Utilities Operator 3 - Utilities Operator

Objectives / Purpose of the Job:

Utilities Operator III is a senior-level operations and maintenance professional responsible for the safe, reliable, and compliant operation of critical utility systems supporting pharmaceutical manufacturing. This role operates, monitors, troubleshoots, maintains, and documents GMP-critical utility systems including steam, chilled water, compressed air, purified water, water for injection (WFI), HVAC, clean steam, power distribution, and process waste systems.
The role also responds to alarms, abnormal conditions, maintenance needs, contractor coordination, project execution, safety requirements, and continuous improvement initiatives while operating, monitoring, troubleshooting, maintaining, and documenting critical utility systems that support pharmaceutical manufacturing.

Key Activities / Responsibilities / Job Functions

Utility System Operation and Monitoring:

•    Operate, monitor, and maintain utility systems through field inspections and centralized BMS, EMS, PLC, and HMI systems including repeated operation, monitoring, and control-room responsibilities described in later sections.
•    Monitor critical operating parameters and respond appropriately to alarms, abnormal conditions, and system failures.
•    Perform routine rounds, inspections, operational checks, and equipment status verification.•    Maintain complete and accurate operational records, logbooks, and GMP documentation.•    Steam Generation and Distribution Systems
•    Operate and maintain industrial boilers and associated steam distribution equipment.
•    Perform boiler water chemistry testing, chemical treatment checks, blowdowns, and support boiler cleaning activities.
•    Monitor and troubleshoot; condensate return systems, steam traps, condensate stations, surge tanks, deaerator tanks, boiler feed pumps, water level controls, steam regulators, steam hot water heaters, and HVAC reheat systems.
•    Perform natural gas leak checks
•    Maintain awareness of boiler certification and site compliance requirements.
•    Chilled Water, Condenser Water, and Cooling Tower Systems
•    Operate and maintain the chiller plant, including screw chillers, centrifugal chillers, chilled water pumps, condenser water pumps, and associated valves and controls.
•    Monitor cooling tower operation, balancing, water treatment, and chemical management activities.
•    Troubleshoot chilled water bypass pressure control and system flow issues.
•    Use York and Trane chiller HMIs to monitor performance, identify system concerns, and support corrective actions.

Compressed Air and Vacuum Systems:

•    Operate and maintain; oil-free screw compressors, desiccant air dryers, receivers, regulators, auto drains, and condensate management equipment.
•    Monitor compressed air quality requirements, including dew point performance.
•    Use Atlas Copco compressor and air dryer HMIs to support troubleshooting, alarms, and routine operations.•    Operate and maintain vacuum systems.•    Pharmaceutical Water, WFI, and Clean Steam Systems
•    Operate, maintain, and troubleshoot multimedia filters, carbon filters, water softeners, brine systems, flow meters, UV systems, fine filters, reverse osmosis equipment, and purified water support systems.
•    Operate and support MECO vapor compression stills, WFI storage tanks, spray balls, MECO clean steam generators, and associated monitoring systems.
•    Monitor TOC and conductivity instrumentation and support routine clean water sampling activities.
•    Complete and review GMP forms related to water systems and perform stainless steel passivation activities as required.

HVAC and Environmental Control Systems:

•    Operate HVAC systems supporting GMP manufacturing spaces and controlled environments.
•    Troubleshoot chilled water air handlers, DX air handlers, reheat systems, temperature control, and relative humidity control.
•    Understand relationships between temperature, relative humidity, and cleanroom environmental performance.•    Support investigations and corrective actions related to environmental excursions and utility-driven alarms.•    Electrical, Power, and Fire Protection Support
•    Support operation and monitoring of generators, switchgear, diesel fire pumps, and related electrical equipment.
•    Work safely around 480V three-phase systems and troubleshoot relay logic and control circuits within qualification and site safety requirements.
•    Follow Lockout/Tagout procedures and support safe equipment isolation during maintenance activities.
•    Monitor and maintain simplex fire alarm system 
•    Process Waste and Facility Support Systems
•    Operate and maintain process waste systems, lift stations, and pH neutralization systems.
•    Control Room Operations and Alarm Response
•    Monitor utility systems from the central control room and respond to system alarms generated through facility monitoring platforms.
•    Use PLC/HMI interfaces, PI Vision, Trane Tracer, and related systems to evaluate equipment status and coordinate corrective action.
•    Create work orders and purchase orders when required to support timely repair, maintenance, and operational follow-up.
•    Communicate effectively with manufacturing, maintenance, quality,engineering, contractors, and leadership during normal and abnormal operating conditions.

