Process Controls Engineer

About the role

This role requires formal knowledge and certification in several process controls and safety systems. Each certification requires bi-annual refresher training to remain current on the systems. It requires an understanding of network design and the associated hardware/infrastructure. It must be capable of setup, configuration, and maintenance of supporting systems such as alarm management, data historian, asset management, etc. This role requires a broad understanding of industrial communications protocols and programming languages. It requires a strong understanding of control theory, process dynamics, and instrumentation and how they can be applied in the control of chemical processes. This role requires an in-depth knowledge of the process, facility installation, and operating conditions to evaluate, and optimize control schemes and sequences.

Responsibilities

• Routinely provides guidance to operations personnel on process control and optimization and to maintenance personnel on troubleshooting.
• Directs contractors and consultants when required to support large projects and TARs.
• Schedules and oversees the preventive maintenance required for the system hardware and the testing required for the safety interlocks, which requires support for the operations and maintenance departments.
• Coordinates these activities across multiple departments requiring high levels of planning, organization, & control.
• Evaluates the data and documents the findings. Tracks any items needing further attention to completion.
• Maintains detailed records for tracking the long-term integrity of the system hardware & instrumented safety systems and supports audits (INEOS, insurance, OSHA, etc.) when required.
• Communicates with the operations, maintenance, and engineering departments in the development of process control improvements, troubleshooting process controls issues, and training on process control systems and philosophies.
• Communicates across all levels of the organization, conveying technical information to both non-technical and technical stakeholders.
• Schedules and implements the interlock testing and preventive maintenance on the automation hardware systems. Coordinates these activities with both the maintenance and operations departments to ensure resources are available to support the work and that these tasks do not interfere with the operation of the facility.
• Develops and implements a long-term preventive maintenance and testing plan to ensure the ongoing reliability of the system hardware and the safety interlocks.
• Designs and implements the infrastructure of the systems to protect against cybersecurity threats and ensure reliable performance.
• Works independently to perform critical designs and system changes, which are also reviewed by additional knowledgeable resources to validate the design or change.
• Continuously makes decisions on system optimization and changes to control and safety philosophies, including significant changes such as interlock set points/actions and process sequence configuration.
• Develops and implements advanced control algorithms and control sequences to continuously improve process safety, stability, efficiency and reliability.
• Supports the production, maintenance, ES&H, laboratory, and engineering departments by analyzing process and system data to evaluate upsets, equipment failures, quality issues, and other operational concerns.

Qualifications

• Formal knowledge and certification in several process controls and safety systems.
• Bi-annual refresher training for certifications.
• Understanding of network design and associated hardware/infrastructure.
• Setup, configuration, and maintenance of supporting systems such as alarm management, data historian, asset management, etc.
• A broad understanding of industrial communications protocols and programming languages.
• A strong understanding of control theory, process dynamics, and instrumentation.
• An in-depth knowledge of the process, facility installation, and operating conditions.
• Experience with industrial control and safety systems.
• High levels of planning, organization, & control.
• Effective communication skills, both technical and interpersonal.
• Ability to work independently and within teams.
• Knowledge of SAP, OSI Pi, Visio, and databases (e.g. Access & SQL).
• Continuous learning and adaptation to new technologies.

Skills

• Control theory, process dynamics, and instrumentation.
• Industrial communications protocols and programming languages.
• Process control and safety systems.
• Network design and infrastructure.
• System design, simulation, implementation, testing, and maintenance.
• Advanced control algorithms and control sequences.
• Reliability and availability measurement and reporting.
• Process data analysis and improvement.
• Emergency shutdown systems and data historian.
• Alarm management and interlock functionality.
• Preventive maintenance planning and execution.
• System testing and documentation.
• Regulatory compliance and industry standards.
• Technological advancements and integration.
• Third party support coordination.

Benefits

• Ownership of the business and empowerment to make a difference.
• Opportunities for career growth and advancement.
• Competitive compensation and benefits package.
• Flexible work environment and schedule.
• Work-life balance and employee wellness programs.
• Professional development and training opportunities.
• Collaborative and supportive work culture.

Pay

Compensation is competitive and commensurate with experience and qualifications.

Schedule

The position offers a flexible schedule to accommodate the needs of the individual and the company.