Process Controls Engineer

About the role

We are looking to hire a Process Controls Engineer in our Ladysmith, WI paper mill to develop and manage analysis methods for determining reliability of components, equipment, and processes. Consistency will be a key attribute for the right candidate as this role will assist in creating a culture of continuous process improvement, and employee development to ensure downtime is kept to a minimum.

Key Accountabilities

• Improve existing controls, streamline operator tasks, increase machine productivity and lead troubleshooting efforts of ongoing issues.
• Utilize DCS engineering stations to maintain and modify machine control logic, human machine interfaces, control hardware and machine communication networks.
• Ensures all machine control system device programs and settings are backed up on a regular basis to a known and readily available central location.
• Responsible for maintaining all electrical schematics to insure changes are recorded and that all library copies are accurate and available to all members of the E&I department.
• Assist with developing data acquisition historian reports and trends. Also, perform historian system maintenance.
• Perform resource functions for E&I technicians, including scoping, engineering and ordering parts, as needed.
• Maintain and troubleshoot all machine instrumentation and electrical systems up to 2300 VAC, as needed.
• Configure, troubleshoot and repair motors, motor control centers, variable frequency drives and soft-starts up to 4160 Volt.
• Installation, calibration and troubleshooting of pressure, level, flow, temperature, consistency, conductivity, turbidity and pH transmitters.
• Tuning of process control loops and machine control systems.
• Programming and troubleshooting of DCS, PLC and HMI interfaces.
• Perform configuration and logic modifications to DCS and PLC control systems. Modifications will include programming in ladder logic, block logic, sequential logic and statement logic.
• Troubleshoot and diagnose configuration and implementation of integrated and stand-alone graphic human machine interfaces.
• Troubleshoot and diagnose specification of communication protocols, including Profibus, serial and industrial Ethernet.
• Design and implement process control strategies including; regulatory control, control sequence, logic, and advanced control for both continuous and batch processes.
• Develop, modify, and enhance HMI.
• Monitor control system performance, which includes loop analysis and tuning.
• Implement new control system technology.
• Support process problem solving by identifying sources of process upsets and other anomalies.
• Develop and maintain alarm systems.
• Support capital projects. Must be able to develop project justification and manage a capital project or sub-project related to process controls.

Required Experience

• Must have a minimum of a BS Degree in Engineering (Electrical, Mechanical, Chemical, or Pulp/Paper Science).
• Minimum of five (5) years process control experience desired.
• Good working knowledge of Distributed Control Systems (DCS).
• Experience with Programmable Logic Controllers (Allen Bradley PLC5 and ControLogix) is a plus.
• Firm foundation in industrial process knowledge. Pulp and Paper desired.
• Experience with instrumentation and electrical systems associated with process control systems.
• Excellent computer skills – particularly Microsoft including Outlook, Excel, Word, Project, Power point.
• Highly competent in data analysis and use of process data historians such as OSI PI and Honeywell PHD.
• Understand P&ID drawings, loop sheets, and motor elementaries and can create these drawings as necessary to support project work and to maintain existing drawing using AutoCad or equivalent drawing tools.

Work Environment

• Work is performed in a climate controlled office as well as the manufacturing facility with high humidity, variable temperatures, loud equipment and dust.
• Some exposure to odors and chemicals.
• Required to wear PPE when in manufacturing areas.
• Some travel may be required.