Process Controls Engineer

Job Description

Job Description

Purpose

The Process Controls Engineer supports the safe, reliable, and efficient operation of the Texas facility through the design, implementation, maintenance, troubleshooting, and continuous improvement of process control systems, automation technologies, instrumentation, and electrical distribution equipment. This role provides technical expertise for capital projects, process optimization, equipment reliability initiatives, and troubleshooting efforts while partnering with Operations, Maintenance, and Engineering to improve plant performance and support business objectives.

Essential Job Functions / Accountabilities

Instrumentation, Controls, & Automation

• Design, configure, troubleshoot, and maintain hardware for DCS, PLC, HMI, process historian systems, and network systems.
• Develop and modify control logic, graphics, alarms, historian tags, and operator interfaces for DCS, PLC, HMI, and process historian systems.
• Maintain control system backups, documentation, and configuration records.
• Implement control system upgrades, migrations, patches, hardware replacements, and other improvements to automation systems.
• Analyze process data and system performance to identify and implement opportunities for improved process control, efficiency, product quality, and equipment reliability.
• Support commissioning, startup, and optimization of new equipment, instrumentation, and control systems.
• Troubleshoot instrumentation and control system issues and lead root cause investigations to identify corrective actions.

Capital Projects & Continuous Improvement

• Lead and/or support controls, instrumentation, and electrical capital projects from concept development through startup and project closeout.
• Develop project scopes, technical specifications, cost estimates, schedules, and equipment requirements.
• Coordinate activities with Operations, Maintenance, Engineering, contractors, equipment suppliers, and consultants to ensure successful project execution.
• Investigate process, quality, productivity, and reliability issues and implement sustainable solutions.
• Identify and implement improvements that enhance safety, reliability, efficiency, and operational performance.
• Develop and execute process control modifications resulting from continuous improvement initiatives and business needs.
• Obtain vendor quotations, support procurement activities, and assist with capital justification requests.
• Recommend improvements in the application and design of instrumentation and control systems using current industry best practices.
• Provide oversight and coordination to external contractors in the design, installation, startup, and modification of electrical systems supporting plant operations.

Reliability & Maintenance Support

• Drive maintenance, testing, and reliability programs for controls, instrumentation, and electrical distribution equipment.
• Assist with troubleshooting electrical equipment failures and power distribution issues.
• Participate in root cause investigations related to equipment failures and process interruptions.
• Provide technical support during plant shutdowns, turnarounds, and startup activities.
• Track equipment performance metrics, and identify opportunities to improve electrical system reliability, maintainability, and performance.

Safety, Compliance & Leadership

• Follow and promote all Safety, Health, Environmental, and Process Safety Management (PSM) requirements.
• Support and ensure compliance with the Integrated Management System (ISO 9001, ISO 14001, and ISO 45001).
• Develop, revise, and maintain engineering, maintenance, and operating procedures, standards, and specifications as needed.
• Develop, maintain, and provide oversight for electrical drawings, control narratives, and associated technical documentation
• Ensure electrical installations and modifications comply with applicable codes, standards, and regulations.
• Monitor adherence to plant safety procedures and promote continuous improvement in safety and housekeeping performance.
• Train and support operators and maintenance personnel on new equipment, control systems, and processes.
• Provide guidance and mentorship to co-ops, interns, and less experienced technical personnel.

Qualifications

Education

• Bachelor's Degree in Electrical, Chemical, or Mechanical Engineering is required
• Degree in Electrical Engineering is preferred.

Experience

• Minimum seven (7) years of experience in controls engineering, automation engineering, electrical engineering, or a related industrial engineering role. 
• Experience supporting PSM-covered processes is required.
• Experience managing or supporting DCS, PLC, instrumentation, capital projects and/or electrical systems in a manufacturing environment. 
• Experience with Rockwell/Allen-Bradley PLCs, FactoryTalk applications, and Yokogawa DCS is preferred.
• EIT, PE, or PMP certification is a plus.

Knowledge, Skills & Abilities

• Strong familiarity with applicable industry standards and codes including NFPA, NEC, NEMA, IEEE, and ISA.
• Working knowledge of industrial control systems, automation technologies, and process control principles.
• Working knowledge of instrumentation, control valves, analyzers, and process measurement devices.
• Working knowledge of electrical power distribution systems, MCCs, VFDs, motor controls, switchgear, and related equipment.
• Strong troubleshooting and root cause problem-solving skills.
• Ability to manage multiple projects and priorities simultaneously.
• Effective verbal and written communication skills and the ability to work effectively with employees at all levels of the organization.
• Strong analytical, organizational, and project management skills.

Benefits:

Zeon employees enjoy growth opportunities as well as a highly competitive salary and benefits program. 

Zeon Chemicals does not discriminate in employment on the basis of race, color, religion, national origin, age, sex, physical or mental disability, or any other characteristic protected by applicable law.