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The HYCO DCS Operator, reporting to the HYCO Lead/Shift Supervisor, is accountable for the day-to-day DCS Operation & Field Operation of HYCO facility, ensuring the production requirements set by the customer are achieved. HYCO DCS Operator is responsible for the safe, efficient and stable operation of the entire Hydrogen Manufacturing Unit from a centralized control room using DCS. This includes monitoring, controlling and optimizing to meet production targets, quality specifications and environmental regulations. This includes actively supporting plant performance, process optimization and production stability while maintaining strong focus on safety & compliance. The HYCO DCS Operator will execute daily tasks which include preparing and implementing safety work permits, LOTO, completing operations preventative maintenance activities, and assist the maintenance and engineering teams in preparing and executing corrective maintenance activities
Principal Accountabilities:
Safety, Health & Environment
- Maintain a safe & stable environment. Demonstrate leadership with all Company & 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 and Lock-out Tag-out and management of change procedures.
- Be the first line of response for process emergencies. Execute emergency operating procedures, initiate plant trips if necessary and direct field operators.
- Monitor status of Safety Instrumented System (SIS) and Fire & Gas Systems. Understand the cause & effect chart for all safety interlocks.
- Ensure all plant emissions (from reformer stack, 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
- 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 the Work Instruction Procedures
- Operate the pipeline network to supply Hydrogen, steam and CO2 to customers’ pipelines safely and efficiently.
- 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.
- Ensure BHIG standards, and global best practices for EH&S, productivity, reliability, quality, and overall customer services are met.
- 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.
- Follow the Site Work Instruction Manuals for production & supply of Product H2, CO2 & Steam along with other operating and maintenance procedures and checklists to meet the customer’s satisfaction with safety, reliability, product quality, and flexibility of product supply while compliance with requirements.
- Maintain a relationship with the customer’s counterparts from other Refinery Units where from BHIG either receiving Feedstock, Utilities & Power or supplying Hydrogen and Steam to different Refinery Units on a regular basis through Refinery Shift Superintendent to ensure alignment of expectations for BHIG and the customers current and future product demand.
- 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 sable operations of all integrated units.
- Use historical data and trends to predict equipment performance degradation, identify inefficiencies and prevent potential trips and failures.
- Execute & supervise the detailed start up sequence for the entire plant or individual units/loops form a cold condition, warm condition or hot stand by condition, ensuring a smooth & safe transition to full load normal operations. Assist in the commissioning activities of the facility
- Maintain constant communication with field operators, providing instructions for equipment adjustments, isolations and rounds.
- Liaise with the maintenance team to co-ordinate equipment preparation for maintenance (isolation, purging & blinding) and safe taking equipment back in line.
- Conduct detailed and accurate shift handovers with incoming operators, highlighting any abnormalities, ongoing work and special instruction. Follow shift turnover protocols to ensure a safe and efficient handover to the following shift.
- Maintain accurate and timely logs of operating parameters, significant events and production data. Fully accountable to ensure his logs and that his operator’s logs are accurate and compliant with published matrix.
- Identify the root cause of process deviations and equipment malfunction. Work with engineers to implement long-term solutions.
- Suggest and participate in operational improvements and de-bottlenecking projects to enhance safety, reliability and profitability.
- Ensure compliance with all CM, PM tasks & Environmental Regulatory requirements.
- Support and prepare for Shutdown Planning and Turnaround Planning.
- Provide coaching and motivation with the field operations team to achieve operational excellence and customer satisfaction.
- Establish & maintain close working relationships with engineering and maintenance personnel to continuously monitor & evaluate plant systems & equipment performance.
- Ensure compliance with process safety, MOC’s, and OPHR requirements.
- Provide operations support and participate in investigations and Root Cause Analysis to identify & implement sustainable corrective actions.
- Facilitate attainment of operational excellence and customer satisfaction via operations productivity, reliability, quality, and continuous improvement initiatives.
- Communication of plant activities with other shifts to maintain continuity between shifts for a safe and reliable operation.
- Execute other duties as assigned by reporting managers in a timely and efficient manner.
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We are the world’s largest hydrogen producer with over 80 years of industrial gas experience. We are hydrogen and industrial gas experts delivering safe, end-to-end solutions, investing in real, clean energy projects at scale, and driving the industry forward to generate a cleaner future.
At Air Products, we work in an environment where we put safety first, diversity is essential, inclusion is our culture, and each person knows they belong and matter. To learn more, visit About Air Products.
