Position Name: Engineer / Sr. Engineer PLC / DCS / SCADA – Central Maintenance (Utilities – E&I;)

Department: Central Maintenance

Sub-Department: Utilities – Electrical & Instrumentation (E&I;)

Reporting To: Manager – Central Maintenance (Utilities – E&I;)

Role Objective:

To ensure the reliable, safe, and efficient operation, maintenance, troubleshooting, and continuous improvement of PLC, DCS, SCADA, and Industrial Automation systems supporting utility operations across the iron and steel plant. The role is responsible for maximizing automation system availability, ensuring process continuity, enhancing cybersecurity awareness, supporting modernization initiatives, and improving operational efficiency through advanced automation and control technologies.

Role Responsibilities:

- Plan, supervise, and execute preventive, predictive, corrective, and breakdown maintenance activities for PLC, DCS, SCADA, HMI, Industrial PCs, Remote I/O, and utility automation systems.
- Ensure uninterrupted operation of automation systems controlling utilities such as Power Plants, Water Treatment Plants, Pump Houses, Cooling Towers, Air Compressors, Oxygen Plants, Blast Furnace Utilities, Gas Distribution Systems, and other central utility facilities.
- Diagnose and troubleshoot hardware, software, communication, and process control issues affecting PLC, DCS, SCADA, and HMI systems to minimize downtime.
- Maintain PLC controllers, DCS controllers, engineering stations, operator workstations, historian servers, SCADA servers, industrial networking equipment, and field communication systems.
- Perform PLC and DCS program backup, restoration, modification, documentation, version control, and change management in accordance with approved procedures.
- Develop, modify, and optimize PLC logic, DCS control strategies, HMI graphics, alarms, interlocks, sequences, and automation applications to improve system reliability and process performance.
- Configure, maintain, and troubleshoot industrial communication protocols including Profibus, Profinet, Modbus RTU/TCP, Ethernet/IP, OPC, Foundation Fieldbus, HART, CAN, DeviceNet, and Industrial Ethernet networks.
- Monitor and maintain industrial servers, virtual machines, engineering workstations, operator consoles, industrial switches, firewalls, and network infrastructure supporting automation systems.
- Coordinate commissioning, loop checking, SAT/FAT activities, I/O testing, control logic validation, and startup support for automation projects and plant expansion activities.
- Maintain system backups, disaster recovery plans, cybersecurity patches, antivirus protection, user access management, and software license compliance for automation systems.
- Perform periodic health assessments of PLC/DCS hardware, controllers, communication modules, power supplies, servers, network devices, and redundancy systems.
- Analyze recurring automation failures using Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), and reliability engineering methodologies.
- Support integration of field instruments, analyzers, electrical systems, Variable Frequency Drives (VFDs), Motor Control Centers (MCCs),



and process equipment with PLC/DCS platforms.
- Coordinate with Electrical, Instrumentation, Mechanical, Operations, IT, OEMs, system integrators, and contractors during maintenance, upgrades, shutdowns, and modernization activities.
- Prepare automation system documentation including architecture drawings, network diagrams, software backups, logic narratives, maintenance procedures, alarm management reports, and technical manuals.
- Monitor automation system performance, controller loading, communication health, alarm statistics, historian performance, and system availability KPIs.
- Ensure compliance with Management of Change (MOC) procedures during software modifications and automation upgrades.
- Support digitalization, Industry 4.0, IIoT, Advanced Process Control (APC), predictive maintenance, and smart utility initiatives.
- Ensure compliance with PTW (Permit to Work), LOTO (Lockout-Tagout), electrical safety procedures, cybersecurity requirements, and statutory regulations during maintenance activities.
- Conduct technical training and knowledge-sharing sessions for engineers, technicians, operators, and contractors on automation systems and troubleshooting methodologies.
- Responsible for fostering a respectful and inclusive work environment, free from all forms of harassment and discrimination.
- ISO (9001, 14001, 45001 & 50001):
- Customer Focus: Ensure reliable automation and control systems that support uninterrupted utility operations and stable production across all plant facilities.
- Process Effectiveness: Improve automation system availability, reduce process interruptions, optimize control strategies, and enhance maintenance effectiveness through standardized engineering practices.
- OH&S; Contribution: Ensure strict adherence to electrical safety, functional safety, cybersecurity awareness, hazard identification, PTW, LOTO, emergency response procedures, and incident reporting requirements during automation maintenance.
- Environmental Responsibility: Maintain automation systems that support environmental compliance by ensuring reliable monitoring and control of emissions, water treatment, gas handling, energy systems, and environmental protection equipment.
- Energy Performance: Optimize control systems, process automation, utility monitoring, and energy management systems to improve overall plant energy efficiency and support ISO 50001 objectives.
- Ensure compliance with SA8000 requirements and promote ethical labor practices, workplace safety, and employee welfare within the assigned area of responsibility.

