Distributed Control System Engineer

Job Description – Boiler DCS Engineer (AFBC Boiler)

Department: Power Plant / CPP

Position Title: Engineer

Reports to: Manager/HOD

Location: Meghalaya - Plant.

1. Job Objective

To ensure safe, efficient, and reliable operation of AFBC/CFBC boilers through effective control room (DCS) monitoring, operational adjustments, troubleshooting, and coordination with field teams to achieve maximum plant availability, performance, and compliance with safety and environmental standards.

2. Key Responsibilities

A. Boiler Operation & Control (DCS)

• Monitor and control AFBC/CFBC boiler parameters through the DCS system.
• Maintain stable combustion, bed temperature, drum level, furnace draft, and steam parameters.
• Execute start-up, normal operation, load changes, and shutdown activities as per SOPs.
• Manage fuel feeding systems, air/bed controls, and ash handling operations.

B. Equipment Monitoring & Troubleshooting

• Continuously monitor equipment health—ID/FD/PA fans, ESP, air preheater, feeders, and fuel handling system.
• Respond promptly to alarms, deviations, and trippings; coordinate immediate corrective actions.
• Identify abnormalities and perform preliminary troubleshooting from DCS.

C. Coordination with Field & Maintenance Teams

• Coordinate with field operators for smooth running and feedback.
• Notify maintenance teams of breakdowns and support in isolation/normalization procedures.
• Ensure logbook entries and shift handover reports are accurate.

D. Safety, Compliance & SOP Adherence

• Ensure adherence to safety protocols, LOTO procedures, and environmental norms.
• Participate in safety toolbox talks, audits, and risk assessments.
• Maintain compliance with operational SOPs and statutory requirements.

E. Performance Monitoring & Reporting

• Monitor boiler efficiency, heat rate, fuel consumption, and auxiliary power consumption.
• Maintain shift reports, event logs, and performance data in DCS/ERP.
• Support in RCA of boiler trips, repeated alarms, and performance deviations.

F. Continuous Improvement

• Suggest improvements for performance optimization and reliability enhancement.
• Support condition monitoring activities and energy-saving initiatives.

KPI Category Performance Indicator Target

Boiler Operation Performan
e Boiler Availability ≥ 95%

Boiler Load Factor ≥ 90%

Combustion Efficiency ≥ 85% (AFBC/CFBC)

Safety & Compliance

Zero Accidents / LOTO Compliance 100%

Adherence to SOPs 100%

Pollution Control Parameters (ESP / Emissions) Within statutory norms

DCS Monitoring & Control
Alarm Response Time ≤ 2 minutes

Trip Handling & Restoration Time ≤ 15 minutes

Maintenance Coordination
Breakdown Reporting Accuracy 100%

Support in RCA and Action Closure As per schedule

Documentation & Reporting
Logbook Accuracy 100%

Shift Report Timeliness Within shift closing

Efficiency & Cost Control
Specific Fuel Consumption Within approved limits

Auxiliary Power Consumption (CPP) Within target limits

4. Competency Framework

A. Must-Have Technical Competencies

• Hands-on experience in
  AFBC/CFBC boiler operations
  .
• Strong knowledge of
  DCS operations (ABB/Siemens/Emerson/etc.)
  .
• Understanding of steam cycle, turbine interface, water/steam systems.
• Knowledge of fuel handling systems (coal, lignite, biomass).
• Awareness of ESP, ash handling, air/flue systems.
• Boiler protection logic, interlocks, and emergency handling.

B. Desired Competencies

• Knowledge of turbine operation basics.
• Exposure to PLC/SCADA systems.
• Ability to support maintenance planning and shutdown operations.
• Basic understanding of energy efficiency and heat rate improvement.

C. Behavioural Competencies

• Attention to detail and accuracy.
• Strong decision-making in high-pressure situations.
• Excellent coordination and communication skills.
• Discipline, accountability, and safety-first mindset.
• Team collaboration and shift management discipline.

5. Roadmap to Success (1–3 Years)

Year 1 – Skill Building & Stabilization

• Gain proficiency in AFBC/CFBC boiler operations and DCS control philosophy.
• Achieve complete compliance with safety and operational SOPs.

Year 2 – Performance & Efficiency Improvement

• Independently handle start-ups and shutdowns.
• Contribute to efficiency improvement projects (combustion tuning, draft optimization).

Year 3 – Optimization & Leadership

• Take charge of shift-level boiler operations.
• Lead initiatives for reliability improvement and energy optimization.
• Prepare for role expansion into Sr. DCS Engineer / Boiler In-charge.

6. Career Path (CPP / Power Plant)

Boiler DCS Engineer → Senior Boiler/DCS Engineer → Shift In-charge → Assistant Manager – CPP → Deputy Manager – CPP → Manager – Power Plant → Head – CPP / Power Plant