Process Controls Engineer
ineos · Theodore, AL ·
- Category
- Industrial engineering
- Experience
- 5+ years
ineos · Theodore, AL ·
Interested in joining a winning team? A team whose employees share in the ownership of the business and are empowered to make a difference?
Knowledge & Skills:
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.
Management:
This role routinely provides guidance to operations personnel on process control and optimization and to maintenance personnel on troubleshooting. In addition, it directs contractors and consultants when required to support large projects and TARs. It is required to schedule and oversee 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. Coordination of these activities across multiple departments requires high levels of planning, organization, & control. After completing these activities, this position is responsible for evaluating the data and documenting the findings. Any items that need further attention must be tracked to completion. All information must be maintained with a high level of detail for tracking the long-term integrity of the system hardware & instrumented safety systems and also to support audits (INEOS, insurance, OSHA, etc.) when required.
Human Relations/Communication:
This position continuously 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. It must be capable of communicating across all levels of the organization, with the ability to convey technical information to both non-technical and technical stakeholders. This position must be able to listen to input from others to fully understand process issues or to incorporate operational experience into the configuration of control concepts and sequences. When implementing new control schemes, it must work closely with the operators to ensure understanding of the control concept and at times persuade them that it will be an improvement over the long term. This position is responsible for scheduling and implementing the interlock testing and preventive maintenance on the automation hardware systems. It must coordinate 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. This coordination requires significant communication, understanding, persuasion, and compromise to complete the scope of work on time without impacting the operation of the facility.
Job Complexity:
The primary responsibility of this position is to ensure the integrity and reliability of the DCS/PLC control systems, Emergency Shutdown system, Data Historian, and Alarm Management system. This requires an expert level of knowledge to ensure that the infrastructure of the systems is properly designed and precisely implemented to protect against cybersecurity threats and ensure reliable performance. It requires all configuration and parameter changes to be properly developed, simulated, inputted, and tested without error, to ensure proper operation of the safety and control systems. It requires the development of a long-term preventive maintenance and testing plan to ensure the ongoing reliability of the system hardware and the safety interlocks. The design and implementation of these responsibilities are performed independently by this position except for critical designs and system changes, which are also reviewed by additional knowledgeable resources to validate the design or change. There are few industry standards governing industrial control and safety systems. These standards allow for a wide range of options in the design and configuration. This position has a great deal of autonomy in performing its role in the organization. For this reason, this position should be held by a highly experienced person with an awareness of their limitations and extreme attention to detail.
Decision Making & Problem Solving:
This position continuously makes decisions on system optimization and changes to control and safety philosophies. Some of the decisions are low level such as simple changes in controller tuning, data collection, and report characteristics. However, many of the decisions are significant, dealing with changes such as interlock set points/actions and process sequence configuration. Although these types of changes are reviewed and approved by a group, the method of executing the desired change is developed by this position. In most cases, it works independently and implements changes based on technical knowledge and personal experience. This includes changes to infrastructure/hardware, control concepts, interlock functionality/limits, control sequence development/modification, preventive maintenance planning/execution, system testing, system reporting, and documentation of all actions. The quality and accuracy of these changes is critical to the safe and reliable operation of the facility. When challenges arise from major changes or findings are identified during inspection/testing, this position is responsible to inform the broader group including management and work within this team to determine the path forward including immediate actions and long-term resolutions.
Responsibilities:
This position is independently responsible for all of the aspects in designing, simulating, implementing, testing, maintaining, and documenting a reliable control network including the associated software systems. It works independently with little or no immediate direction in performing these responsibilities. This includes routine control optimization responsibilities as well as support provided to other departments or working groups. Additional guidance and support are normally only provided when major changes or findings have an immediate or excessive impact on safety, reliability, or cost.
The decisions and recommendations from this position have a significant impact on the safe operation and optimization of the facility. In addition to performing the primary duty of system design/maintenance, it also supports the ongoing operational optimization. This position works independently and within teams to develop sequences and control strategies that reduce the number required personnel by lowering the number of operator actions/interventions and reduce costs by minimizing the consumption of raw materials and utilities. The input and actions from this position are essential to ensuring the safety and reliability of the facility and the implementation of continuous operation improvement.
Working Environment:
This position requires a combination of field and office work. The field work deals primarily with remote mounted control systems and includes installation/upgrade, maintenance/inspection, testing, troubleshooting, etc. These activities are normally scheduled in advance but could also be required after hours on a call-in basis. Work in the field requires the ability to work in all weather conditions as needed to support the facility. Activities include climbing ladders, work at elevated heights, work on energized systems, etc. The office work includes process and system simulation & optimization, implementing approved changes to control/safety systems, analyzing & reporting on process/system data, scheduling inspection/testing activities, developing scopes of work for upcoming projects or TARs, supporting the review process for Management of Change and Incident investigation, continuing & self-directed education, etc. These tasks require the use of standard software such as Microsoft office but also require extensive knowledge in the use of SAP, OSI Pi, Visio, and databases (e.g. Access & SQL).
External:
Regulatory Environment:
This position is required to stay informed of changes to regulations that could impact the process control and safety instrumented systems. It is responsible for making the necessary changes to comply with new/modified regulations. Regulatory agencies that could impact the systems include OSHA, EPA, ADEM, Coast Guard, Homeland security, etc.
Industry Standards:
This position is required for staying informed of changes to industry standards that could impact the process control and safety instrumented systems. It is responsible for making the necessary changes to comply with applicable new/modified standards. Industry standards that could impact the systems include ISA, IEC, NFPA, AIChE, API, ASME, ISO, etc.
