Engineer I - Instrument Maintenance

About Emirates Global Aluminium

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry.  EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

JOB PURPOSE:

Plan, control and execute maintenance activities of the DCS of the Power Plant in a safe, cost effective and efficient manner to minimize operational disruptions.

KEY ACCOUNTABILITIES:

• Oversees that all aspects of maintenance work are carried out in adherence with EGA’s Occupational Health and Safety standards and plant operating requirements.
• Identifies the needs for capital replacement projects of obsolete instrumentation and control systems.
• Plans & Executes control in control & instrumentation maintenance in the Power Generation and Balance plant areas efficiently within agreed budget.
• Maintain the DCS to an extremely high level of reliability, availability with defects corrected expeditiously
• Manages effective and timely completion of breakdown maintenance activities in the DCS with minimal equipment downtime and interruptions to Operations.
• Plans & Executes control in DCS maintenance in the Power Plant within agreed budget.
• Develops and initiates continuous improvement projects in the DCS to improve plant efficiency and to overcome obsolescence.
• Oversees DCS Spare Parts inventory is up-to-date and continually review spare parts requirements (in coordination with SCM and GE) to ensure that stock levels are maintained to minimize equipment down time.
• Identifies the needs for capital replacement projects of obsolete components in the DCS
• Effectively manages all maintenance crews under his control for safe, efficient and cost effective performance.
• Oversees effective and timely completion of breakdown maintenance activities with minimal equipment downtime and interruptions to operations' areas.

AUTHORITY/ DECISION MAKING:

• The major challenge in the job is analysing and generating corrective actions on non-routine problems occurring during emergency breakdown situations.
• The jobholder is responsible for carrying out the maintenance activities in accordance with the established operating procedures/policies, safety regulations and compliance with the IEC standards. However, for any changes to the existing procedures, prior approval by the area Engineer will be required
• The jobholder is responsible for carefully identifying equipment obsolescence and technology changes and to initiate repair, replacement and upgrades. The major decision making areas for the job holder are diagnostics and repair strategies in a major breakdown situation and defining job scope in major maintenance projects.

Equipment supervised (in brief):

Jebel Ali Site:

• Power Plant of 2350MW capacity with 23 Gas Turbines, 23 Heat Recovery Steam Generators, 7 Steam Turbines, Desalination Plant of 30MGPD capacity (with Product Water Blending and Distribution System), and essential auxiliary systems like Gas and Distillate Fuel Storage & Supply System, Compressed Air Supply & Distribution Systems, Sea Water Intake & Chlorination Plant System, all controlled by eight different types of OEM Control Systems and DCS.

Taweelah Site:

• Power Plant of 3000MW capacity with 9 Gas Turbines, 8 Heat Recovery Steam Generators, 9 Steam Turbines, RO plant, Fuel Gas Compressors, Air Compressors, Black Start Generators, Liquid Fuel Storage and Supply System, and Sea Water Intake & Chlorination System, controlled by GE Mark-VIe based DCS and OEM PLC Systems (GE-Fanuc and others).

QUALIFICATIONS & SKILLS:

Minimum Qualifications:

• Degree or diploma in Industrial Instrumentation or Electronics Engineering including computer related subjects or an equivalent qualification

Minimum Experience:

• Degree holder: Five years in a GE DCS –based combined cycle power plant in the C&I Maintenance Department
• Diploma holder: Twelve years in a GE DCS –based combined cycle power plant in the C&I Maintenance Department (GE Mark VIe control system and GE ICS).

Skills:

• Strong skills in interpreting engineering drawings/manuals
• Good planning, organizing & decision-making skills
• Excellent communication skills