To execute day-to-day maintenance, calibration, troubleshooting, and monitoring of instrumentation and automation systems in the API manufacturing plant, ensuring reliable operation of process equipment and utilities while maintaining compliance with GMP, EHS, SOPs, and data-integrity requirements. 2.

Key Responsibilities A.

Instrumentation Maintenance

Carry out preventive, predictive, corrective, and breakdown maintenance of field instrumentation. Attend day-to-day instrument breakdowns and ensure timely restoration of equipment.

Troubleshoot and maintain: Pressure transmitters and gauges. Temperature transmitters, RTDs, and thermocouples. Flow meters and flow transmitters. Level transmitters and level switches. Control valves and positioners.

Solenoid valves and I/P converters. Load cells and weighing systems. pH, conductivity, and other process analyzers. Check instrument health and identify abnormal conditions before equipment failure. Maintain instrument history and breakdown records.

B. API Process Equipment Support Provide instrumentation support for: Reactors and agitated vessels. Glass-lined and SS equipment. Centrifuges. ANFD / filter dryers. Dryers. Vacuum systems. Solvent recovery systems.

Storage and process tanks. Heat exchangers and condensers. Scrubbers. Process skids. Ensure reliable measurement and control of critical parameters such as temperature, pressure, vacuum, level, flow, pH, and weight.

C. PLC / Automation Support Monitor and troubleshoot PLC-based control systems. Troubleshoot PLC I/O, field signals, communication faults, and control-loop problems. Check HMI/SCADA indications and alarms.

Support PLC/DCS troubleshooting in coordination with senior engineers and OEMs. Perform authorized changes only through approved procedures and change control. Maintain PLC/automation system backups as per site procedures.

D.

Calibration

Execute scheduled calibration of process and utility instruments. Perform calibration of pressure, temperature, flow, level, analytical, and weighing instruments as applicable. Coordinate with external calibration agencies when required. Maintain calibration records and certificates. Ensure calibration labels/status are updated. Report and document out-of-tolerance calibration results. Support investigation and impact assessment of calibration failures. E.

Preventive Maintenance

Execute monthly/weekly preventive-maintenance activities as per schedule. Complete maintenance checklists and work orders within defined timelines. Inspect critical instruments and control valves.



Identify recurring failures and report them to the supervisor. Assist in implementing corrective actions for repetitive problems. F.

Control Valve Maintenance

Perform inspection and basic troubleshooting of control valves. Check valve positioners, actuators, I/P converters, solenoid valves, and air supply. Carry out functional checks and calibration. Verify valve operation and fail-safe condition. Coordinate valve overhauling with maintenance/vendor teams. G.

Utility Instrumentation

Support maintenance of instrumentation associated with: Boilers and steam systems. Chillers and cooling towers. Air compressors. Nitrogen systems. Vacuum systems. HVAC systems. RO/DM/water-treatment systems.

ETP systems. DG and other utility equipment. H. GMP & Documentation Follow all applicable GMP, SOP, GDP, and EHS requirements. Maintain accurate and timely maintenance and calibration records. Complete equipment/instrument logbooks as per GDP requirements.

Raise maintenance work orders and close them with proper documentation. Report deviations, breakdowns, and abnormal observations to the reporting manager. Support investigation of deviations related to instrumentation.

Participate in CAPA and change-control activities as assigned. I. Qualification & Validation Support Support IQ/OQ/PQ activities for recent and existing equipment where applicable. Perform loop checking and instrument functional testing.

Support alarm and interlock verification. Assist in commissioning and qualification of new instruments and automation systems. Coordinate with QA/Validation and Production teams during qualification activities.

J. Projects & Modification Support installation and commissioning of new instruments. Assist in preparation/review of instrument datasheets, I/O lists, P&IDs;, and related documents. Support FAT/SAT activities where applicable.

Assist in plant modification and improvement projects. Ensure modifications are performed through approved change-control procedures. K.

Spare Parts

Monitor critical instrumentation spares. Inform the supervisor about low-stock or critical spare requirements. Assist in maintaining instrument BOMs and spare records.



Support identification of suitable replacement instruments/components. L. Vendor & Contractor Coordination Coordinate with OEMs, calibration agencies, and service contractors. Supervise routine service activities at site. Verify service reports and work completion. Ensure contractors follow plant GMP and EHS requirements. M.

Safety Follow

Permit-to-Work and LOTO procedures. Ensure safe isolation before working on instruments and control systems. Follow electrical and process-safety requirements. Use appropriate PPE. Report unsafe conditions, near misses, and incidents immediately. 3.

Key Performance

Indicators (KPIs) Preventive maintenance compliance. Calibration compliance. Instrument-related breakdown reduction. Timely breakdown response and restoration. Reduction in repeat instrument failures. Timely closure of maintenance work orders. Availability of critical instruments. Timely closure of deviations/CAPA assigned to Engineering. GMP and EHS compliance. Support for successful qualification and validation activities. 4.

Qualification & Experience Qualification: B.E./B.Tech. in Instrumentation / Electronics & Instrumentation / Instrumentation & Control Engineering. Diploma candidates with strong relevant experience may also be considered.

Experience: 2–5 years of experience in instrumentation maintenance. API, pharmaceutical, specialty chemical, or chemical-process industry experience preferred. Hands-on experience in process instrumentation and calibration is essential. 5.

Required Technical Skills

Pressure, temperature, flow, and level instrumentation. Control valves and positioners. Calibration techniques. PLC/DCS/SCADA basics. HMI and alarm systems. Basic control-loop troubleshooting. P&ID; and instrument-drawing reading. Basic knowledge of electrical systems. Preventive and breakdown maintenance. GMP and Good Documentation Practices. SAP/CMMS knowledge is an advantage. 6.

Behavioral Competencies

Good troubleshooting and analytical skills. Strong safety and quality awareness. Good communication and coordination skills. Ability to work effectively with Production and Maintenance teams. Willingness to work in shifts and attend emergency breakdowns. Good documentation skills. Positive attitude toward learning and continuous improvement. 7.

Overall Objective To ensure safe, reliable, accurate, and GMP-compliant operation of instrumentation and automation systems, minimizing instrumentation-related production downtime and supporting uninterrupted API manufacturing operations.

📌 Executive (Mumbai)
🏢 CPL Pharmaceuticals Private
📍 Mumbai