Senior Engineer - Automation مهندس أول - الأتمتة

Brief Posting Description
The Senior Engineer – Automation is responsible for leading the maintenance, reliability, availability, and performance optimization of automation, process control, and industrial digital systems across the Copper Concentrator Plant.
The role ensures the safe, reliable, and cost-effective operation of Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), SCADA systems, Human Machine Interfaces (HMI), industrial communication networks, historians, servers, workstations, and associated automation infrastructure through effective maintenance strategies, shutdown planning, reliability improvement initiatives, cybersecurity compliance, asset integrity management, and continuous improvement programs.The position provides technical leadership to automation personnel, supports operational excellence, and maximizes plant availability while minimizing lifecycle costs and production losses. The incumbent is responsible for the maintenance and reliability of automation and control systems associated with the Primary Crusher, Apron Feeders, Conveyors, Ore Stockpile Stacking & Reclaiming Systems, SAG Mill, Ball Mills, HIG Mill, Flotation Plant, Thickeners, Concentrate Filtration Plant, Slurry Pumps, Process Water Systems, Tailings Systems, and associated plant infrastructure.
The role works closely with Operations, Reliability, Mechanical Maintenance, Electrical, Instrumentation, and Project teams to achieve production, safety, reliability, and asset performance objectives while ensuring compliance with safety, environmental, and asset management standards.
Detailed Description
AUTOMATION & CONTROL SYSTEM MANAGEMENT
Lead maintenance activities for automation, process control, and industrial digital systems across the concentrator plant.
Ensure automation systems support safe, reliable, and efficient plant operation.
Develop and implement maintenance strategies to maximize system reliability and availability.
Monitor automation system performance and recommend corrective and preventive actions.
Ensure compliance with OEM recommendations, engineering standards, and statutory requirements.
Support long-term asset lifecycle management and replacement planning.
Provide technical guidance on automation maintenance planning, scheduling, and execution.
Support commissioning, startup, and ramp-up activities for automation systems and equipment.
DCS, PLC & SCADA SYSTEMS
Lead reliability improvement initiatives for DCS, PLC, SCADA, HMI, historian, and control system infrastructure.
Manage automation system architecture, configuration, and performance optimization.
Support troubleshooting of control logic, process interlocks, alarms, permissives, and control loops.
Ensure backup, restore, and disaster recovery procedures are maintained and tested.
Manage automation software version control and change management processes.
Review and approve DCS, PLC, and SCADA modifications.
Ensure documentation, logic diagrams, and system architecture drawings remain updated.
MOC & CHANGE GOVERNANCE
Ensure automation system modifications, upgrades, software changes, and configuration changes are managed through the approved Management of Change (MOC) process.
Review proposed changes to DCS, PLC, SCADA, HMI, historian, control logic, alarms, interlocks, and associated automation infrastructure for technical and operational impacts.
Ensure appropriate risk assessments, technical reviews, testing requirements, approvals, and implementation plans are completed before changes are introduced.
Coordinate with Operations, Instrumentation, Electrical, Reliability, Projects, and relevant stakeholders during automation change activities.
Ensure backup and recovery arrangements are completed before implementing critical system changes.
Support FAT, SAT, simulation, functional testing, commissioning, and post-implementation verification of automation modifications.
Ensure updated logic diagrams, configuration records, I/O documentation, system architecture drawings, software versions, and other technical documents are maintained following approved changes.
Participate in post-change reviews and verify that modifications achieve the intended reliability, safety, control-performance, and operational objectives.
PROCESS CONTROL & OPTIMIZATION
Support operational performance through advanced process control and automation improvements.
Analyze process performance and identify opportunities for control optimization.
Support tuning of control loops and optimization of process control strategies.
Drive initiatives aimed at improving throughput, recovery, plant stability, and energy efficiency.
Support implementation of advanced process control technologies and digital solutions.
Work closely with Operations and Metallurgical teams to optimize plant performance.
IT/OT CYBERSECURITY INTERFACE
Coordinate with IT/OT Cybersecurity teams to implement cybersecurity requirements for DCS, PLC, SCADA, HMI, historian, servers, workstations, and industrial network infrastructure.
