Instrument Engineer

Description

Summary: The Instrumentation & Automation Engineer ensures safe, reliable, and efficient operation of I&A assets through planning, execution, and monitoring of maintenance activities. Highlights: 1. Maximize availability, reliability, and operational efficiency of I&A assets. 2. Supervise Instrument Technicians, providing technical guidance and coaching. 3. Implement continuous improvements for equipment, services, and tasks. **JOB SUMMARY** * The Instrumentation \& Automation Engineer is responsible for ensuring safe, reliable, and efficient operation of Instrumentation \& Automation assets by planning, executing, and monitoring preventive, corrective, and shutdown maintenance activities. The role supports VPS principles and complies with Vale’s HSE, and Code of Ethics standards while maintaining high\-quality work and equipment performance. **MAIN CHALLENGES*** Maximize the availability, reliability, and operational efficiency of instrumentation and automation assets by implementing proactive maintenance strategies, optimizing maintenance practices, and minimizing unplanned downtime while ensuring compliance with HSE and quality standards. * Analyze equipment and control system performance data to identify trends, predict potential failures, and implement preventive actions that improve asset performance, reliability, and operational continuity. * Maximize the reliability and availability of Continuous Emission Monitoring Systems (CEMS), Particulate Matter (PM) monitoring systems, gas analyzers, process analyzers, sampling systems, and associated control equipment to ensure compliance with environmental regulations, operational integrity, and process optimization. Experienced in preventive and corrective maintenance, analyzer shelters, sample conditioning systems, environmental monitoring equipment, and data acquisition systems. * Ensures instrument reliability through root cause analysis, failure investigations, predictive maintenance strategies, and adherence to international standards and safety requirements. * Supervise Instrument Technicians within the assigned area, providing technical guidance, work planning, coaching, competency development, and performance oversight to ensure maintenance activities are executed safely, efficiently, and in accordance with company standards and procedures. **MAIN RESPONSIBILITIES*** **Safety and Compliance:** * Adhere to Vale’s Health, Safety, and Environment (HSE) guidelines in all activities. * Comply with all aspects of Vale Production System (VPS). * Raise safety issues, conduct behavior dialogues, and promote a safe work environment. * Elaborate/review Work Instructions. * Follow up and treat the Unsafe Conditions of the area under your responsibility. * Follow up the 5S demands (Cleaning, Civil Works, Painting, etc.) for the workstations under your responsibility. * **Maintenance Planning and Execution:** * Plan and coordinate maintenance activities for instrumentation and automation systems (PLC, DCS, SCADA, field instruments) based on maintenance schedules and operational requirements. * Review and optimize maintenance plans using historical maintenance data and equipment condition. * Ensure proper execution of preventive, predictive, and corrective maintenance activities, including calibration programs. * Coordinate and supervise maintenance during shutdowns and Turnarounds (T/A). * Develop and improve SOPs and JSAs to enhance safety and operational efficiency. * Monitor availability of critical spare parts and support inventory control. * Ensure maintenance activities are executed and recorded in CMMS (e.g., SAP) as per approved plans. * Daily verify shift reports and GPV for Downtimes and Losses and Analysis. * Join weekly planning and performance meetings. * Apply DBM to the team under your responsibility. * **Equipment Performance and Mentoring:** * Monitor instrumentation and control system performance to ensure stable and safe operation. * Review reports and system diagnostics to identify abnormalities and recommend corrective actions. * Support troubleshooting of control system issues (PLC/DCS faults, signal failures, control loop issues). * Assist in maintaining calibration accuracy and system functionality. * **Technical Expertise and Support:** * Provide technical support for instrumentation and automation systems troubleshooting. * Liaise with OEMs and vendors for technical support and spare parts clarification. * Support safety and incident investigations related to instrumentation and automation systems. * Review technical specifications and procurement requests. * Guide technicians and junior staff in maintenance practices and standards. * Implement continuous improvements of equipment / services, tasks. * Provide Innovative ideas to support instrument asset performance management. * Supporting Instrument \& Automation Supervisor in implementing key instrument Engineering initiatives to maximize plant availability, without compromising plant safety * Provide instrumentation technical support to Bad actors’ resolution. * Identify gaps in existing practices and tools and manage the process of developing new practices or toolkit items that enhance Vale technological offerings. * Troubleshooting analyzer faults, communication failures, drift issues, and sampling system problems. * Verifying compliance with environmental regulations and emission permit requirements. * Managing analyzer spare parts, consumables, and maintenance contracts. * Configuring analyzer communication interfaces with DCS, PLC, SCADA, and Environmental Reporting Systems. * Leading analyzer upgrades, migrations, and modernization projects. * Troubleshoot complex instrumentation and control system failures. * Manage instrument spare parts, critical equipment inventory, and obsolescence programs. * **Documentation and Reporting:** * Understand and complete daily reports/checklists for all maintenance activities. * Ensure WO confirmation with Failure Codes, Tech Reports and any other relevant information in a standardized way (historical basis for reliability studies). * **Budget Support:** * Contribute to budget preparation and monitor costs to ensure efficiency. * Prepare monthly reports, including KPIs, equipment performance, and HSE indicators, and present findings to management. * **Contract Management:** * Oversee external maintenance contracts, including preparing Statements of Work (SOWs), evaluating technical proposals, and managing contract execution. * **Lead Project and Change Management:** * Lead and implement the project and management of change through continuous improvement of departmental systems, processes, and practices. ***(\*) At anytime, Vale can review, at its own discretion, the job roles and responsibilities according to its strategy.*** **QUALIFICATION*** Experience: Minimum of 5 years’ Experience in the same field * Bachelor in Instrument, Automation, Control System, Electronics, Electrical Engineering or any related field. * Solid knowledge of instrumentation and automation systems, including control systems, DCS/PLC, industrial networks, safety, maintenance, and reliability.