Job Purpose

The Site Process & Instrumentation Engineer is responsible for the technical integrity, reliability, performance and continuous improvement of the site’s lubricant blending, transfer and filling processes. The role provides site level engineering ownership of the SMB, DDU, Filling Lines bulk storage and transfer systems, process instrumentation, automation and associated production equipment.

The position works closely with Plant Manager, Maintenance, Quality, HSE, Projects and external engineering specialists to ensure plant systems are safe, reliable, accurate, compliant and capable of meeting production, quality and efficiency requirements. A key focus is ensuring that process measurements and automated systems are reliable and traceable, including flow, weight, level, pressure, temperature, dosing, blending and transfer systems.

How You Make an Impact (Job Accountabilities)

1. Process Engineering

· Provide technical ownership and support for lubricant blending and transfer processes including the SMB, DDU, base oil and additive storage, tank farm, transfer systems, pumps, valves, pipework, filtration, heating systems, manifolds, pigging/flushing systems where applicable, finished product storage and transfer to filling lines and filling line processing.

· Analyse and improve blend accuracy, batch consistency, dosing accuracy, flow rates, cycle times, product losses, flush volumes, cross contamination, rework, yield, throughput and process stability.

· Investigate process abnormalities and develop technically supported corrective and preventive actions.

2. Instrumentation & Process Control

· Provide site technical ownership of process instrumentation and control systems associated with blending, storage, transfer and filling operations.

· Maintain and optimise flow meters, load cells, weigh systems, radar level transmitters, pressure and temperature instruments, control valves, solenoids, position feedback devices, variable speed drives, PLC, HMI and SCADA interfaces or data logging software and hardware, alarms, interlocks and permissives.

· Ensure instrumentation is appropriately selected, installed, calibrated, verified, maintained, tested and documented.

· Develop calibration and verification frequencies based on equipment criticality, risk, historical performance and manufacturer requirements.

· Investigate discrepancies between inventory quantities, tank level readings, flow meter quantities, blend system quantities, filling quantities and finished product volumes.

3. SMB & DDU Technical Ownership

· Act as the site’s primary technical owner for the SMB and DDU systems.

· Monitor equipment performance and investigate dosing, blending and control deviations.

· Verify flow meter and weighing system, telemetry performance and ensure appropriate calibration and validation controls are in place.

· Review recipe execution, control system faults, alarms, interlocks, permissives, operating sequences and duel and or double redundancy.

· Support software and logic changes through formal change control processes.

· Work with OEMs and specialist contractors to maintain equipment reliability, technical documentation, preventive maintenance requirements and critical spares strategies.

· Ensure SMB and DDU systems operate within approved design parameters and OEM operating envelopes.

4. Process Accuracy & Measurement

· Develop and maintain systems for verifying process measurement accuracy from raw material receipt through to finished product filling.

· Support mass balance calculations and reconciliation of raw materials, base oils,



additives, blend quantities, transfers and finished product output.

· Provide technical support for yield analysis, overfill analysis, process loss analysis, meter accuracy and tank level accuracy.

· Identify measurement gaps and recommend appropriate engineering controls where existing systems are insufficient to verify process performance.

5. Commissioning & Engineering Projects

· Support commissioning, validation and handover of new plant and equipment.

· Review P&IDs;, process flow diagrams, instrument schedules, equipment specifications, control philosophies, cause and effect documentation or RCA, alarm/interlock schedules and as built documentation.

· Support FAT, SAT, commissioning plans, punch lists, performance testing and equipment acceptance.

· Provide site engineering input to design reviews, capital projects, tank inspections and plant modifications.

6. Engineering Documentation

· Maintain accurate and current P&IDs;, process flow diagrams, as built drawings, instrument schedules, equipment registers, calibration records, control philosophies, functional descriptions, equipment datasheets, OEM manuals, cause and effect matrices, alarm schedules, interlock schedules, operating limits and engineering-change records.

· Ensure engineering documentation accurately reflects the installed plant and approved operating configuration.

7. Reliability Engineering

· Support the development and improvement of site equipment reliability through Root Cause Analysis, equipment criticality assessment, failure mode analysis, preventive maintenance optimisation, condition monitoring vibration, thermal and liters per minute, lifecycle planning, spare parts review and failure trend analysis.

