Sr. Process Control Engineer

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POSITION SUMMARY

Purpose

The I&C Engineer (Sr Process Control Engineer) will work closely with the site Maintenance team, Operations, Technical Management and responsible for coordinating, organizing, and executing Instrumentation & Controls activities for preventative and corrective maintenance, with the aim of reducing maintenance related costs while improving plant reliability and availability, in line with business needs for facilities which range across multiple technologies such as Air Separation (ASU), Steam Methane reformer (HYCO), CO2 capture and Utilities, along with ancillary equipment to support the facility. The role supports the O&M team in providing similar services to our joint venture partners, sale of equipment and new customers as required for APQ Jubail, Saudi Arabia.

NATURE & SCOPE

The I&C Engineer, reporting to the Lead Controls Engineer / Engineering Manager is responsible for providing day-to-day support, maintaining safe, reliable, and efficient operation of the Instrument & Controls systems in the facility as well as executing preventative and corrective maintenance activities for all site low voltage Instrument & Controls equipment as cascaded by Maintenance Management and Engineering. The position will work closely with internal and external resources and ensure the scope of work is executed in a safely and reliably.

The facilities range across multiple technologies such as Air Separation (ASU), Hydrogen and CO2 production (HYCO) and H2 Mobility. As a member of the O&M team, the I&C Engineer will interact routinely with plant operations, maintenance, and Instruments Technicians to execute troubleshooting support, instructions, and technical guidance related to the site’s Instrumentation & Controls systems.  The position emphasizes teamwork, communications, organization, change management, work process optimization, planning, leadership, and hands-on technical skills with comprehensive knowledge across disciplines.

PRINCIPAL ACCOUNTABILITIES

Safety 

• Maintain a safe work environment. Demonstrate leadership with all company & industry safe work processes to prevent all injuries. Insure proper documentation is maintained for safety related activities. 

Technical

• Provide technical solution, lead execution plan of SAP PM activities for all aspects of plants Instrumentations, Analysers, Gas Chromatography, and process controls systems including DCS, local PLC’s, and related control loops. 
• Maintain responsibility for the long-term Instrumentation & controls planning and support with respect to calibrations, Spare parts management, controls logic, programming, graphics changes, operational changes, systems migration & back up.
• Perform Safety Integrity Level (SIL) assessments and verification.
• Provide engineering support & prepare punch list during the construction & commissioning of the plants & ensure close out of punch items timely. Maintain accurate document control and monitor quality assurance initiatives.
• Interface with Process Engineering to:  Identify gaps & scope of improvements in operating and control strategies to achieve productivity targets. Develop tracking programs and metrics for plant optimization and efficiency, and controller on-stream. Monitor the targets against expected performance. Areas of emphasis include manufacturing cost reduction, waste handling and reduction, raw materials, utilities consumption/cost/supply, production process reliability and capacity expansions. 
• Interface with the Advanced Controls to define appropriate DCS interface requirements, and jointly design, implement and test those interfaces. 
• Contribution in support of plant productivity or improvement projects, including specification of instruments, configuration of control systems, detailed cable and wiring design, provision of work packages for contractors to bid and installations.
• Ensure availability & record of most updated detailed engineering specifications (including sizing calculations) for the procurement of Instrument & Controls systems components and equipment (control valves, flow meters, inline devices, transmitters, analyzer, etc.). 
• Provide engineering input for development and maintenance of Instrument & Controls systems & equipment standards, procedures, best practices, inspection contracts, and contractor selection guidelines. 
• Lead and provide technical support services in the new installation, existing plant modifications, on-going operations, and continuous improvement and maintenance activities for the facilities in the Region. Insure the activities related meet legal requirements and comply with Air Products Qudra safety and technical standards.
• Provide Technical Sales Support to the Equipment Sales & Product Services Team for new installations, existing plant modifications, on-going operations, and continuous improvement and maintenance activities for Air Products Qudra, sale of equipment and potential new customers in the Region. The support will be provided by either onsite visits, phone support, or from the Process Intelligence Centre via mentored monitoring capabilities. 
• Provide technical support and safety leadership for MOC’s, OPHR’s, and other safety related initiatives in order to drive process safety compliance. Consult Air Products Qudra process safety personnel as required for additional technical support. 
• Provide technical leadership in supporting/leading investigations and Root Cause Analysis in order to identify & implement sustainable corrective actions.