Competencies:

- Robust technical expertise in PLC, DCS, SCADA, HMI, and industrial automation systems.
- In-depth understanding of industrial process control, utility automation, instrumentation integration, and industrial communication networks.




- Expertise in automation troubleshooting, control logic development, and system optimization.
- Knowledge of industrial cybersecurity principles, redundancy architectures, and automation lifecycle management.
- Strong analytical and problem-solving capabilities using RCA, FMEA, and reliability engineering techniques.
- Effective planning, project coordination, vendor management, and documentation skills.
- Commitment to operational reliability, process safety, digital transformation, and continuous improvement.

Key Skills:

- PLC Programming (Siemens, Rockwell, Schneider, Mitsubishi, ABB, Omron, GE, etc.)
- DCS Platforms (ABB, Yokogawa, Honeywell, Emerson, Siemens, Foxboro, etc.)
- SCADA Development and Maintenance
- HMI Configuration and Visualization Systems
- Industrial Communication Networks (Profibus, Profinet, Modbus, OPC, Ethernet/IP, Foundation Fieldbus, HART)
- Industrial Ethernet, Managed Switches, Fiber Optic Networks, and Redundant Communication Systems
- PLC/DCS Integration with Electrical Systems, Drives, MCCs, and Field Instrumentation
- Industrial Server Administration, Virtualization, Backup, and Disaster Recovery
- Alarm Management, Historian Systems, Process Data Collection, and Reporting
- Functional Safety Systems, Interlocks, Sequence Control, and Logic Validation
- Automation Project Commissioning, Loop Checking, FAT/SAT, and Startup Support
- CMMS/SAP Maintenance Management and Technical Documentation
- Industrial Cybersecurity Awareness and Automation Network Management

Abilities:

- Lead troubleshooting of critical automation and control system failures during plant operations.
- Develop and optimize PLC/DCS logic for improved process reliability and operational efficiency.
- Coordinate multidisciplinary maintenance activities involving automation, instrumentation, electrical, mechanical, and operations teams.
- Manage automation system upgrades, migrations, software revisions, and modernization projects.
- Analyze complex process control issues and implement sustainable engineering solutions.
- Mentor engineers and technicians in automation technologies, industrial networking, and control system maintenance.
- Adapt to emerging technologies including IIoT, digital twins, advanced analytics, cloud connectivity, and Industry 4.0 applications.

Knowledge:

- Diploma / B.E. / B.Tech in Electrical, Electronics, Electronics & Instrumentation, Instrumentation, Automation, Control Engineering, or equivalent Engineering discipline.
- Minimum 2 - 7 years of experience in PLC, DCS, SCADA, and industrial automation maintenance within an integrated Iron & Steel Plant or other continuous process industries.
- Strong knowledge of process automation, industrial networking, control systems, instrumentation integration, electrical systems, and utility automation.
- Experience with major automation platforms such as Siemens, ABB, Honeywell, Yokogawa, Emerson, Rockwell Automation, Schneider Electric, Mitsubishi Electric, or equivalent.
- Familiarity with industrial cybersecurity practices, ISA/IEC standards, Indian Electricity Rules, ISO 9001, ISO 14001, ISO 45001, ISO 50001, and utility maintenance best practices.

📌 Senior Engineer/Engineer (Chandrapur)
🏢 Lloyds Metals & Energy
📍 Chandrapur