· Work closely with Maintenance to identify repetitive equipment failures and implement permanent corrective actions.

8. Continuous Improvement

· Identify and implement opportunities to improve plant capacity, throughput, OEE, reliability, product quality, process stability, changeover time, flush losses, energy efficiency and equipment utilisation.

· Use structured problem solving and improvement methodologies such as RCA, 5 Why, DMAIC, Lean, Six Sigma and Statistical Process Control and Statistical quality control

· Support Operations in developing sustainable process control standards and operating windows.

9. Process Safety & Engineering Compliance

· Ensure engineering changes and process modifications are appropriately assessed, approved, documented and verified prior to implementation.

· Participate in Management of Change, HAZOP, risk assessments, engineering reviews, commissioning risk assessments, plant modification reviews and management of change in processes.

· Ensure changes to equipment, instrumentation, PLC logic, recipes, piping, valves, control systems and operating parameters follow approved change control requirements.

· Support compliance with applicable WHS requirements, Australian Standards, environmental requirements, company engineering standards and site procedures.

10. Filling & Packaging Engineering Support

· Provide engineering support where process or instrumentation issues impact filling and packaging performance.





· Support troubleshooting of filling accuracy, supply pressure, flow instability, tank to line reconciliation, filling machine instrumentation, check weighing systems, product temperature effects, pump performance and filling cycle optimisation.

· Work with Operations and Quality to determine whether deviations originate from blending, transfer, instrumentation or filling equipment.

11. Contractor & Vendor Management

· Manage technical relationships with equipment OEMs, instrumentation contractors, automation specialists, calibration providers, engineering consultants, mechanical contractors and electrical contractors.

· Develop clear technical scopes of work and ensure contractors meet site safety, engineering, quality and documentation requirements.

· Vehicle orders based in accordance with motor vehicle policies and guidelines.

Environment, Health & Safety

· Follows all environmental policies and procedures.

· Reports all accidents, incidents and near misses to their Manager.

· Promotes Valvoline principles. Drives in a responsible manner

· Participates in training as required.

· Participates in consultation on all EH&S; related matters.

What You Bring to the Role (Job Qualifications / Education / Skills / Requirements / Capabilities)

Qualifications

· Bachelor’s degree in Instrumentation Engineering, Process Engineering, Chemical Engineering, or Electrical/Electronic Engineering with strong process control experience.

· Mechanical Engineering may also be considered where the candidate has substantial process instrumentation, automation and liquid processing experience

Essential experience:

· 8+ years of demonstrated engineering experience in a manufacturing or process environment involving automated liquid processing systems. (oil Industry an advantage)

· Experience with several of the following: liquid blending, batch manufacturing, chemical processing, lubricants, oil/fuel processing, bulk liquid storage, flow measurement, automated dosing, process instrumentation, PLC controlled equipment, SCADA/HMI and maintenance systems, tank farms, pumps, pumping systems, filling systems and commissioning.

· Experience with Coriolis mass flow measurement, automated blending and weighing systems is highly desirable.

Competencies Desired

Technical Competencies:

· Process control and instrumentation.

· Flow, mass, level, pressure and temperature measurement.

· Calibration and measurement system verification.

· Process troubleshooting and data analysis.

· PLC or computer based control systems and industrial automation.

· P&IDs; and engineering documentation.

· Pumps, valves, tanks and liquid transfer systems.

· Process safety and Management of Change.

· Root Cause Analysis and reliability engineering.

· Commissioning, validation and performance testing.

Behavioural Competencies:

· Strong analytical and structured problem solving capability.

· High attention to detail and engineering discipline.

· Ability to challenge technical assumptions using evidence and data.

· Strong ownership and accountability.

· Practical, hands on approach in a manufacturing setting.

· Ability to work effectively with Operations, Maintenance, Quality and HSE teams.

· Clear written and verbal communication.

· Ability to manage contractors and specialist technical providers.

· Ability to prioritise competing engineering issues.

Working Conditions / Physical Requirements / Travel Requirements

· Working Conditions / Physical Requirements: Factory and Office

· Travel Requirements: 10%

📌 Site Process & Instrumentation Engineer (Wetherill Park)
🏢 Valvoline Global Operations
📍 Wetherill Park