Operations

• Insure the safety of all operations personnel by utilizing the Air Products Qudra Basic Safety Practice program, which includes Safety Work Permits, LOTO, Confined Space, etc. The position provides technical support for executing, organizing, and auditing the safety systems, to build the Air Products Qudra safety culture into the organization.
• Provide instrument and controls engineering support to operations in order to effectively operate the ASU, HYCO, CO2 and H2 mobility facilities in region to meet the customer’s satisfaction on safety, reliability, product quality, and flexibility of product supply while in compliance of contractual requirements. 
• Ensure Air Products Qudra standards, best practices for EH&S, productivity, reliability, quality, and overall customer services are met.
• Provide technical support, working with the commissioning team, assisting in the commissioning, start-up, and troubleshooting activities. 
• Participate in the training of the Operations team up to plant commissioning. 
• Assist Operations in maintaining accurate document control and monitor quality assurance initiatives. 
• Maintain alignment with the Operations Plant Managers, Site Leadership and the Business Area to align with asset management opportunities and commercial priorities  
• Provide technical support for turnarounds.
• Implement and maintain compliance with all Critical Safety Circuits (CSS), Safety Integrity Levels (SIL), and Safety Instrumented Systems (SIS) implementation and revalidation programs. 
• Establish & maintain a relationship with the local inspection bureau, maintain relevant statutory, regulatory, technology standards, and code information consistent with Jubail IG Hub plant operational objectives. 
• Establish & maintain compliance with all company and local regulations. 
• This position is also responsible for helping to implement Critical Safety Systems (CSS) revalidation work, MOC and spare parts strategy in the plant. 
• Participating in technical reviews, equipment design, installation, operation, and optimizations (productivity) of equipment & systems including validations, Mechanical Integrity, and Management of Change along with procedures development & implementations. 

Repair & Maintenance 

• Establish & maintain close working relationships with plant process engineering & operations personnel to continuously monitor & evaluate plant performance & process controls systems & equipment.
• Develop and implement a comprehensive process controls systems & equipment maintenance plan and provide appropriate technical guidance and detailed instructions to schedule, execute, and monitor compliance of plans.
• Provide guidance to help develop and implement engineering solutions to repetitive failures and other conditions which adversely impact plant operations.
• Provide engineering support and participate / lead incident investigations and Root Cause Analysis. Identify & implement sustainable corrective action(s).
• Provide engineering guidance to the Maintenance team in setting spare parts inventory levels, manage quality, and provide input to inventory strategies. 

Project Management/Budget 

• Employ appropriate project development and project management activities (including scope, budget, schedule, execution strategies, risk plans, cost collection / reporting, etc.) for the execution of all projects and turnaround activities.
• Provide engineering support to develop the annual budget for Process Controls systems & equipment maintenance, repair, and system upgrades. 

Professional 

• Lead by example to promote an atmosphere of team spirit through good example, open communication, good listening, and timely problem resolutions.
• Drive continuous improvement in safety performance, reliability, and cost of quality goals. 
• Foster and support positive working relationships with internal and external customers. 
• Support, mentor and develop local instrument technicians.

We are the world’s largest hydrogen producer with over 80 years of industrial gas experience. We are hydrogen and industrial gas experts delivering safe, end-to-end solutions, investing in real, clean energy projects at scale, and driving the industry forward to generate a cleaner future. 

At Air Products, we work in an environment where we put safety first, diversity is essential, inclusion is our culture, and each person knows they belong and matter. To learn more, visit About Air Products.