plants.
• Safety and Emergency Shutdown Systems: Validate and maintain safety-critical systems for compliance and operational reliability.

Skills and Knowledge Required:

• Advanced knowledge of process control systems, including SCADA, DCS, and PLC programming.
• Proficiency in industrial communication protocols such as Modbus, Profibus, and HART.
• Strong diagnostic and analytical skills to address complex system issues.
• Comprehensive understanding of safety regulations, risk management, and emergency procedures.
• Familiarity with advanced control system integration and optimization techniques.

Educational Qualifications:

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Instrumentation Engineering, or a related technical field.
• Certifications in SCADA, DCS, or process control systems (e.g., Siemens, ABB, Honeywell) are highly desirable.

Experience:

• 3-5 years of experience in process control systems, including commissioning, testing, and optimization.
• Proven ability to manage maintenance and troubleshooting activities independently.

Tools and Technologies:

• Proficiency with advanced diagnostic tools such as oscilloscopes, loop calibrators, and vibration analyzers.
• Experience with software platforms like Siemens TIA Portal, Honeywell Experion, ABB DCS, or Yokogawa CENTUM.
• Familiarity with data visualization and analytics tools for performance monitoring.

Other Requirements:

• Strong leadership and communication skills to mentor junior team members and coordinate with stakeholders.
• Ability to manage multiple tasks and prioritize effectively under tight deadlines.
• Commitment to maintaining safety, quality, and compliance in all control system operations.
• Willingness to travel for site inspections and project-related activities.