Senior Engineer/Engineer (Instrumentation Specialist)

Lloyds Metals and Energy Ltd.; Ghugus; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Lloyds Metals and Energy Ltd. is seeking an Engineer/Sr. Engineer Instrumentation Specialist – Central Maintenance (Utilities – E&I) to ensure safe, reliable operation of instrumentation across utility facilities.

You will plan and execute maintenance, calibrations, and fault-finding for field instruments in Power Plants, Water Treatment, and related systems. The role requires experience with calibration, DCS/SCADA integrations, and RCA-driven improvements, with a focus on ensuring measurement

Qualifications

• Diploma / BE / BTech in Instrumentation or equivalent engineering discipline.
• Experience in maintenance, calibration, and process control in a continuous process plant is preferred.
• Knowledge of hazardous area instrumentation and industrial safety standards.

Responsibilities

• Plan, supervise, and execute preventive, predictive, corrective, and breakdown maintenance for field instrumentation and process control.
• Maintain high availability of instrumentation in Power Plants, Water Treatment, cooling and gas systems.
• Inspect, calibrate, test, commission, and maintain instrumentation (pressure, temp, flow, level, analytical).
• Troubleshoot transmitters, RTDs, thermocouples, gauges, valves, actuators, and field wiring.
• Coordinate shutdowns, commissioning, and modernization with cross-functional teams.
• Ensure calibration traceability and documentation; integrate field instrumentation with PLC/DCS/SCADA.

Skills

Industrial instrumentation

Calibration

Process control systems

DCS/SCADA integration

Root Cause Analysis

Predictive maintenance

HART/Fieldbus

Instrumentation troubleshooting

Education

Diploma / B.E. / B.Tech in Instrumentation

Tools

HART Communicators

Multifunction Calibrators

CMMS/SAP

Process Automation Software

Job description

Position Name: Engineer / Sr. Engineer Instrumentation Specialist – 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 safe, reliable, and efficient operation and maintenance of industrial instrumentation, process control, and field measurement systems across utility facilities in the iron and steel plant. The role is responsible for maximizing instrument reliability, ensuring measurement accuracy, supporting process automation, maintaining statutory compliance, and driving continuous improvement through effective maintenance and calibration practices.

Role Responsibilities:

• Plan, supervise, and execute preventive, predictive, corrective, and breakdown maintenance activities for field instrumentation and process control systems across utility facilities.
• Maintain high availability and reliability of instrumentation installed in Power Plants, Water Treatment Plants, Pump Houses, Cooling Towers, Air Compressors, Oxygen Plants, Blast Furnace Utilities, Gas Distribution Systems, and other central utility facilities.
• Perform inspection, calibration, testing, commissioning, and maintenance of pressure, temperature, flow, level, analytical, vibration, and process measurement instruments.
• Maintain and troubleshoot smart transmitters, RTDs, thermocouples, pressure gauges, control valves, on-off valves, actuators, positioners, solenoid valves, pneumatic systems, and field-mounted instrumentation.
• Diagnose faults in process measurement loops, signal transmission systems, instrument power supplies, field wiring, junction boxes, marshalling panels, and control panels.
• Carry out loop checking, instrument calibration, functional testing, proof testing, and commissioning activities during shutdowns and plant modifications.
• Maintain and troubleshoot process analyzers including gas analyzers, oxygen analyzers, pH analyzers, conductivity analyzers, dissolved oxygen analyzers, moisture analyzers, and water quality monitoring systems.
• Ensure proper functioning of instrument air systems, air preparation units, pneumatic tubing, manifolds, regulators, and associated accessories.
• Perform preventive maintenance of field instruments using calibration equipment, HART communicators, multifunction calibrators, pressure calibrators, temperature calibrators, and diagnostic software.
• Maintain calibration schedules and ensure traceability of calibration standards in accordance with statutory and quality requirements.
• Support integration of field instrumentation with PLC, DCS, SCADA, historians, and process automation systems.
• Monitor instrument health, process measurement accuracy, control loop performance, alarm status, and instrument diagnostics to improve plant reliability.
• Conduct Root Cause Analysis (RCA) of recurring instrumentation failures and implement corrective and preventive actions.
• Prepare and maintain calibration certificates, maintenance history, instrument index, loop drawings, hook-up drawings, cable schedules, and technical documentation.
• Coordinate shutdown maintenance, commissioning, expansion projects, and modernization of instrumentation systems with operations, electrical, automation, and project teams.
• Ensure availability of critical instrument spares, transmitters, control valves, sensors, analyzers, cables, fittings, and calibration equipment.
• Coordinate with OEMs, vendors, contractors, and service providers for specialized maintenance, calibration, upgrades, and troubleshooting activities.
• Support implementation of predictive maintenance, smart instrumentation, Industrial IoT (IIoT), digital diagnostics, and asset management systems.
• Ensure compliance with PTW (Permit to Work), LOTO (Lockout-Tagout), confined space entry, hazardous area requirements, gas safety procedures, and statutory safety regulations during maintenance activities.
• Participate in energy conservation, process optimization, emission monitoring, and environmental compliance initiatives through reliable instrumentation systems.
• Provide technical guidance and mentoring to engineers, technicians, operators, and contractors on instrumentation maintenance, calibration, and troubleshooting.
• 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 process measurement and instrumentation systems to support uninterrupted utility operations and stable plant performance.
• Process Effectiveness: Improve instrument reliability, calibration compliance, measurement accuracy, and control loop performance through effective maintenance and continuous improvement initiatives.
• OH&S Contribution: Ensure strict compliance with instrumentation safety standards, PTW, LOTO, hazardous area practices, functional testing, emergency preparedness, and incident reporting procedures.
• Environmental Responsibility: Maintain reliable instrumentation for emissions monitoring, gas handling, water treatment, wastewater management, and environmental protection systems to ensure regulatory compliance.
• Energy Performance: Optimize process control, utility monitoring, combustion efficiency, and energy management systems through accurate measurement and reliable instrumentation supporting 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:

