Reporting to the Maintenance Manager, the Instrument Technician is responsible for executing the maintenance schedules of the Air Products Kochi facility.
Working with the guidance of the Maintenance Manager and alongside the Shift engineer and Assistant Plant Manager to ensure the smooth and reliable operation and maintenance of all aspects of the plant, with the aim of achieving the highest plant reliability and availability, whilst controlling maintenance related costs within the budget.
Nature and Scope
The Kochi Plant is Air Products first fully owned and operated plant in India; it represents a significant investment and includes “State of the Art” technology which makes it the most advanced Hydrogen Plant within the Corporation.
The plant consists of 3 main elements: -
2x80 MMSCFD Steam Methane Reformers (SMR) with PSA’s for H2 purification.
18 MW Kawasaki Gas Turbine integrated with both reformers.
An Air Products Air Separation Unit (ASU) Producing Nitrogen and Oxygen.
A future expansion is expected for Syngas (H2/CO) production consisting of: -
Amine System for CO2 removal (aMDEA)
Cryogenic separation and purification of CO.
The scope of maintenance for the Production Plants, equipment and associated systems includes: -
Compressors, Gas Turbines, Generators, Motors, Fans, Pumps (cryogenic and other), Pressure Vessels and piping systems, Relief Valves, Control Valves, Heat exchangers, Furnaces, Burners, Cryogenic turbines, Computer control systems, Trip Systems, Analysis equipment, measurement and metering system etc.
The customer is Bharat Petroleum Corporation Ltd. (BPCL), Kochi refinery and the Air Products plant is located within the customer’s site. The products from the Air Products plants go directly to the customer as part of their refinery expansion. There is a high level of integration between BPCL and Air Products with respect to feed stock’s, products and utilities. The products are critical to refinery unit operations.
The plants run on continuous basis and there is a strong emphasis of high reliability and high efficiency with contractual penalties against Air Products for under performance.
Air Products owns, operates and maintains Hydrogen Plants and ASU’s around the globe with Operations in over 50 countries, in excess of 80 hydrogen plants and 350 ASU’s. As such we have a wealth of expertise and have well established work processes in place for the reliable and efficient operation of our plants. The Plant Manger will be expected to work closely with the Global Communities of expertise and ensure consistent compliance with these work processes.
Prior to facility operation the individual will have a period of training before plant commissioning begins, where they will have a role setting up the permanent site maintenance team, establishing site procedures and participating in plant commissioning.
Ensuring all planned and unplanned maintenance work is carried out according to Air Products safety procedures, ensuring KPIs are met or exceeded.
Ensure to comply with AP and local safety, health and environment standard, fulfill the mandatory safety requirement and activities: safety training, safety meeting, and all other requirements by AP EH&S and local regulation.
Troubleshooting and rectifying equipment upsets and failures in a timely and efficient manner. Monitor the serviceability of plant equipment and facilities and ensure they adhere to safety, housekeeping and environmental requirements.
Responsible for all instrument and control system equipment regular maintenance and repairing, such as all field instrumentation, valves, flow meter, transmitter, control circuit, monitoring, DCS, PLC etc.
Response to maintenance requirements that could be scheduled or unscheduled/emergency jobs, on 24/7 base, prompt response to requests for assistance and putting in the time and effort to meet our customer’s expectations.
To be familiar with all equipments in plants, maintain all maintenance equipments accurate documents integrity and equipment history database reachable.
Provide hand-on technical skills at the troubleshooting and all related maintenance work or supporting work responsible.
Perform preventive maintenance work and support to implement Mechanical Integrity work, troubleshooting, repair for all equipment.
Coordinate or assist of supervision the contractor’s work in the facility or shop to guarantee safety and quality and reliability.
Provide technical reports through the specified datasheet or checklist.
Reporting-Time entry weekly and assist supervisor to prepare technical reports.
A diploma in Control and Instrumentation engineering with minimum 10 years as a hands-on maintenance technician in refinery, ammonia, methanol, chemical process, power generation, marine industries or similar.
Will have experience in major shutdown support, project work, plant operations and maintenance efforts.
Ability to read & understand P&ID’s, single line diagrams.
Familiarity with process control and communication protocols. Experience with Siemens DCS would be preferable.
Familiarity with Analytical and Emerson Metering system would be highly desirable.
Knowledge of vendor contracts and knowledge of shop support in the region is desirable.
Must be team oriented and have a willingness to learn and further develop technical skills.
Working experience in a gas, petrochemical or chemical refinery, ammonia, methanol, chemical process, power generation, marine industries or similar for instrument/control hand on troubleshooting experience in the field at some areas of field instrumentation, valves, flow meter, transmitter, control circuit, monitoring, DCS, PLC etc with basic skills and knowledge in understanding control circuit, wiring and schematic drawing.
Favorable hand on experience at least one of below instrument equipments: Field valves: Fisher, Samson, Jamesbury/Metso, Severn Glocon, Mapag, IR valve, NELES-JBURY, VERIFLO, FOXBORO, Flowmeters; Analyzers: THERMO, TELEDYNE, SERVOMEX, DELTA F, KONTROL, XENTAUR, GE Panametrics, ABB, Angilent, SIEMENS, SYSTECH, PMS, Peak, Drager, ANALOX, Michell, UHP LOX, Sensidyne, MSA, Hartmann&Braun; DCS/PLCs: Siemens, GE, ABB, Honeywell; Metering/Measurement System : Emerson Magnetic, DP, Coriolis, Ultrasonic Flowmeters
Good Communication & coordination skills.
Fluent in oral and written English language.
Knowledge of Malayalam is preferable.