Experience: • Graduate Engineer: 5–7 years • Diploma Engineer: 8–10 years No. of Positions: 1 Maintenance Model: 100% In-house Instrumentation Maintenance Preferred Industry: API / Pharmaceutical / Chemical / Process Industry Reporting To: Engineering / Maintenance Head Job Purpose To take complete ownership of in-house instrumentation maintenance, troubleshooting, calibration, automation, and control systems across the API plant, including critical utility equipment. The incumbent will be responsible for ensuring high availability and reliability of instrumentation and automation systems, with strong hands-on experience in DCS/SCADA systems, plant implementation, commissioning, preventive maintenance, and breakdown troubleshooting. Key Responsibilities 1. Instrumentation Maintenance • Take complete responsibility for preventive, predictive, and breakdown maintenance of all plant instrumentation. • Ensure reliable operation of field instruments, control systems, panels, and automation equipment. • Independently troubleshoot instrumentation-related failures and minimize plant downtime. • Develop and implement comprehensive in-house instrumentation maintenance practices. • Ensure proper functioning of instruments associated with process and utility equipment. 2. DCS / SCADA / Automation • Hands-on experience with Yokogawa, Emerson, Siemens, or equivalent DCS/SCADA systems. • Troubleshoot DCS/SCADA hardware, software, communication, I/O, control loops, alarms, interlocks, and associated systems. • Understand DCS architecture including: o Controllers o I/O modules o Engineering stations o Operator stations o Communication networks o Marshalling panels o Field instrumentation • Monitor and troubleshoot PLC/DCS/SCADA communication issues. • Understand control logic, sequence control, interlocks, permissives, alarms, and trip systems. • Support modifications in control logic and configuration in accordance with approved change-control procedures. 3. Plant Implementation & Commissioning • Experience in plant instrumentation implementation and commissioning is essential. • Participate in instrumentation engineering, installation, loop checking, testing, commissioning, and start-up activities. • Review instrument specifications, datasheets, P&IDs, instrument index, I/O lists, cable schedules, and loop diagrams. • Coordinate installation and commissioning of: o Pressure instruments o Temperature instruments o Flow instruments o Level instruments o Analytical instruments o Control valves o On/off valves o Transmitters o Switches o Sensors • Perform loop checking, calibration, functional testing, interlock verification, and commissioning support. 4. Utility Equipment Instrumentation The incumbent must have good knowledge of instrumentation associated with plant utility equipment, including: • Water and brine chillers • Air compressors • DG sets • Captive power generators • AHUs/HVAC systems • Boilers/steam systems, wherever applicable • Cooling towers • Pumps • Water treatment systems • ETP/STP and other utility systems • Other critical process and plant utilities • Troubleshoot sensors, transmitters, control valves, actuators, VFD interfaces, alarms, trips, and interlocks associated with utility equipment. • Understand the impact of instrumentation faults on overall equipment and plant operation. 5. Preventive & Predictive Maintenance • Develop and execute an effective instrumentation preventive maintenance schedule. • Define PM frequencies based on instrument criticality, OEM recommendations, operating conditions, and historical failure data. • Ensure timely calibration, inspection, testing, and servicing of instruments. • Identify potential failures through condition monitoring and parameter trends. • Analyze recurring failures and implement corrective and preventive actions. • Ensure minimum breakdown and maximum availability of critical instrumentation. 6. Calibration & Instrument Reliability • Plan and execute calibration of critical process and utility instruments. • Ensure calibration is carried out using appropriate standards and approved procedures. • Maintain calibration records and instrument history. • Troubleshoot calibration failures, instrument drift, signal abnormalities, and measurement errors. • Coordinate with QA/Validation teams for instrumentation-related qualification and calibration requirements in pharmaceutical environments. 7. Control Valves & Final Control Elements • Troubleshoot and maintain control valves, actuators, positioners, solenoid valves, and associated accessories. • Understand valve sizing/basic characteristics and positioner operation. • Diagnose issues such as valve hunting, sticking, signal failure, air supply problems, and position feedback errors. • Ensure proper functioning of final control elements in process and utility systems. 