Electrical & Instrumentation Supervisor at SANDFIRE RESOURCES

Reporting to the Process Maintenance Superintendent, the incumbent is entrusted with the comprehensive oversight and accountability for the Process Plant and associated infrastructure, encompassing maintenance, fault identification, enhancement initiatives, and new projects across HVAC, Electrical, Control, and Instrumentation Maintenance Planning domains. The primary objective of this role is to ensure that all activities related to Electrical, Control, and Instrumentation maintenance, fault diagnosis, enhancement endeavours, new projects, and HVAC operations are executed to exacting standards, while adhering strictly to prescribed safety and regulatory frameworks. In addition to these responsibilities, duties will encompass Training, Budget Planning, and Workflow management on a daily basis. Moreover, this position demands a broad-ranging knowledge base, facilitating the seamless deployment of the incumbent across diverse operational facets of the company, inclusive of open cast assets, processing plants, and various other EC&I applications intrinsic to the company’s operational landscape.

Key Performance Areas

Electrical:

• Responsible for maintenance scheduling, contractor management and troubleshooting, testing, and repair of high voltage circuit breakers and switchgear.
• Execute scheduled inspections, testing, servicing, and oil sampling of power transformers. Overall monthly and annual maintenance and defect repairs.
• Diagnose/repair HV and LV electrical assets safely and efficiently.
• High Voltage protection relay programming, interrogation, and testing/troubleshooting.
• Protection discrimination analysis and maintenance for optimum and safe circuit performances.
• The monitoring and analysing of Power meter readers for cost effective energy consumption.
• Maintaining a variety of apparatus including UPS systems, Solar Charging Systems and DC battery maintenance.
• Undertaking preventative maintenance inspections in accordance with maintenance planning systems and recommending appropriate follow-up action.
• Overseeing the installation, removal, transfer, maintain and/or repair cross arms, pins, insulators, guys, transformer and switch racks and other overhead pole and Underground Mining Distribution equipment using a variety of hand tools, equipment, and power tools and industry standard installation techniques.
• Inspection of lines, poles and equipment for signs of damage or wear and reports deficiencies including of the installation of new reticulation infrastructure.
• Outage management and network control in collaboration with the Client Control Centres Coordinate with National Grid and attend commissioning panel meetings.
• Variable Speed drives Maintenance and troubleshooting (WEG & Toshiba)
• Electrical isolations/lockouts as per the site LOTO procedures
• Statutory inspections & testing of safety devices. Earthing and Lightning / Surge Protection.
• The managing and analysing of Power Quality Energy Efficiency and Energy Use.
• All Electrical aspects of equipment including Conveying system, Blowers, Crushers, Mills, Oxygen Plant, Compressor Functionalities Filter presses, Flotation applications, MSA and other sampling applications, Lubrication Systems, Thickener Operations.
• Planning and overseeing of electrical/plant shutdowns.

Reliability:

• Reliability Engineering Functions with regards to plant optimization, predictive maintenance, statistics and probability and the general planning and installation of measuring devices to achieve this.
• Overseeing and assisting Reliability Engineers in reliability measurement technique and data analysis through comprehensive business analytical principals.

Industrial Networks and Server Maintenance:

• Develop the Logic and Design electrical panel design, testing and commissioning for plant guidelines based on given requirements and specifications and mechanical/electrical designs.
• Maintain / Troubleshoot Fiber networks, Stratix switches, Network Technologies, Patch Panels, and both Fiber and cat5/6 terminations.
• I/O selection, I/O list preparation and testing of plant applications.
• Design C&I system and equipment as per the requirements for plant an mining facilities.
• Redline and design Piping & Instrumentation Diagram (P&ID) and/or control schematics as required.
• Review and management of all engineering documentation within discipline including, but not limited to, the following documents, lists, calculations and detail drawings; Instrumentation and Controls Design Criteria, Control Philosophy and conceptual design of ,industrial control systems, Control Narratives, instrument index, I/O lists, instrumentation calculations, data sheets, specifications, selection and sizing, P&ID’s, system architecture drawings, instrument location drawings, installation detail drawings, wiring and interconnection diagrams, ISA loop drawings, motor control schematics.
• Develop control system deliverables such as:
• Field connection diagrams, DCS Connection diagrams, Loop Drawings
• Overseeing and controlling Control Panel Design, Instrument wiring diagrams, Cable Schedule
• Maintain/manage Server installation, programming, software updates.
• Develop instrumentation deliverables such as: Instrument demolition/ installation diagrams, Instrument datasheets, Instrument location plans, Conduit routing
• Plant Industrial Network Support Manage, maintain, and support all industrial network server hardware, virtual machines, and installed software. Analyse existing network infrastructure, identify weaknesses, vulnerabilities, and IT policy compliance issues.
• Develop and maintain documentation of network architecture Manage and support all industrial network PC’s running CITECT software, as well as PCs used for industrial programming and development. Develop and provide written training of network and server troubleshooting for existing plant technical resources including engineers and maintenance technicians.
• Maintain Plant-wide Security Access Point Control Systems to include automated gate openers, server-based biometric scanning systems and CCTV surveillance systems.
• Maintain Plant-Wide Radio network including all repeaters, radio installations, repairs and documentation of assets and allocation.