• Strong technical knowledge of industrial instrumentation, process control systems, and field measurement technologies.
• Expertise in calibration, troubleshooting, commissioning, and maintenance of process instruments and analytical systems.
• Strong understanding of control valves, pneumatic systems, smart transmitters, analyzers, and industrial communication protocols.
• Knowledge of PLC, DCS, SCADA integration and industrial automation systems.
• Strong analytical and troubleshooting capabilities using Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), and reliability engineering principles.
• Excellent planning, coordination, documentation, and technical communication skills.
• Commitment to operational reliability, process safety, measurement accuracy, and continuous improvement.

Key Skills:

• Pressure, Temperature, Flow, Level, and Analytical Instrumentation
• Smart Transmitters, RTDs, Thermocouples, Pressure Gauges, and Sensors
• Control Valves, Actuators, Positioners, Solenoid Valves, and Pneumatic Systems
• Gas Analyzers, Water Quality Analyzers, Oxygen, pH, Conductivity, Moisture, and Emission Monitoring Systems
• Calibration Management using HART Communicators and Multifunction Calibrators
• Instrument Loop Checking, Functional Testing, and Commissioning
• PLC, DCS, SCADA, HMI, and Process Automation Integration
• Industrial Communication Protocols (HART, Foundation Fieldbus, Profibus PA, Modbus)
• Instrument Air Systems and Pneumatic Control Networks
• Root Cause Analysis (RCA), FMEA, Reliability Improvement, and Predictive Maintenance
• CMMS/SAP Maintenance Management and Technical Documentation
• Hazardous Area Instrumentation and Industrial Safety Compliance

Abilities:

• Lead troubleshooting of critical instrumentation and process control failures during plant operations.
• Analyze complex measurement and control problems and implement effective engineering solutions.
• Coordinate maintenance activities with operations, automation, electrical, mechanical, and project teams.
• Manage shutdown maintenance, commissioning, calibration campaigns, and modernization projects efficiently.
• Develop and implement preventive maintenance and calibration strategies to maximize equipment reliability.
• Mentor engineers, technicians, and contractors on instrumentation maintenance and process control best practices.
• Adapt to emerging technologies including smart instrumentation, Industrial IoT (IIoT), digital asset management, predictive diagnostics, and advanced process monitoring.

Knowledge:

• Diploma / B.E. / B.Tech in Instrumentation, Electronics & Instrumentation, Electronics, Electrical & Instrumentation, Control Engineering, or equivalent Engineering discipline.
• Minimum 2- 7 years of experience in industrial instrumentation, calibration, process control, and maintenance within an integrated Iron & Steel Plant or other continuous process industries.
• Strong knowledge of process instrumentation, analytical systems, control valves, industrial automation, calibration standards, and utility process control.
• Experience with major instrumentation and automation OEMs such as Emerson, Endress+Hauser, Yokogawa, Honeywell, ABB, Siemens, Schneider Electric, VEGA, Krohne, Rosemount, WIKA, or equivalent.
• Knowledge of hazardous area classifications, IEC/ISA standards, Indian Electricity Rules, ISO 9001, ISO 14001, ISO 45001, ISO 50001, and industrial instrumentation maintenance best practices.