DCS operator

1. Key Result Areas: Incident free operations, Adherence to INEOS Styrolution SHE guidelines, Compliance with local regulations.

Major Activities:

• Participate on regular safety training at site:
  • Safety rules and guidelines
  • Operating procedures
  • Incident sharing and learning
  • Permit to work and Risk Assessment, etc.
• Active support to the safety culture at site and work safely for incident free operation.
• Understand and follow annual SHE improvement plan for the site.
• Work in line with SHE KPIs and Targets set by management from time to time.
• Contribute to Behavior Based Safety (BBS) program at site.
  • Participate on training at site to take BBSO to next level of reporting.
• Support Site SHE committee to resolve safety issues and drive SHE performance.
• Be conscious that all incidents including Near Miss at site must be reported, investigated and action items must be tracked to closure.
  • Active use of KMS for incident reporting and investigation, MOC, action item tracking.
  • Able to use the software like Success factor, SAP.
  • Collaborate to track and close all SHE related action items from audit, plant walkthroughs.
• Support the Asset Manager, responsible for the overall integrity of the site.
  • Contribute to INEOS Styrolution Asset Care program
  • Take responsibility for maintaining the asset and integrity of the protective system.
• Follow site procedures aligned with INEOS Group Guidance Notes (IGGNs).
• Accountable for
  • Following and practicing INEOS 20 principles of Behavior Safety and Process Safety at site through site rules and procedures
  • Following and practicing Life Saving Rules at site
  • Safety of other Employees, Contractors, Visitors and partners at site
  • Following Permit to Work as per the site procedure
  • Following Management of Change (MOC) as per the site procedure.
• Responsible for
  • Participating in HAZOPs at site as per procedure
  • Tracking action items from HAZOP to closure.
• Work in compliance with all legal regulations.
  • Adherence to site licenses and permits.

• Participate on the INEOS Styrolution Sustainability program at site.
• Stop work whenever there is an unsafe condition and immediately inform the Shift Leader and/or Head of Department.
• Directly intervene with those in your working area not using PPE or not following INEOS Styrolution standards and procedures.
• Maintain the respective workplace in order and clean, as per best practices of housekeeping.

Outcome: Zero incident/accident in the plant with sustainable and safe operation.

2. Key Result Areas: Enhance Safety Culture

Major Activities:

• Lead the team towards a safe operation of Rubber, Compounding, Utilities and WWTP.
• Maintain SHE standards and support SHE program (like RIR, BBS, KMS, Sustainability)
• Plan Safety talks & Risk assessments with employees
• Establish effective work permit system, Implementation of process safety.  

      Outcome:

      Zero incident/accident in the plant.

3. Key Result Areas: Plant operation

Major Activities:

• Follow all safety guidelines and work procedures to operate the processes of preparation of solutions, charging batches (base rubber, graft rubber & agglomerator), controlling process parameters (temperatures, levels, pressures, etc.), dumping and transferring finished batches to storage tanks and supervising reactor cleaning.
• Supervise and control temperature, level and pressure of day-tanks of materials such as: Styrene, Butadiene, Acrylonitrile, Acetic Anhydride, Soap, etc.
• Operate as per the Alarm Management System and review it regularly to keep it updated.

Outcome: Prime production, raw material & energy saving, zero incident of unsafe acts.

4. Key Result Areas: Startup / Shutdown

Major Activities:

• Follow all safety guidelines and work procedures during startups and shutdowns. Monitor temperature and pressure of reactors, vessels, day tanks during shutdown period.

• Execute pressure testing of reactors after cleaning.

Prepare all batch solutions required during startups

Outcome:

Perform safe and smooth startup/shutdown monitoring & minimizing off-grade/off-spec generation of product, zero incidents of unsafe acts.

Key Result Areas: Troubleshooting and coordination with other departments

Major Activities:

• Monitor process conditions and results to identify variations of fluctuations which could lead to abnormal operations, unsafe conditions or adversely affect product quality – notifying Shift Leader immediately of major potential issues.
• Investigation and identification of the root cause of problems related to safety performance and quality of the product. Support Maintenance department (Instrumentation, Electrical and Mechanical) during break downs & shutdowns.

Outcome:

Reduction of off grade/off-spec generation. Reduction of downtime of reactors. Improved product consistency.

5. Key Result Areas: Maintain records

Major Activities:

• Maintain Log Sheets for rubber production (hourly Panel Log Sheet) and Log Sheets for vessel entry (Confined Space Entry).
• Review results and entries of data on Log Sheets to identify trends or abnormalities when they occur.

Outcome:

Production data recorded properly to maintain history of the operating conditions and parameters. Data can be used immediately to identify issues and in the future to identify trending issues in the plant and/or quality complains investigations. Data is a Quality record for ISO audits.

6. Key Result Areas: Communication

Major Activities:

• Perform clear communication when given operational instructions to Field Operators and during troubleshooting of problems. Communicate properly with Plant Manager, HODs – Head of Departments, Shift Leader and employees of other departments (Mechanical, Utilities, Electrical, Instrumentation, HR, Security, SHE, Stores & Warehouse, Quality) to reduce confusion and improve response to issues.
• To follow the all Management guideline and company policies

Outcome:

Improve quality of communication for intended implementation of plans, investigations, and improvements

Facts

Number or amount in €

Rubber Production

Capacity of 27 kton/year of P60 Rubber

DCS operation of Base Rubber and/or Graft/CWD (Coagulation, Washing and Drying).

Base Rubber: 6 reactors, BD surge tanks

Agglomeration: 2 reactors

Graft: 3 reactors

Coagulation: 2 lines

Centrifuges- 7 nos.

Dryer: 1 line

Co-ordination with support team

Mechanical, Electrical, Instrumentation

Direct

Indirect

Total

02 per section

Contract supervisor

3

Who

Frequency of contacts

My role in those contacts ^[1]

• Responsible
• Accountable
• Consulted
• Informed

Purpose of contacts

Field Operators

Daily

R

Plant operation, start up, stoppage etc.

Engineering service depts.

Daily

C

Routine cross functional co-ordination

SHE, Quality, SCM and HR/IR

Daily

R,I, A

Routine cross functional co-ordination

Projects

NA

I

For MOC/Projects

Pollution Control Board

NA

I

Compliance audit, sampling

Factory Inspector

NA

I

Compliance audit,

Contractors

NA

NA

• Productivity

• Team work
• EHS & Quality conscious

• Communication

• Reliability & Responsibility
• Coordination with the other department
• Cost saving attitude
• Smooth operation
• Reduction in Batch Cycle time
• Training of operation and safety to shop floor person