Ensure automation systems comply with approved OT cybersecurity policies, standards, access-control requirements, and security procedures.
Coordinate user-access management, privileged access, password controls, system hardening, backup requirements, patch management, and cybersecurity monitoring in accordance with approved procedures.
Support identification, assessment, and mitigation of cybersecurity risks affecting critical automation and control systems.
Participate in OT cybersecurity audits, vulnerability assessments, risk assessments, and incident investigations as required.
Coordinate cybersecurity-related upgrades and remediation activities while minimizing impact on plant availability and process safety.
Ensure cybersecurity considerations are incorporated into automation modifications, procurement, system upgrades, and lifecycle replacement planning.
Maintain appropriate coordination between IT, OT Cybersecurity, Automation, Instrumentation, Electrical, Operations, and Projects teams.
Ensure cybersecurity-related changes are controlled through the approved MOC and change-management processes.
INDUSTRIAL NETWORKS & CYBERSECURITY
Maintain industrial Ethernet, fiber-optic communication networks, fieldbus systems, wireless instrumentation networks, and associated automation infrastructure.
Monitor communication system health and reliability.
Ensure industrial cybersecurity standards and policies are implemented and maintained.
Manage user access controls, system security, backups, and patch management.
Support cybersecurity audits and risk assessments.
Coordinate implementation of automation system upgrades and cybersecurity improvements.
MAINTENANCE PLANNING & EXECUTION
Support development of annual maintenance plans and budgets for automation assets.
Review and optimize preventive and predictive maintenance programs.
Coordinate automation resources for planned and corrective maintenance activities.
Ensure work orders are properly executed, documented, and closed in SAP PM.
Improve maintenance work management processes and effectiveness.
Monitor maintenance backlog and prioritize critical automation activities.
SHUTDOWN & TURNAROUND MANAGEMENT
Lead preparation and execution of automation shutdown and turnaround activities.
Develop shutdown scopes, resource requirements, budgets, and schedules.
Coordinate contractors, OEM specialists, and internal teams during shutdown execution.
Monitor shutdown progress and manage critical path activities.
Ensure shutdown work complies with safety, environmental, and quality requirements.
Conduct post-shutdown reviews and capture lessons learned.
ASSET INTEGRITY MANAGEMENT
Ensure integrity and reliability of critical automation and control system assets.
Review system health reports and establish corrective actions.
Support predictive maintenance and system performance monitoring programs.
Participate in risk assessments and asset criticality evaluations.
Ensure compliance with asset management standards and engineering requirements.
Support development of automation asset lifecycle and modernization plans.
TECHNICAL SUPPORT & TROUBLESHOOTING
Provide advanced troubleshooting support for automation and process control system failures.
Support operations in resolving process control, alarm management, and system performance issues.
Review system diagnostics, communication failures, and automation performance reports.
Evaluate control system modifications and process control improvements.
Review OEM recommendations, technical reports, and upgrade proposals.
Support FAT, SAT, commissioning, testing, and startup of new automation systems and modifications.
PEOPLE LEADERSHIP & DEVELOPMENT
Provide technical leadership, guidance, and mentoring to automation engineers, technicians, and maintenance personnel.
Develop team competency in DCS, PLC, SCADA, HMI, industrial communication networks, process control, and automation systems.
Identify competency gaps and support the development and implementation of technical training and competency development programs.
Promote knowledge sharing, technical coaching, and transfer of automation best practices across the maintenance team.
Establish clear performance expectations and promote accountability, teamwork, and a continuous improvement culture.
Support succession planning and workforce capability development for critical automation and control-system positions.
Encourage effective collaboration between Automation, Instrumentation, Electrical, Mechanical, Operations, Reliability, and Projects teams.
Promote a strong safety and cybersecurity culture and ensure team members understand and comply with approved procedures, HSE requirements, access controls, and change-management processes.
Support performance reviews and provide constructive technical feedback to improve individual and team performance.
