Brief Posting Description

The Senior Engineer Instrumentation Maintenance is responsible for leading the maintenance, reliability, availability, and performance optimization of all instrumentation systems across the Copper Concentrator Plant. The role ensures the safe, reliable, and cost-effective operation of field instrumentation, analyzers, control valves, actuators, weighing systems, process measurement systems, and associated plant equipment through effective maintenance strategies, shutdown planning, reliability improvement initiatives, asset integrity management, and continuous improvement programs. The position provides technical leadership to maintenance teams, supports operational excellence, and maximizes equipment availability while minimizing lifecycle costs and production losses. The incumbent is responsible for the maintenance and reliability of instrumentation systems associated with the Primary Crusher, Apron Feeders, Conveyors, Ore Stockpile Stacking and Reclaiming Systems, SAG Mill, Ball Mills, HIG Mill, Flotation Plant, Thickeners, Concentrate Filtration Plant, Slurry Pumps, Process Water Systems, Tailings Systems, and associated plant infrastructure. The role works closely with Operations, Reliability, Mechanical Maintenance, Electrical, Automation, and Project teams to achieve production, safety, reliability, and asset performance objectives while ensuring compliance with safety, environmental, and asset management standards.

Detailed Description

INSTRUMENTATION MAINTENANCE MANAGEMENT

Lead maintenance activities for instrumentation systems across the concentrator plant and supporting infrastructure.

Ensure maintenance practices support safe, reliable, and efficient plant operation.

Develop and implement maintenance strategies to maximize equipment reliability and availability.

Monitor equipment condition and recommend corrective and preventive actions.

Ensure compliance with OEM recommendations, instrumentation standards, and statutory requirements.

Support long-term asset lifecycle management and replacement planning.

Provide technical guidance on instrumentation maintenance planning, scheduling, and execution.

Support commissioning, startup, and ramp-up activities for instrumentation systems and equipment.

INSTRUMENTATION AUTOMATION / PLC / DCS INTERFACE

Provide technical leadership for the interface between field instrumentation and PLC, DCS, SCADA, and associated automation systems.

Ensure reliable communication and signal integrity between transmitters, analyzers, control valves, actuators, weighing systems, and PLC/DCS/SCADA systems.

Support troubleshooting of instrumentation-related PLC/DCS input and output signals, communication faults, alarms, interlocks, and control-loop performance issues.

Coordinate with Automation and Electrical teams for instrument signal interfaces, control system modifications, logic changes, and system upgrades.

Review instrumentation requirements for PLC/DCS/SCADA modifications, including I/O requirements, signal types, communication protocols, alarm and trip interfaces, and control-loop functionality.

Support loop checking, instrument calibration, functional testing, interlock testing, commissioning, energization, and startup activities involving instrumentation and automation systems.

Ensure proper configuration, documentation, and management of instrument I/O, loop drawings, instrument data sheets, cause-and-effect diagrams, alarm settings, and associated technical documentation.

Participate in troubleshooting and Root Cause Failure Analysis (RCFA) where instrumentation, PLC/DCS, or communication-system interfaces contribute to equipment or process failures.

Support implementation of improvements to process control, instrumentation reliability, measurement accuracy, and automation system performance.

Ensure instrumentation and automation interfaces comply with approved engineering standards, OEM requirements, cybersecurity requirements, HSE procedures, and applicable statutory requirements.

INSTRUMENT RELIABILITY & PERFORMANCE

Lead reliability improvement initiatives for field instrumentation, analyzers, control valves, actuators, weighing systems, sampling systems, and process monitoring equipment.

Analyze equipment failures and identify opportunities to improve reliability and maintainability.

Conduct Root Cause Failure Analysis (RCFA) for major instrumentation failures.

Facilitate Failure Modes and Effects Analysis (FMEA) studies.

Identify recurring equipment issues and implement sustainable corrective actions.

Develop reliability-centered maintenance strategies.

Monitor instrument performance against established reliability and availability KPIs.

Support predictive and condition monitoring programs for critical instrumentation assets.

PROCESS INSTRUMENTATION & ANALYZER SYSTEMS

Ensure safe and reliable operation of process instrumentation systems.

Maintain pressure, flow, level, temperature, density, pH, conductivity, and other process measurement devices.

Maintain online analyzers, sampling systems, and associated instrumentation.

Monitor instrument accuracy and implement corrective actions where necessary.

Ensure compliance with calibration standards and measurement integrity requirements.

Support process optimization and operational efficiency initiatives through accurate measurement and monitoring.

Experience:

Bachelor s Degree with 10+ years of experience in a Copper Concentrator Plant or related process plant with similar type of equipment is mandatory.

Minimum 8 years of experience in Instrumentation maintenance and reliability engineering is mandatory.

Proven track record of successfully managing maintenance and reliability of Instrumentation assets in large-scale mineral processing facilities.

Certifications: Candidates holding or pursuing any of the following certifications will have an added advantage:

Certified Maintenance & Reliability Professional (CMRP)

ISA Certified Control Systems Technician (CCST)

ISA Certified Automation Professional (CAP)

Six-sigma (BB)