8. Instrumentation Troubleshooting • Diagnose faults related to: o 4–20 mA signals o Digital signals o HART communication o Fieldbus/industrial communication o RTDs and thermocouples o Pressure/DP transmitters o Flow meters o Level transmitters o Control valves o PLC/DCS I/O o Power supplies o Instrument air systems • Use appropriate testing and calibration instruments for fault finding. • Conduct root-cause analysis of critical instrumentation failures. 9. Spare Parts & Maintenance Planning • Identify critical instrumentation and automation spares based on equipment criticality and failure history. • Develop and maintain critical spare lists for DCS/SCADA, PLC, transmitters, control valves, sensors, I/O modules, power supplies, communication components, etc. • Ensure availability of critical spares to support in-house maintenance. • Coordinate with stores/procurement for timely procurement of critical items. • Maintain equipment and spare-part history. 10. SAP & Documentation • Plan and record preventive and breakdown maintenance activities in SAP PM, wherever applicable. • Raise, execute, and close maintenance work orders. • Maintain instrument history, calibration records, breakdown reports, PM checklists, and corrective-action records. • Maintain updated: o Instrument index o I/O list o Loop diagrams o Instrument datasheets o Calibration procedures o PLC/DCS documentation o Control narratives o Cause & Effect diagrams o As-built drawings 11. Safety, GMP & Compliance • Ensure compliance with GMP, EHS, SOP, LOTO, Permit-to-Work, electrical safety, and process safety requirements. • Follow approved procedures for modifications to DCS/PLC/SCADA systems. • Ensure appropriate change-control procedures are followed for automation modifications. • Support internal, customer, regulatory, and external audits related to instrumentation and automation. • Ensure instrumentation maintenance activities do not compromise product quality, safety, or validated systems. Required Technical Competencies • Strong hands-on experience in instrumentation maintenance in API/Pharma/Chemical/Process industries. • Strong experience with Yokogawa / Emerson / Siemens DCS/SCADA or equivalent systems. • Experience in plant implementation, commissioning, start-up, and troubleshooting. • Strong knowledge of preventive maintenance systems. • Good knowledge of field instrumentation and control systems. • Experience with PLC/DCS/SCADA communication and troubleshooting. • Knowledge of control valves, actuators, positioners, transmitters, sensors, and analytical instruments. • Strong troubleshooting capability for analog/digital signals, I/O systems, communication, and control loops. • Good understanding of P&IDs, loop diagrams, instrument datasheets, I/O lists, and Cause & Effect diagrams. • Knowledge of utility equipment instrumentation is essential. • Working knowledge of SAP PM and computerized maintenance systems. • Good computer literacy. Behavioral Competencies • Strong hands-on approach with willingness to independently troubleshoot instrumentation systems. • High ownership for plant automation and instrumentation reliability. • Strong analytical and problem-solving skills. • Ability to handle critical breakdowns under time pressure. • Good team leadership and coordination skills. • Strong focus on preventive maintenance and reliability improvement. • Good communication and documentation skills. • Safety- and compliance-oriented approach. Key Performance Indicators (KPIs) • Instrumentation system availability and reliability. • Reduction in instrumentation-related breakdowns and plant downtime. • Preventive maintenance compliance. • Calibration compliance for critical instruments. • Timely resolution of instrumentation breakdowns. • Reduction in recurring instrumentation failures. • DCS/SCADA/PLC system availability. • Critical spare availability. • Successful execution of commissioning and plant modification projects. • Compliance with GMP, EHS, change control, and engineering procedures. • Accuracy and timely completion of SAP/maintenance documentation. Candidate Profile The ideal candidate should be an experienced Instrumentation & Automation professional from an API, pharmaceutical, chemical, or process industry, with strong hands-on expertise in DCS/SCADA systems such as Yokogawa, Emerson, or Siemens. The candidate should have proven experience in plant implementation, commissioning, preventive maintenance, breakdown troubleshooting, calibration, and utility instrumentation, and should be capable of establishing and managing a robust 100% in-house instrumentation maintenance system.