Develop and maintain a technically competent, motivated, and high-performing automation maintenance team.
COST CONTROL & BUDGET MANAGEMENT
Support the preparation and management of annual automation maintenance budgets and forecasts.
Monitor maintenance expenditures and ensure spending remains within approved budget limits.
Identify opportunities to optimize maintenance and automation lifecycle costs.
Review and control costs related to automation service contracts, software support agreements, and external resources.
Support development of business cases for automation upgrades, modernization projects, and digital transformation initiatives.
Monitor and optimize spare parts inventory for automation systems and critical control hardware.
Participate in procurement activities including technical evaluations, vendor selection, and contract reviews.
Track and report maintenance cost performance, budget variances, and cost-saving initiatives.
Support lifecycle cost analysis and long-term automation asset replacement planning.
CONTINUOUS IMPROVEMENT
Drive continuous improvement initiatives to enhance control system reliability, process stability, and plant throughput.
Identify opportunities to reduce maintenance costs and minimize unplanned downtime.
Implement reliability improvement and Lean Maintenance methodologies.
Develop business cases for automation upgrades and modernization projects.
Track and report benefits realized from improvement initiatives.
Promote automation and operational best practices across the organization.
SAFETY, HEALTH, ENVIRONMENT & QUALITY
Ensure compliance with company HSE policies, procedures, and regulatory requirements.
Promote safe work practices and adherence to plant safety standards.
Participate in risk assessments, incident investigations, and hazard identification programs.
Support management of Safety Instrumented Systems (SIS), critical interlocks, and automation-related protection systems.
Ensure compliance with automation standards, cybersecurity requirements, quality requirements, and engineering procedures.
Support achievement of zero-harm and operational excellence objectives.

Job Requirements
Education:
• Bachelor's Degree in Automation Engineering, Control Systems Engineering, Electrical & Automation Engineering, Mechatronics Engineering, Instrumentation & Control Engineering, or related discipline is mandatory.
Experience:
• Bachelor’s Degree with 10+ years of experience in a Copper Concentrator Plant or related process plant with similar type of equipment is mandatory.
• Minimum 8 years of experience in Automation maintenance and reliability engineering is mandatory.
• Proven track record of successfully managing maintenance and reliability of Automation assets in large-scale mineral processing facilities.
Certifications: Candidates holding or pursuing any of the following certifications will have an added advantage:
• ISA Certified Automation Professional (CAP)
• Certified Maintenance & Reliability Professional (CMRP)
• ISA Certified Control Systems Technician (CCST)
• Six Sigma (BB)
Technical Skills:
• Extensive experience with DCS platforms such as ABB 800xA, Siemens PCS7, Honeywell Experion, Yokogawa Centum, Emerson DeltaV, or equivalent systems.
• Experience with PLC systems including Siemens, Allen-Bradley, Schneider Electric, ABB, and associated programming environments.
• Experience with SCADA, HMI, Historian, industrial communication networks, and OT infrastructure.
• Strong knowledge of industrial Ethernet, Profibus, Profinet, Modbus, OPC, Foundation Fieldbus, and related communication protocols.
• Experience supporting concentrator assets including Primary Crusher, Conveyors, Ore Stockpile Stacking & Reclaiming Systems, SAG Mill, Ball Mills, HIG Mill, Flotation Plant, Thickeners, Concentrate Filtration Plant, Slurry Pumps, and utility systems.
• Strong knowledge of process control, alarm management, SIS systems, OT cybersecurity, reliability engineering, and asset management principles.
• Strong knowledge of SAP PM, CMMS/ERP systems, RCFA, FMEA, and reliability-centered maintenance methodologies.
Soft Skills:
• Fluency in English, with excellent written and verbal communication skills
• Strong leadership and people management skills.
• Excellent negotiation and influencing abilities.
• Strategic thinking and problem-solving capabilities.
• Strong communication and stakeholder management skills.
• High ethical standards and commercial integrity.
• Ability to work effectively in a multicultural environment.
• Strong decision-making and organizational skills.
• Ability to manage multiple priorities and perform under pressure