Job Purpose

To design, implement, and commission instrumentation and control systems for the greenfield project, ensuring seamless integration, safety compliance, and operational reliability in a batch chemical plant environment.

Principal Accountabilities

1. Develop and review PFDs, P&IDs, mass & energy balances, and process datasheets for the new plant. 
2. Scale up processes from pilot/lab to commercial scale, ensuring design integrity and safety.
3. Provide field supervision during equipment erection, ensuring compliance with P&IDs and process intent. 
4. Lead process troubleshooting in existing operations and support debottlenecking studies. 
5. Drive process safety by participating in HAZOP, LOPA, and implementing recommendations. 
6. Coordinate with other engineering disciplines (Mechanical, Electrical, Instrumentation) for integrated design. 
7. Support commissioning, startup, and performance testing of process units. 
8. Optimize process parameters for yield, quality, and utility consumption. 
9. Document process manuals, operating procedures, and training modules for operations handover.

Major Challenges

• Translating lab/pilot data into a safe, efficient, and commercially viable full-scale plant design. 
• Managing process uncertainties and ensuring smooth commissioning with minimal operational disruptions.

Decisions

Independent Decisions:

• Day-to-day process design calculations and troubleshooting recommendations.
• Field adjustments during erection and commissioning within design limits.  

Decisions Requiring Approval:

• Major process technology changes and deviations from basic engineering design.

Interactions

Internal Clients - Roles you need to interact with inside the organization to enable success in your day to day work           

• DGM – Projects, R&D, Operations, and Safety teams.
• All engineering departments (Mechanical, Electrical, Instrumentation). 

External Clients - Roles you need to interact with outside the organization to enable success in your day to day work         

• Technology licensors (if any) and process consultants. 
• EPC contractors and equipment vendors. 
• Regulatory and environmental agencies.

Behavioural / Leadership Competencies

• Directing: Leads instrumentation team and coordinates with cross-functional groups. 
• Analysis & Decision Making: Analyzes technical specifications and selects optimal instrumentation solutions. 
• Communication: Effectively liaises between engineering, operations, and vendors.  
• Specialist Skill: Expertise in designing and commissioning instrumentation for hazardous chemical batch processes.

Dimension Skills

Contributes to capital and operating cost optimization through process design improvements.  

Knowledge

Educational Qualificationsa)    Qualifications

• Minimum Qualification: B.E./B.Tech. in Instrumentation/Electronics & Instrumentation/Control Engineering.
• Work Experience
• 8–12 years in instrumentation design and commissioning in chemical/pharmaceutical batch plants.

Specialist Skill / Niche Experience

• Greenfield/brownfield project experience is essential. 

 

Functional Competencies

• Expertise in process design, scale-up, P&ID development, and HAZOP.
• Proficiency in process simulation tools (Aspen Plus, HYSYS, ChemCAD).
• Strong knowledge of unit operations (reaction, distillation, filtration, drying) in batch mode.
• Understanding of process safety management (PSM) and environmental regulations.
• Troubleshooting and root cause analysis skills.