Senior Engineer, Plant Operations

About the Job

• The jobholder is responsible to provide with engineering theories and expertise to support the plant operations’ teams, assets, processes, and products to run safely and achieve the planned targets.

• This role includes monitoring the respective plant’s operations, reviewing, analysing and communicating the assets performance with various stakeholders, providing with the required support to the plant, and critically reviewing the plant processes, while enriching the HSE culture within the respective plant and teams.

Key Accountabilities

Operations Control

• Provide daily operation coordination of the plant to produce safely the targeted quantities with right quality keeping in consideration cost aspect.

• Review the operating data as per the planned production targets, past and present prevailing conditions including laboratory analysis, operating plant performance; highlight any major deviations from the operating envelopes (parameters), and ensure suitable actions are taken towards their mitigation.

• Develop Integrity Operating Window for critical equipment  and systems in coordination with other departments to ensure the plant is operating at optimum efficiency and safety.

• Ensure safe, efficient and optimal operability of plant, its operating units and systems. Contributes to the continuous improvement of the facility and its capabilities.

• Write daily instructions and guidelines for the shifts to meet the defined targets. Highlights abnormalities and recommends corrective actions for Shift Supervisors to deal with process or quality problems.

• Collaborate with Plant Shift Supervisors to identify improvement possibilities and strengths in their shifts.

Asset Performance

• Monitor equipment and systems performances, identify potential problems and submits recommendations to the management, OPEX team and shift teams for appropriate actions such as revising operating modes or conditions.

• Review, monitor overall reliability efforts and participate in reliability improvement programs, like problem identification, root cause analysis and recommendations.

• Collaborate with maintenance personnel to ensure regular planned, statutory and unplanned / emergency maintenance is carried out in the most efficient and safe manner and  that the downtime due  to maintenance work is minimized.

• Follow up and suggest system modifications & development in the plant operating units to maintain and improve safety, efficiency and flexibility of operations.

• Participate in incident / accident investigation teams to provide recommendations to maintain high level of plant safety, integrity and reliability.

• Assist Manager, Plant Operations in preparing regular and ad-hoc plant reports and analyses as required to keep management informed of the performance of the plant.

• Act as a focal point to plan and coordinate turnaround activities or any other major activity.

• Analyze, review, and assess the improvement initiatives to assure its effectiveness.

• Lead, or participate in troubleshooting activities, investigations, network meetings, projects and product reviews.

Process Monitoring

• Provide advice and guidance to the Operations staff to solve operating problems and optimizing/monitoring conditions through data acquisition, analysis, and applications to assure reliability and to achieve high efficiency.

• As a Focal point for the advanced process control systems, e.g. APC, ensure that the systems are always functional and troubleshoot various shortcomings in coordination with maintenance or technical services

• Contribute to review, improve and optimize the plant operations and operability.

• Keep close communication with Olefin, Polyolefin, QC laboratory and Material Handling to ensure optimum plant operation.

• Participate or lead the task forces to study and resolve chronic problems in different areas of the plant with OPEX Engineers and other Technical Services disciplines

• Assist in preparing and following up plant test runs. Assemble results & monitor/report performance

Emergency Readiness

• Review start-up, shutdown, emergency and other operating procedures, SOP’s, Operating Manuals and standing instructions for units and updates them according to practical experiences gained with a view to ensure high operation reliability and safety levels.

• Prepare reports for all abnormalities and alarm management system. Produce specialized reports as required, such as recommendations for improvements pertaining to safety, energy saving, cost saving and operation convenience

• Contribute to the establishment of and operate appropriate plant procedures to ensure safe, hazard-free working at all times in compliance with company and statutory environmental policies.

• Carry out plant technical on-call duty. Part of the asset on call system

• Review continuously the safe operating conditions of the running equipment. Plans and ensures testing of critical / emergency shutdown systems and keeps up-to-date records.

• Review and monitor the operating conditions, and reports to ensure compliance of Safety Critical Procedures and regular audits

Plant Support

• Contribute to align and harmonize the operations and all procedures between the asset plants.

• Coordinate with relevant engineering disciplines, the data collection for new projects, audits and surveys. Participates in the review of projects definition and new facilities description.

• Review and develop operating procedures for existing plants and new modifications to ensure safe start up and integrate with those of other affected sections, to be a focal point for all ISO related activities.

• Organize and participate daily, weekly and monthly asset coordination meetings e.g. morning meeting, maintenance planning meeting, OPEX meeting, etc.

• Participate and facilitate audits and follow and close any recommendation or improvement.

HSE Culture

• Provide professional advice and support Operations staff in solving operating problems to assure reliability, high efficiency and to achieve best practice production in line with HSE Management System

• Resolve noncompliance to all relevant process safety elements and integrity compliance KPI, and monitor and report any deviation from the environment requirements.

• Participate and provide high quality input in various studies like Hazop, SIL, Risk assessment, Root Cause Analysis, etc.

• Participate and contribute to HSE Committee meetings. Participate and lead in plant safety observation tours, engagement sessions, and follow up the agreed actions.

• Review proposed process modifications and gives comments on these proposals.

• Suggest improvements where necessary in coordination with Management to ensure that operations safety requirements are also included.