Job Title: Process Control Specialist (Power Plants)

Job Summary:

The Senior Process Control Specialist is responsible for leading the design, implementation, optimization, and maintenance of process control systems in power generation facilities. This role involves managing large-scale projects, providing technical expertise, and troubleshooting advanced issues to ensure reliability and efficiency. The Senior Specialist also mentors junior team members, collaborates with stakeholders, and drives innovation in systems like turbines, generators, boilers, SCADA, Distributed Control Systems (DCS), and safety mechanisms.

Key Responsibilities:

System Design and Implementation:

• Lead the design and integration of process control systems, including SCADA, DCS, and safety mechanisms for turbines, generators, and boilers.
• Oversee the commissioning, testing, and calibration of advanced control systems to meet operational and compliance requirements.
• Validate control logic, system interlocks, and configurations to ensure seamless integration and optimal performance.

System Maintenance and Optimization:

• Manage the operation, troubleshooting, and maintenance of complex process control systems, ensuring minimal downtime.
• Develop and implement strategies for system optimization, including performance tuning and efficiency improvements.
• Lead the execution of preventive maintenance programs to enhance system reliability.

Troubleshooting and Advanced Diagnostics:

• Conduct root cause analysis and resolve critical issues in process control systems.
• Collaborate with vendors and contractors to address and resolve complex technical challenges.
• Recommend and implement long-term solutions to prevent recurring system faults.

Compliance and Safety:

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

Documentation and Reporting:

• Prepare comprehensive reports on system performance, maintenance activities, and project outcomes for stakeholders.
• Maintain accurate records of system configurations, calibration data, and compliance documents.
• Develop and refine standard operating procedures (SOPs) and training materials for process control systems.

Leadership and Collaboration:

• Mentor and provide technical leadership to junior and mid-level engineers and technicians.
• Collaborate with operations, maintenance, and safety teams to align process control activities with organizational goals.
• Act as the primary point of contact for stakeholders, including clients, vendors, and regulatory authorities, for process control matters.

Project Management:

• Lead large-scale projects involving the upgrade, retrofit, or installation of process control systems.
• Manage project schedules, budgets, and resource allocation, ensuring timely and cost-effective delivery.
• Identify risks and implement mitigation strategies to ensure successful project execution.

Innovation and Continuous Improvement:

• Evaluate and implement emerging technologies to enhance process control system efficiency and reliability.
• Lead initiatives to upgrade legacy systems and integrate advanced automation tools.
• Stay updated on industry advancements to maintain technical excellence and propose innovative solutions.

Key Focus Areas:

• Power Generation Control Systems: Oversee and optimize the operation of turbines, generators, and boiler control systems.
• SCADA and Distributed Control Systems (DCS): Manage advanced configuration, testing, and troubleshooting of SCADA/DCS platforms.
• Thermal and Nuclear Plant Control Systems: Lead commissioning and optimization of control systems for thermal and nuclear power plants.
• Safety and Emergency Shutdown Systems: Ensure compliance, reliability, and readiness of safety-critical systems.

Skills and Knowledge Required:

• Extensive knowledge of process control systems, including SCADA, DCS, and advanced control logic programming.
• Proficiency in industrial communication protocols such as Modbus, Profibus, and HART.
• Advanced diagnostic and analytical skills for troubleshooting and optimizing complex systems.
• Comprehensive understanding of safety regulations, risk management, and emergency procedures.
• Expertise in project management, system integration, and control system optimization.

Educational Qualifications:

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

Experience:

• 7-10 years of experience in process control systems, with a proven track record of managing large-scale projects and optimizing operations.
• Demonstrated expertise in troubleshooting and resolving advanced issues in power generation environments.

Tools and Technologies:

• Proficiency in advanced diagnostic tools such as oscilloscopes, vibration analyzers, and thermal cameras.
• Expertise in software platforms like Siemens TIA Portal, Honeywell Experion, ABB DCS, or Yokogawa CENTUM.
• Familiarity with data analytics tools for monitoring and improving system performance.

Other Requirements:

• Exceptional leadership and communication skills to manage teams and collaborate with stakeholders.
• Strong organizational and multitasking abilities to oversee multiple high-priority projects.
• Commitment to maintaining safety, quality, and compliance in all process control operations.
• Willingness to travel for project oversight, site inspections, and industry forums.