Sr Lead DCS Control System

1 Job Purpose

To provide technical leadership in the design engineering implementation and integration of Distributed Control Systems (DCS) Programmable Logic Controllers (PLC) and other control systems across Hindalcos major projects. This role focuses on ensuring the reliability efficiency and security of control systems while aligning with industry best practices safety standards and sustainability norms. The Sr. Lead DCS & Control Systems will collaborate with crossfunctional teams to deliver innovative and costeffective automation solutions that meet project timelines and objectives.

Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

1. Conceptualization and Basic Engineering Review and Validation

• Collaborate with stakeholders to define project scope requirements and objectives for automation systems.
• Review basic engineering designs for Distributed Control Systems (DCS) and related control systems to align with strategic project goals.
• Validate engineering designs against standards codes and operational requirements.
• Identify potential automation technologies and tools for optimal system performance.

1. Budget Tendering & Ordering support

• Review detailed technical specifications to assist in creating accurate project budgets.
• Evaluate vendor proposals for technical compliance and recommend suitable options.
• Participate in negotiations with suppliers to ensure the procurement of costeffective highquality automation systems.
• Support tendering processes by providing expertise in system components functionalities and integration needs.

1. Detail Engineering Review and Validations

• Conduct indepth reviews of detailed engineering drawings documents and specifications.
• Validate configurations of control systems ensuring alignment with project requirements and operational goals.
• Coordinate with engineering consultants and vendors to address any discrepancies or gaps in design.
• Ensure detailed designs incorporate maintainability scalability and safety considerations.

1. Erection and Commissioning support

• Oversee the installation of DCS and control systems ensuring adherence to project timelines and quality standards.
• Provide onsite technical support during commissioning resolving issues promptly.
• Validate system performance through rigorous testing and troubleshooting during commissioning phases.
• Ensure the seamless transition of systems into operational readiness.

1. Cost Control

• Establish guidelines for DCS and control system design implementation and integration.
• Train teams on advanced control systems and automation technologies.
• Assist site teams in project staffing and technical problemsolving.
• Document project learnings to enhance team competencies.
• Conduct workshops to build expertise in process control and system optimization.

1. Quality Control & Safety Compliance

• Establish quality assurance processes for control system components and installations.
• Conduct audits and inspections to ensure compliance with quality and safety standards.
• Monitor contractor and vendor adherence to safety protocols during design installation and commissioning phases.
• Implement corrective actions for any deviations in quality or safety compliance.

5 Technical Competencies

Essential technical competencies

• Expertise in Distributed Control Systems (DCS) architecture configuration and implementation.
• Knowledge of automation standards such as IEC 61511 ISA 88/95 and other relevant codes.
• Proficiency in control logic design loop tuning and system integration.
• Experience with SCADA systems PLCs and communication protocols (e.g. Modbus OPC Profibus).
• Strong skills in network design and cybersecurity for industrial automation systems.
• Ability to interpret P&IDs wiring diagrams and technical drawings.
• Handson experience with system commissioning troubleshooting and validation.

Desired technical competencies

• Familiarity with advanced technologies like IoT Industry 4.0 and AI/ML in automation.
• Knowledge of functional safety standards and SIL assessment.
• Experience in energy management and optimization using control systems.
• Proficiency in HMI/GUI development and usability principles.
• Awareness of sustainability practices and compliance in automation projects.

Nos. of Years of experience in Project Automation/Instrumentation

• 1520 years of experience in automation and instrumentation with a strong focus on project across greenfield brownfield or largescale industrial setups.
• Experience in leading multidisciplinary teams and managing vendor relationships is highly desirable.

Required Experience:

Director