Technological Advancements:
This role is required to stay informed on new and developing technologies in process controls systems, instrumented safety systems, data analysis, simulation, network/infrastructure, smart instrumentation, etc. It is responsible for achieving continuous improvement by incorporating new technologies into the automation network and associated systems.
Third Party Support:
This role is required to maintain good relationships with external companies and stay informed on their capabilities and availability. It coordinates support required for normal and emergency support of the facility as well as projects and TARs.
Accountabilities of the job: describe the main results expected from the job
Promote and ensure a sustained commitment to operating without harm to our employees, contractors, third parties, communities, the environment, and our assets by visibly demonstrating leadership in safety Promote safety and safe actions through communication such as discussing safety with employees/contractors before job tasks, during meetings, and as opportunities arise to promote safety to the fullest extent possible Develop and implement preventative maintenance and inspection plans for the facility’s DCS/PLC control systems, Emergency Shutdown system, Data Historian, and Alarm Management system to ensure safe and reliable performance Develop and implement a system to measure, track, and report on reliability and availability of the DCS, ESD, PLC, Data Historian, and Alarm management systems. Causes of deviations and failures should be evaluated and communicated to the organization Coordinate with the I&E department for the maintenance and inspection of the DCS and ESD systems without interruptions to operations. This includes ensuring the DCS AMS database is maintained when devices are added, replaced, or modified Perform and document annual and bi-annual safety Interlock checks to ensure compliance with mechanical Integrity requirements Maintain DCS & ESD system backups and cyber security tools as per policies Analyze process data to identify areas for improvement. Develop and implement control strategies including loop tuning, process variable calculations, alarm configuration, and interlocks to improve operational performance Develop and implement advanced control algorithms and control sequences to continuously improve process safety, stability, efficiency and reliability Support to the production, maintenance, ES&H, laboratory, and engineering departments, by analyzing process and system data to evaluate upsets, equipment failures, quality issues, etc. Provide training for all applicable plant personnel on automated systems as required Support the PHA, PSSR, and SIL processes and PSPM initiatives as needed Support the management of change processes (TEC, procedure review, and TPCC) by reviewing the feasibility and accuracy of the proposed change and completing all actions required by the automations group. Including a process to store, modify, and control the technical data for the DCS, ESD, PLC, Data Historian, and Alarm Management Systems Compile, review, and produce reports required to track the ongoing performance of plant automations including but not limited to alarms, operator actions, controller mode, system health, system utilization, etc. Design and execute projects required for automation hardware or software systems Design, implement, and support projects required improve instrumented process systems and automated functionality of the facility operations Participate on the Phenol Smart Manufacturing team. Support global initiatives and when applicable, implement new initiatives at the Mobile facility. Provide Technical support for special interfaces to the DCS such as Loading operations (Z-load), SAP, Profibus, Modbus, and SQL applications Support and participate in audits and reviews to support internal and external requirements, including INEOS 20 Principles, insurance, OSHA, ISO, etc.
Level of Education & Experience in general
BS Degree in Engineering with minimum 5 years of experience in an industrial environment, or
AAS Technical Degree with minimum 10 years of experience in industrial electrical, instrumentation & process controls
Technical Skills
In depth understanding of control theory, including PID control, advanced control strategies (model predictive control, adaptive control), and statistical process control (SPC)
Expertise in a variety of instrumentation technologies (pressure, temperature, flow, level, etc.), distributed control systems (DCS), programmable logic controllers (PLCs), and human-machine interfaces (HMIs)
Able to configure and troubleshoot distributed control systems (Emerson RS3, Emerson DeltaV, Honeywell Experion)
Able to configure and troubleshoot safety instrumented systems (Honeywell FSC, Hima).
Proficient in PLC programming languages (e.g., ladder logic, structured text) and able to configure and troubleshoot field industrial controllers (Allen Bradley PLCs, Siemens PLCs, Local HMIs)
Able to configure and troubleshoot data acquisition and alarm management systems (e.g. OSI PI, Process View, etc.)
Proficient in using simulation tools to model and analyze complex chemical processes.
Able to collect, analyze, and interpret large datasets to identify trends, anomalies, and opportunities for improvement
Knowledgeable in industrial communications configuration protocols (e.g., Modbus, Profibus) and capability to configure and troubleshoot
Knowledge of programming languages and scripting languages for automation, data analysis, and control system development.
Understanding of industry standards (e.g. ISA and IEC) to ensure safe and sustainable operations
Able to configure and troubleshoot smart instrumentation
Able to read, generate, and modify P&IDs, loop sheets, and single line diagrams associated with instrumentation and controls connections to skid packages, distributed control systems (DCS), and safety instrumented systems (SIS)
Behavioral skills
Ability to identify and troubleshoot complex technical issues, develop innovative solutions, and make data-driven decisions
Able to effectively communicate with technical and non-technical stakeholders, including clear and concise written and verbal communication, presentation skills, and active listening
Ability to work effectively in cross-functional teams, collaborate with engineers, technicians, and operations personnel, and build strong relationships
Meticulous approach to ensure accuracy and precision in all work, including control system design, configuration, and troubleshooting
Strong commitment to safety and environmental compliance, including adherence to safety procedures and risk assessments
Commitment to lifelong learning and professional development to stay up to date with the latest technologies, industry standards, and best practices in mechanical integrity and inspections
Objective oriented self-starter able to effectively manage priorities, quality, and timelines of self and contractors/consultants
Maintains well developed outside contacts among other INEOS sites, technology providers, equipment suppliers, engineering firms, professional associations, and industry peers to share expertise and implement best practices
Capacity to adapt to changing priorities, learn new technologies, and work under pressure in a dynamic environment
Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance. On our team, people are acknowledged for embracing new practices that help create real value for customers.