Company: INEOS Phenol
Interested in joining a winning team? A team whose employees share in the ownership of the business and are empowered to make a difference?
Knowledge & Skills
This role requires formal knowledge and certification in several process controls and safety systems. Each certification requires bi-annual refresher training to remain current on the systems. It requires an understanding of network design and the associated hardware/infrastructure. It must be capable of setup, configuration, and maintenance of supporting systems such as alarm management, data historian, asset management, etc. This role requires a broad understanding of industrial communications protocols and programming languages. It requires a strong understanding of control theory, process dynamics, and instrumentation and how they can be applied in the control of chemical processes. This role requires an in-depth knowledge of the process, facility installation, and operating conditions to evaluate, and optimize control schemes and sequences.
Management
This role routinely provides guidance to operations personnel on process control and optimization and to maintenance personnel on troubleshooting. In addition, it directs contractors and consultants when required to support large projects and TARs. It is required to schedule and oversee the preventive maintenance required for the system hardware and the testing required for the safety interlocks, which requires support for the operations and maintenance departments. Coordination of these activities across multiple departments requires high levels of planning, organization, & control. After completing these activities, this position is responsible for evaluating the data and documenting the findings. Any items that need further attention must be tracked to completion. All information must be maintained with a high level of detail for tracking the long-term integrity of the system hardware & instrumented safety systems and also to support audits (INEOS, insurance, OSHA, etc.).
Human Relations/Communication
This position continuously communicates with the operations, maintenance, and engineering departments in the development of process control improvements, troubleshooting process controls issues, and training on process control systems and philosophies. It must be capable of communicating across all levels of the organization, with the ability to convey technical information to both non-technical and technical stakeholders. This position must be able to listen to input from others to fully understand process issues or to incorporate operational experience into the configuration of control concepts and sequences. When implementing new control schemes, it must work closely with the operators to ensure understanding of the control concept and at times persuade them that it will be an improvement over the long term. This position is responsible for scheduling and implementing the interlock testing and preventive maintenance on the automation hardware systems. It must coordinate these activities with both the maintenance and operations departments to ensure resources are available to support the work and that these tasks do not interfere with the operation of the facility. This coordination requires significant communication, understanding, persuasion, and compromise to complete the scope of work on time without impacting the operation of the facility.
Job Complexity
The primary responsibility of this position is to ensure the integrity and reliability of the DCS/PLC control systems, Emergency Shutdown system, Data Historian, and Alarm Management system. This requires an expert level of knowledge to ensure that the infrastructure of the systems is properly designed and precisely implemented to protect against cybersecurity threats and ensure reliable performance. It requires all configuration and parameter changes to be properly developed, simulated, inputted, and tested without error, to ensure proper operation of the safety and control systems. It requires the development of a long-term preventive maintenance and testing plan to ensure the ongoing reliability of the system hardware and the safety interlocks. The design and implementation of these responsibilities are performed independently by this position except for critical designs and system changes, which are also reviewed by additional knowledgeable resources to validate the design or change. There are few industry standards governing industrial control and safety systems. These standards allow for a wide range of options in the design and configuration. This position has a great deal of autonomy in performing its role in the organization. For this reason, this position should be held by a highly experienced person with an awareness of their limitations and extreme attention to detail.
Decision Making & Problem Solving
This position continuously makes decisions on system optimization and changes to control and safety philosophies. Some of the decisions are low level such as simple changes in controller tuning, data collection, and report characteristics. However, many of the decisions are significant, dealing with changes such as interlock set points/actions and process sequence configuration. Although these types of changes are reviewed and approved by a group, the method of executing the desired change is developed by this position. In most cases, it works independently and implements changes based on technical knowledge and personal experience. This includes changes to infrastructure/hardware, control concepts, interlock functionality/limits, control sequence development/modification, preventive maintenance planning/execution, system testing, system reporting, and documentation of all actions. The quality and accuracy of these changes is critical to the safe and reliable operation of the facility. When challenges arise from major changes or findings are identified during inspection/testing, this position is responsible to inform the broader group including management and work within this team to determine the path forward including immediate actions and long-term resolutions.
Responsibilities
This position is independently responsible for all of the aspects in designing, simulating, implementing, testing, maintaining, and documenting a reliable control network including the associated software systems. It works independently with little or no immediate direction in performing these responsibilities. This includes routine control optimization responsibilities as well as support provided to other departments or working groups. Additional guidance and support are normally only provided when major changes or findings have an immediate or excessive impact on safety, reliability, or cost. The decisions and recommendations from this position have a significant impact on the safe operation and optimization of the facility. In addition to performing the primary duty of system design/maintenance, it also supports the ongoing operational optimization. This position works independently and within teams to develop sequences and control strategies that reduce the number required personnel by lowering the number of operator actions/interventions and reduce costs by minimizing the consumption of raw materials and utilities. The input and actions from this position are essential to ensuring the safety and reliability of the facility and the implementation of continuous operation improvement.
Working Environment
This position requires a combination of field and office work. The field work deals primarily with remote mounted control systems and includes installation/upgrade, maintenance/inspection, testing, troubleshooting, etc. These activities are normally scheduled in advance but could also be required after hours on a call-in basis. Work in the field requires the ability to work in all weather conditions as needed to support the facility. Activities include climbing ladders, work at elevated heights, work on energized systems, etc. The office work includes process and system simulation & optimization, implementing approved changes to control/safety systems, analyzing & reporting on process/system data, scheduling inspection/testing activities, developing scopes of work for upcoming projects or TARs, supporting the review process for Management of Change and Incident investigation, continuing & self-directed education, etc. These tasks require the use of standard software such as Microsoft office but also require extensive knowledge in the use of SAP, OSI Pi, Visio, and databases (e.g. Access & SQL).
External
Regulatory Environment
This position is required to stay informed of changes to regulations that could impact the process control and safety instrumented systems. It is responsible for making the necessary changes to comply with new/modified regulations. Regulatory agencies that could impact the systems include OSHA, EPA, ADEM, Coast Guard, Homeland security, etc.
Industry Standards
This position is required for staying informed of changes to industry standards that could impact the process control and safety instrumented systems. It is responsible for making the necessary changes to comply with applicable new/modified standards. Industry standards that could impact the systems include ISA, IEC, NFPA, AIChE, API, ASME, ISO, etc.
Technological Advancements
This role is required to stay informed on new and developing technologies in process controls systems, instrumented safety systems, data analysis, simulation, network/infrastructure, smart instrumentation, etc. It is responsible for achieving continuous improvement by incorporating new technologies into the automation network and associated systems.
Third Party Support
This role is required to maintain good relationships with external companies and stay informed on their capabilities and availability. It coordinates support required for normal and emergency support of the facility as well as projects and TARs.
Accountabilities of the Job