Senior Engineer / Assistant Manager - Control & Instrumentation (C&I)

Department: Control & Instrumentation

Reporting To: Head - C&I / General Manager - Operations & Maintenance

Role Summary:

We are looking for an experienced and technically competent Senior Engineer / Assistant Manager - Control & Instrumentation (C&I) to manage and maintain instrumentation and control systems at our 270 MW Power Plant located at Bela, Nagpur.

The candidate will be responsible for ensuring the reliable and efficient operation of C&I systems, with particular focus on Max DNA DCS, PLC, SCADA, field instruments, control valves, transmitters, sensors, analyzers, and related control systems. The role requires strong troubleshooting, preventive maintenance, calibration, and coordination skills to ensure maximum plant availability, reliability, and safe operations.

Key Responsibilities:

1. C&I Maintenance & Operations

• Plan and execute preventive, predictive, and breakdown maintenance of C&I equipment and systems.
• Ensure reliable operation of instrumentation and control systems associated with the 270 MW power plant.
• Monitor the health and performance of field instruments, control systems, and associated equipment.
• Ensure minimum downtime of C&I systems and timely restoration during breakdowns.
• Identify recurring C&I problems and implement appropriate corrective and preventive actions.

2. Max DNA DCS / PLC / Control Systems

• Operate, maintain, troubleshoot, and support Max DNA DCS and associated control systems.
• Troubleshoot DCS hardware, software, communication, I/O, networking, and control-loop related issues.
• Monitor and troubleshoot alarms, interlocks, trips, permissives, sequences, and control logic.
• Carry out necessary checks and modifications in DCS logic and control loops as per approved procedures.
• Maintain proper backups of DCS configurations, logic, graphics, and system parameters.
• Coordinate with OEM / service engineers for major Max DNA DCS issues, modifications, upgrades, and system-related activities.
• Ensure availability and reliability of DCS servers, operator stations, engineering stations, controllers, I/O systems, and communication networks.

3. Field Instrumentation

• Maintain and troubleshoot pressure, temperature, flow, level, vibration, speed, and other process measurement instruments.
• Handle calibration and maintenance of transmitters, sensors, switches, gauges, analyzers, and other field instruments.
• Ensure proper functioning of control valves, actuators, positioners, solenoid valves, and related accessories.
• Maintain calibration records and ensure timely calibration of critical instruments.
• Troubleshoot instrumentation loops and ensure accurate process measurement and control.

4. Preventive Maintenance & Reliability

• Prepare and implement preventive maintenance schedules for C&I equipment and systems.
• Analyze equipment failures and implement corrective / preventive measures.
• Maintain critical C&I spares and ensure availability of essential components.
• Participate in plant shutdown, overhaul, testing, and maintenance activities.
• Identify opportunities for improving C&I system reliability and reducing plant downtime.

5. Plant Coordination & Safety

• Coordinate with Operations, Electrical, Mechanical, and other maintenance teams for plant-related activities.
• Provide technical support during plant start-up, shutdown, equipment testing, and emergency situations.
• Ensure compliance with plant safety procedures and permit-to-work systems.
• Ensure safe isolation and restoration of C&I equipment during maintenance activities.
• Guide and supervise technicians and contract manpower involved in C&I maintenance.

6. Documentation & Reporting

• Maintain records of C&I breakdowns, preventive maintenance, calibration, inspection, and repair activities.
• Prepare daily / weekly / monthly maintenance and equipment status reports.
• Maintain documentation related to Max DNA DCS, PLCs, instrumentation drawings, P&IDs, loop diagrams, manuals, and maintenance history.
• Maintain records of DCS modifications, logic changes, alarms, interlocks, and system backups.
• Monitor maintenance KPIs and provide relevant technical inputs to management.
• Ensure adherence to company maintenance procedures and standards.

Skills Required:

• Strong technical knowledge of Control & Instrumentation systems in power plants.
• Hands-on experience in Max DNA DCS is highly preferred.
• Good knowledge of DCS, PLC, SCADA, HMI, and industrial control systems.
• Strong knowledge of field instrumentation, calibration, control valves, actuators, and analyzers.
• Good understanding of control loops, interlocks, trips, permissives, and process control.
• Ability to troubleshoot DCS hardware, software, I/O, communication, and networking issues.
• Ability to read and interpret P&IDs, instrument datasheets, loop diagrams, logic diagrams, and control schematics.
• Strong analytical and problem-solving skills.
• Good communication, coordination, and team-management skills.
• Proficiency in MS Office / Excel and maintenance reporting tools.

Preferred Candidate Profile:

• 05 to 08 years of relevant experience in C&I maintenance in a power plant.
• Candidates with hands-on experience in Max DNA DCS will be strongly preferred.
• Experience in operation, maintenance, troubleshooting, logic modification, alarm management, interlocks, and configuration of Max DNA DCS will be an added advantage.
• Experience in handling DCS, PLC, field instrumentation, control valves, transmitters, analyzers, and turbine / boiler instrumentation.
• Experience in power plant shutdown, overhaul, commissioning, and breakdown maintenance activities will be preferred.
• Candidates with experience in leading a team of technicians and managing day-to-day C&I maintenance activities will be preferred.
• Should be willing to work in shifts / during plant emergencies and shutdown activities as required.

Qualification:

B.E. / B.Tech - Electronics / Instrumentation / Electronics & Telecommunication or equivalent.