Automation Engineer

Business Unit

Inland BU

Department

Engineering

Site

Dwaalboom

Location - Town / City

Thabazimbi

Job Advert Summary

The Engineer Automation is responsible for providing specialist onsite support relating to automation systems, process control, construction activities, commissioning, testing, training, and operational readiness across the plant environment. The incumbent will play a key role in ensuring that all automation and control systems are implemented, maintained, and optimised in line with PPC operational requirements, engineering standards, safety standards, and business strategy.

Minimum Requirements

Bachelor of Technology Degree in Electrical or Electronic Engineering, (NQF level 7)

Bachelor of Science Degree in Electrical or Electronic Engineering (NQF level 8)

Valid Driver’s License code B with own vehicle

5 - 7 years Experience in Process Control and Instrumentation or 5 - 7 years Experience in Process Control and Instrumentation both in integrated cement operations

Clinker and cement manufacturing experience

Experience in the management of IT / PCS projects within cement industry

Duties and Responsibilities

Process Control and Instrumentation Management

Review the conceptual, basic and detailed design related to process control and instrumentation and ensure adherence to the PPC standards.

Provide technical advice and input to the Project team on quality and procurement-related matters

Provide process control, instrumentation, and automation support to project teams, construction teams and operational teams

Maintain alignment between the project team and operational teams related to the subject matter

Maintain alignment between the project team and industrial support/Group process control and instrumentation specialist related to the subject matter

Assist on-site during the construction and commissioning of the project

Assist Dwaalboom PC&I department to review and update policies and procedures based on project learnings

Manage the change management procedure related to project process control

Quality inspections and checks

Report on project progress activities on site

Act as a lead on the project with regard to process control and instrumentation

Technical Skills

Deep skills in PCS7 skills in including programming, object block, PID loop tuning etc.

Skills in specific electric/electronic cement plant equipment maintenance, like for example:

• Combustion gas analyser
• Stack emissions analysers monitoring systems
• Repair, maintenance and commissioning of new Motor control Centres (MCC) with DP Profibus equipment like Siemens Simocode and ABB smart relays.

High skills in industrial field buses (especially Profibus DP), troubleshooting, assessment, improvement and performance monitoring in both fibre optic and copper wiring

Deep understanding of installation, maintenance and troubleshooting of frequency converters (ABB and Siemens), soft starters, liquid starters, in low and medium voltage and from 1.2 kW to 3 MW power.

Apply deep understanding of cement manufacturing process, interlocks in main equipment, start up sequences, combustion stations, hydraulic systems, mills, kilns, separator, process fans, specific protection machine interlocks, wide range sensors: like level (including nuclear level switches), pressure, temperature, current, voltage, gas, vibration, flow, position, and other sensors.

Calibration, repair, maintenance and commissioning of weighbridges, weight feeders, Coriolis, flowmeters, Pfister, scales, and weighing systems in general.

Develop and feedback a specific care plan for areas related with control, automation and instrumentation

Support and Development

Support the Engineering Manager in CAPEX definition, supervision and planning in areas under their responsibilities

Support Dwaalboom PC&I department with upgrades to their process control systems, and ensure that electrical and instrumentation drawings are correct and up to date

Participate in PPC’s digitalisation efforts from a manufacturing systems technology perspective

Ensure process control strategies and processes are in line with industry specifications and regulations.

Risk Management

Balance risk with the cost for the project in line with PPC standards

Monitor progress and performance of the project in line with the PC&I standards and the contractual agreement specifications.

Conduct a systems audit for reliability and performance on the project

Follow up and support the project as well as operations where required

Contribute to lessons learnt on the project and implement as part of updated standards and procedures.

Compliance and Reporting

Monitor project and plant compliance with discipline-specific legislation and regulations

Provide support to the Project, Industrial support and operations team with their submission of regulatory reports for compliance

Ensure supporting documentation (manuals, operating procedures, certificates), training records are in place as part of operational readiness

Stakeholder Management

Build and maintain positive stakeholder relationships across PPC to ensure proper understanding of user experience and stakeholder requirements

Provide support to PPC Dwaalboom PC&I department by conducting design reviews, construction activities, inspections, investigations, consultations, commissioning and reporting

Share best practices and key learnings with internal stakeholders

Develop or adopt training material from service providers in line with PPC standards and practices

Provide training to all stakeholders based on the needs analysis