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Job Description
I. Job purpose:
To lead all I&C maintenance activities in the IGCC Power plant, including preventative, corrective, and Predictive maintenance, scheduled outages, planning for shutdowns, and overhauling work activities; Organizing maintenance, fixing and modification of all I&C machinery in accordance with overall maintenance plans, HSE guidelines and quality standards to ensure plant availability and machinery reliability.
II. Main Responsibility/ Accountabilities
Leadership
- Supervise the activities and work of the team members to ensure that targets and objectives are achieved, and the business plan is delivered in line with the required policies, processes, procedures, and systems.
- Attract and develop key talent while leading team performance.
- Facilitate the development of explicit knowledge for mentoring and talent pipeline future proofing.
Maintenance Management
- Supervise the I&C preventive, corrective maintenance, and overhauling work activities to ensure safe and efficient application of procedures and implementation of optimal I&C maintenance and availability of I&C Equipment and Control Systems.
- Ensure that all documentation is completed in SAP correctly such as the Log, outlining the fault, method of repair and the time, labor and materials used to support timely availability of information.
- Handle the timely response to all emergency breakdowns and provide prompt corrective action to ensure plant availability, thereby minimizing downtime and the possibility of liquidity damage.
- Develop and promote a condition based preventive maintenance culture on day-to-day basis by conducting fixing and root cause analyses, finding solutions to reduce reactive maintenance.
Health, Safety, Security & Environment
- Ensure all maintenance work is carried out according to JIGPC safety procedures, ensuring critical metrics are met or exceeded.
- Actively promote and drive safety excellence for contractors and JIGPC staff, through active participation and compliance with JIGP’s safety procedures.
- Enforce to all relevant health, safety, security and environmental procedures, instructions, and controls so that the safety of employees and environmental compliance can be guaranteed.
Reliability
- Ensure that effective predictive and integrity-based maintenance programs are followed that are consistent with regional programs, reducing unplanned shutdowns and ultimately enhancing overall plant profitability and reliability.
- Make timely and correct decisions based on fact and sound judgement, in order to keep plant downtime to a minimum, in both planned and un-planned situations.
- Chip in the identification and implementation of change initiatives, programs and projects in line with the organization’s standards.
- Review and analyze I&C machinery maintenance data and conduct site engineering studies to figure out feasibility of introducing modifications to increase reliability and efficiency of plant, thereby ensuring continuous improvement and operational excellence.
- Lead Root Cause Analyses (RCAs) within technology fields, driving solutions to problems.
Skills
Technical Skills
- Fix critical problems/breakdowns of I&C machinery and investigate, diagnose faults to settle the best proper action/repairs while ensuring they follow JIGPC’s quality and HSE standards.
- Provide or identify domain expertise for all aspects of the process and I&C teams, supplying to the overall operational efficiency.
- Lead and prioritize the workload of engineering team & subcontractors.
- Lead technical programs with strategic importance to our operations.
- Develop and maintain technical service bulletins, standard maintenance operating instructions and ensure alignment to technical standards.
- Provide timely support for operational challenges, technical fixing, and propose recommendations to address specific risks.
- Locate and develop local resources (contractors, vendors, etc.) for improved plant support.
- Liaise daily with Production and maintenance staff, to ensure that potential issues are identified, and plans created to rectify the issues in an appropriate and timely manner.
Documentation
- Ensure that all maintenance documentation for the I&C activities are completed correctly including the Maintenance Log, outlining the fault, method of repair and the time, labor and materials used to support timely availability of information.
Cost control
- Capture all relevant information in order to help ensure that all maintenance is carried out in the most cost-effective manner, taking into account the cost of execution relative to downtime and business area needs.
- Work with the Maintenance Manager and Maintenance Planner to help ensure that accurate maintenance budgets are established for longer term work and that the work is subsequently completed within the available budgets.
- Ensure that all ongoing and future maintenance costs are readily available, to ensure cost control and forecasting is achieved.
Material and Tools Management
- Own the preparation of monthly / annual requirements for machinery, spare parts and general materials for the I&C unit within the plant to support timely availability of requirements as per maintenance plans and budget constraints.
- Evaluate quotations provided by the procurement department to identify and provide recommendations on the most appropriate materials / machinery for the plant.
CMMS/SAP Management
- Supervise the effective administration of SAP processes within the I&C maintenance section and enforce to SAP guidelines in all related aspects of maintenance planning, scheduling, data management such as breakdowns review, corrective maintenance notification, creating maintenance work orders and planning to ensure data/system integrity in line with JIGPC defined standards.
III. Dimensions
- All equipment at the Power Block Cogen I & II
- Geographical Scope: Power Block
- Budget Impact: Approx. $78MM in FY 2024
- Replacement investment of facility> $3.0BB
IV. Skills
- Practical experience and know-how of I&C engineering
- Knowledge of downtime analysis and practical knowledge of problem-solving tools
- Knowledge of maintenance management methods, of predictive inspection tools and of CMMS (Computer Maintenance Management System, good knowledge of SAP Template desirable)
- Detailed understanding of preventative/predictive maintenance methods
- Mentoring, coaching and people leadership skills.
- Knowledge of the operations in combined cycle power plants, Siemens Gas and Steam turbine experiences are an added advantage.
V. Qualifications & Experience
- Postgraduate / Graduation in I&C Engineering
- Minimum of 12 to 15 years of Maintenance experience in Power plants/ IGCC/CCPP Plants
- Handson Experience with Siemens and Honeywell Control Systems are an added advantage.
- Solid Understanding of the Maintenance work process.
- Knowledge of Maintenance software – preferably SAP.
- Demonstrated effective leadership and decision-making skills.
- The successful candidate must be a self-starter with a solid work history and excellent references along with the ability to work in a team-oriented environment.
- Must be knowledgeable and experienced in Refining, Chemical, Petro Chemical equipment, and specifications.