Instrumentation:

• Ensure that all Processing Maintenance safety standards are always complied to, and that all Processing Maintenance staff are fully trained in terms of safety processes and procedures.
• Troubleshoot and repair Industrial TCP/IP and Modbus networks of PLC and various I&E field devices such as flow meters, Radar’s, motor controllers, motor starter protection relays, PLC Remote IO Racks, flow control valves, pressure transmitters, vibrations sensors, PH calibrations, Block Chute Sensors, Density Measurements.
• Management of the equipment within the process control domain, best practice for instrumentation developed within relevant legal and safety frameworks.
• Audit high risk and safety critical areas, analyse, and identify problems on the current control solution.
• System trouble shooting and hardware problems resolution, Support on existing instrumentation, networks and hardware, Calibration, and maintenance of all equipment within the control solution.
• Ensure that all legal compliances are met and incorporated in the Processing Maintenance standards.
• Provide technical support for capital projects involving business units at various stages of the plant life cycle.
• Researching new technologies, regulations, and other factors that may affect business model.
• Participation in all project studies such as HAZOP, SIL Study.

Heating, ventilation, and air conditioning (HVAC):

• Prepare / review the HVAC engineering documents, which includes but not limited to: Conversant with P&IDs, Conversant with HVAC Flow Diagram
• Familiar with various HVAC systems, water chillers, air conditioning units and working principals.
• Conversant with functionality/design criteria of following HVAC sub-systems:
• Air Condenser / SW condenser
• Evaporator
• Compressor
• Prepare scope of work, cost estimates, budgets, and technical application and maintenance programs.
• Lead the technical review of the bidders’ proposals and prepare technical recommendations accordingly for maintenance programs and new projects.
• Review & Comment Vendors deliverables, interpret facilities engineering drawings, designs and make necessary recommendations.
• Follow-up Purchase Orders of HVAC equipment to ensure timely approval, conformity of design & participates in technical reviews and FAT with Vendors.

Fire Protection Applications:

• Manage and maintain all fire protection applications with in the prescribed national recommended maintenance framework.
• Maintain plant drawings for fire alarm and fire sprinkler systems.
• Conduct visual inspections during routine walks for sprinklers, fire alarms, fire pumps, water tanks, and fire detection and suppression systems in MCC’s.
• Provide technical support to all process plant during construction ensuring that the appropriate corrective actions are taken to remedy the situation.
• Responsible for the development of a trusting and mutual relationship with both internal and external services suppliers.

Technical Competencies

• Proven Knowledge and experience with Citect SCADA & AVEVA PI System data intelligence system essential with completed AVIVA course material. Aswell as APC combined with OPC infrastructure and architecture
• Familiarity with common communication protocols including TCP/IP, Ethernet/IP, Modbus, Device Net & Profibus.
• Extensive knowledge and experience in designing, implementing and maintaining Plants Automations, Data/Digital Communications and Networking Architecture, Wireless technology and services, communications protocols, systems architecture design and interfaces inside operating plants’ facilities and substations. (Fiber and Copper applications).
• Knowledge of Control Systems and philosophies, Process instrumentation, Equipment selection and specification.
• Knowledge on Fire Engineering systems essential.
• Excellent technical writer for SOW, BOM, SWP and Management plans compilation
• Strong emphasis on the development of staff and tracking through a high quality and standard Skills Matrix.
• Demonstrated experience in operation and maintenance of High Voltage apparatus including bit not limited to load studies and discrimination principals.
• Experience maintaining a variety of high voltage apparatus including protection relays, transformers, circuit breakers DC battery maintenance and Variable Speed Drives
• Ability to read and interpret complex electrical schematics, wiring diagrams, and manuals.
• High-level of knowledge of HV Voltage substation design and architecture including distribution methods earthing standards (ex. Equal potential earthing)
• Sound knowledge in HT jointing and termination methods.
• Proven knowledge an understanding of reliability engineering principal’s implementation and data analysing techniques and the selection of reliability measurement instrumentation.
• Sound knowledge in cost control and reporting against forecast and budget.
• Well-developed contract management skills and commercial acumen.

Behaviours/Personal Attributes

• Ability to impact and influence the team.
• Working experience of teamwork and planning/reporting of such within multi-discipline project teams, including project/scheduling interfaces
• Ability to communicate effectively at all levels of the organisation and build effective relationships and networks.
• Demonstrate strong conceptual skills and be capable of developing lateral and practical solutions.

Qualification & Experience

• Recognised Automation/Electrical Diploma or RPL formally recognised by certified engineering authority, with a significant experience in a CE&I engineering field with other supporting qualifications may be considered.
• Minimum 15+ years-experience in fixed plant/mining, infrastructure, instrumentation, and electrical maintenance/Projects, HVAC.
• Minimum 10+ years-experience in fixed plant/mining, infrastructure, instrumentation, and electrical maintenance/Projects, HVAC in a supervisory or mid-level managerial role.
• Proven experience in managing multi-disciplinary teams across EC&I field (Electricians, Instrumentation Technicians, HVAC Technicians, Radio Technicians, Fiber Optic Specialists and Fire Technicians)
• Proven referable track record in all maintenance functions of mining operation for open cast operations and process plants is essential in the field of EC&I and HVAC.
• Engineers Registration Board certified as a professional.
• Exposure to start-up operations (Greenfields).