DCS Operator

Role Overview

DCS Operator at Air Products. This role operates and manages distributed control systems for a Steam Methane Reformer based hydrogen production facility with CO2 removal, compression, PSA, tail gas compression, and membrane units. The position is located at a hydrogen production plant supplying Hydrogen, Steam, and CO2 to customer pipelines.

Company Overview

Air Products, founded in 1940, is a world-leading industrial gases company with a proud history of innovation, operational excellence, and an unwavering commitment to safety and environmental stewardship.

Role Purpose

To safely and efficiently operate integrated hydrogen production units and pipeline networks, maintain process stability within defined operating limits, manage customer relationships and product supply requirements, and drive operational excellence through continuous monitoring, diagnostics, and improvement initiatives.

Key Responsibilities

Safety, Health & Environment

• Maintain a safe and stable environment and demonstrate leadership with all Company and Industry safe work processes to prevent all injuries.
• Ensure proper documentation is maintained for safety-related activities.
• Enforce and adhere to all Safe Work Permits, Lock-out Tag-out procedures, and management of change procedures.
• Serve as the first line of response for process emergencies, execute emergency operating procedures, initiate plant trips if necessary, and direct field operators.
• Monitor the status of Safety Instrumented System (SIS) and Fire & Gas Systems.
• Understand the cause and effect chart for all safety interlocks.
• Ensure all plant emissions (from reformer stack and vent streams) comply with environmental permits.
• Properly manage waste streams.
• Ensure the safety of all operations personnel by utilizing the BHIG Basic Safety Practice program.

Technical Operations & Process Control

• Operate the Steam Methane Reformer based hydrogen plant with CO2 Removal section, CO2 compression, PSA with Tail Gas compression, Membrane Unit, and related utilities as prescribed by Work Instruction Procedures.
• Operate the pipeline network to supply Hydrogen, Steam, and CO2 to customer pipelines safely and efficiently.
• Constantly monitor all process variables (flows, temperatures, pressures, levels, analytical values) via DCS to ensure they are within defined operating limits.
• Manipulate control loops, setpoints, and cascades to maintain stable operations of all integrated units.
• Use historical data and trends to predict equipment performance degradation, identify inefficiencies, and prevent potential trips and failures.
• Execute and supervise the detailed start-up sequence for the entire plant or individual units/loops from a cold condition, warm condition, or hot stand-by condition, ensuring a smooth and safe transition to full-load normal operations.
• Assist in commissioning activities of the facility.
• Identify the root cause of process deviations and equipment malfunction.
• Work with engineers to implement long-term solutions.

Production Management & Reporting

• Report production progress and plant status to the Shift Supervisor and suggest solutions for any shortfalls.
• Manage plant production efficiently based on input provided by Plant Management to ensure safety and reliability targets are met to achieve maximum profitability.
• Maintain accurate and timely logs of operating parameters, significant events, and production data.
• Ensure logs are accurate and compliant with published matrix.
• Follow Site Work Instruction Manuals for production and supply of Product H2, CO2, and Steam along with other operating and maintenance procedures and checklists.

Stakeholder & Customer Management

• Meet the customer's requirements regarding safety, reliability, product quality, and flexibility regarding product supply.
• Maintain customer communications and relationships at the board level, ensuring customer demand rates are satisfied while maximizing the efficiency and profitability of the facility.
• Maintain a relationship with the customer's counterparts from other Refinery Units where BHIG is either receiving Feedstock, Utilities, and Power or supplying Hydrogen and Steam to different Refinery Units on a regular basis through Refinery Shift Superintendent to ensure alignment of expectations.
• Ensure current and future product demand is understood.
• Provide coaching and motivation to the field operations team to achieve operational excellence and customer satisfaction.

Field Operations & Coordination

• Maintain constant communication with field operators, providing instructions for equipment adjustments, isolations, and rounds.
• Liaise with the maintenance team to coordinate equipment preparation for maintenance (isolation, purging, and blinding) and safe taking of equipment back in line.
• Establish and maintain close working relationships with engineering and maintenance personnel to continuously monitor and evaluate plant systems and equipment performance.

Shift Handover & Documentation

• Conduct detailed and accurate shift handovers with incoming operators, highlighting any abnormalities, ongoing work, and special instructions.
• Follow shift turnover protocols to ensure a safe and efficient handover to the following shift.
• Communicate plant activities with other shifts to maintain continuity between shifts for safe and reliable operation.

Compliance & Continuous Improvement

• Ensure compliance with all CM and PM tasks and Environmental Regulatory requirements.
• Ensure BHIG standards and global best practices for EH&S, productivity, reliability, quality, and overall customer services are met.
• Ensure compliance with process safety, MOC's, and OPHR requirements.
• Support and prepare for Shutdown Planning and Turnaround Planning.
• Suggest and participate in operational improvements and de-bottlenecking projects to enhance safety, reliability, and profitability.
• Provide operations support and participate in investigations and Root Cause Analysis to identify and implement sustainable corrective actions.
• Facilitate attainment of operational excellence and customer satisfaction via operations productivity, reliability, quality, and continuous improvement initiatives.
• Execute other duties as assigned by reporting managers in a timely and efficient manner.

Qualifications & Experience

• Bachelor's degree in Chemical, Mechanical, or Chemical Process Operations with 10 years' experience preferred; or an Associate Technical Degree (2-year certificate) will be considered based on years of experience and competence.
• Minimum of 5 years' Lead DCS Operations experience in SMR based Hydrogen, Ammonia, Methanol, or Syngas plant as DCS Operator.
• Experience in DCS Operation and Field Operation.

Skills & Competencies

• Proficiency with DCS platforms (e.g. Yokogawa Centum VP, Siemens PCS 7).
• Deep understanding of Chemical Engineering Principles, thermodynamics, and process control.
• Wide technical knowledge in operations, engineering, and maintenance activities.
• Ability to maintain high level of awareness and make sound decisions under pressure.
• Strong problem-solving and diagnostic abilities.
• Clear, concise, and effective verbal and written communication.
• Proficiency in English speaking and writing.
• Ability to communicate with the customer at the board level daily.
• Ability to communicate between operations and maintenance teams.
• Strong commitment to employee involvement, team building, and diversity.