Maintenance, Reliability, Projects, and Shutdown Support:

•    Perform preventative maintenance on assigned utility systems and support corrective maintenance activities.
•    Support facility housekeeping, painting, area organization, and inspection readiness within utility spaces.
•    Troubleshoot mechanical and electrical failures involving pumps, valves, actuators, piping, controls, and utility support equipment.•    Work with project managers and engineers during facility upgrades, installations, commissioning, and improvement projects.•    Coordinate contractor activities and participate in semi-annual shutdowns, including extended schedules when required.

GMP, Safety, and Compliance:

•    Work in a regulated pharmaceutical environment and maintain GMP and SOP training compliance.
•    Complete, review, and maintain GMP documentation in accordance with established procedures.
•    Support FDA audits, internal audits, deviation investigations, corrective actions, and inspection readiness expectations.•    Follow safety programs including confined space entry, respiratory protection, hazardous chemical handling, aseptic gowning, and lift equipment requirements.•    Support continuous improvement and safety initiatives.
•    Schedule and Shift Coverage
•    Provide coverage for other operators as required.
•    Work weekends, holidays, non-standard shifts, and extended shutdown schedules when needed to support continuous utility operations.

Work Expectations:

•    Maintain an inspection-ready work area and complete documentation accurately and on time.
•    Demonstrate ownership of utility systems, alarm response, shift turnover, and equipment reliability.
•    Communicate clearly with cross-functional partners and escalate issues according to site procedures.•    Maintain a safety-first mindset while supporting continuous 24/7 pharmaceutical manufacturing operations.

Required Qualifications / Training / Education and Experience:

•    High school diploma or equivalent required.
•    Technical degree, trade school certification, military technical training, or equivalent utility operations experience preferred.
•    Minimum of 5 years of industrial utility operations, maintenance, facilities, or control room experience preferred.•    Experience in a pharmaceutical, biotechnology, medical device, or other regulated manufacturing environment preferred.•    Technical Skills and Knowledge
•    Industrial boiler operation, steam generation, condensate return, and steam distribution systems.
•    Chilled water, condenser water, cooling tower, compressed air, HVAC, WFI, purified water, clean steam, vacuum, and process waste systems.
•    Mechanical troubleshooting, electrical troubleshooting, relay logic, valves, pneumatic actuators, electric actuators, pumps, piping, and utility controls.
•    Piping and fabrication skills including pipe fitting, pipe hanging, pipe bending, pipe threading, ProPress, PVC work, and related maintenance practices.
•    Working knowledge of PLC/HMI platforms, Trane Tracer, PI Vision, Maximo, and Microsoft Office applications including Word and Excel.

Licenses, Certifications, and Work Qualifications:

•    Valid driver’s license required.
•    Boiler certification is preferred or required based on site and jurisdictional requirements.
•    Forklift, JLG, Lull forklift, and scissor lift experience preferred.•    Confined space entry and respiratory protection qualification preferred.•    Ability to perform aseptic gowning where required.
•    Preferred Qualifications
•    Stick welding and TIG welding experience.
•    Lathe and mill operation experience.
•    ABB VFD programming experience.
•    Trane Tracer Ensemble programming experience.
•    PLC programming experience.
•    Arc flash certification.
•    Advanced automation, industrial controls, and pharmaceutical utility troubleshooting experience.
•    Physical and Environmental Requirements
•    Ability to stand, walk, climb stairs and ladders, and access elevated work areas during the work shift.
•    Ability to lift, carry, push, and pull materials and equipment consistent with site requirements.
•    Ability to work in utility spaces, mechanical rooms, cleanrooms, confined spaces, rooftops, and industrial environments.
•    Ability to wear required personal protective equipment, including respiratory protection when qualified and required.•    Ability to work safely around steam, heat, chemicals, noise, rotating equipment, electrical systems, and other industrial hazards.

Tools, Systems Category and Equipment Experience:

•    CMMS / Maintenance - Maximo; work order creation and completion; purchase order support.
•    Monitoring / Control    - PLC/HMI platforms; PI Vision; Trane Tracer; equipment HMIs
•    Utility HMIs - York chiller HMI; Trane chiller HMI; Atlas Copco compressor and dryer HMI•    Office Applications -    Microsoft Word, Excel, Outlook, and general computer-based documentation tools•    Mobile Equipment - Forklift, Lull/telehandler, JLG, and scissor lift experience