Senior Process Control Engineer

Brief Description

Provide control system support for the continuous manufacture of quality high density polyethylene (HDPE) and specialty fluids at a high rate of production and minimum cost, consistent with high standards of quality, safety, housekeeping, and good employee relations. Workflow is varied and often requires urgent resolution.

Responsibilities

Position General

• Perform complex work assignments requiring considerable technical expertise
• Contribute to continuous improvement by offering suggestions for long-term solutions to minimize costs, improve reliability, and improve loss control performance
• Position is in a chemical processing facility and requires overtime to meet plant needs, including alternative shifts as needed to meet facility needs
• Position requires periodic on-call duties and the successful candidate must be able to respond 24/7, 100% of the time to plant emergencies on short notice, including nights, weekends, and holidays while on-call
• Complete all assigned training by deadline
• Understand and follow all lock-out/tag-out (LOTO) and other health, safety, and environmental requirements necessary to achieve plant loss control objectives. This includes the use of loss control software for loss control reporting and communication to management of potentially hazardous conditions or practices.
  
  
  

Operational Responsibilities

• Designs, implements, and maintains all process automation systems on site.
• Independently troubleshoot and solve control issues
• Stay current on new technology and identify new applications to implement.
• Develop new routines and methods to implement new technology
• Develop business case for new technology
• Manage projects that affect APC/DCS applications developed by outside resources
• Develop and modify operator interfaces as needed
• Plan and execute testing as needed
• Train operations staff on new technology and new applications
• Lead the start-up, commissioning and tuning of new applications
• Gathers, selects, analyzes, and interprets data to understand the impact of changes on the Advanced Process Control (APC) system, distributive control systems (DCS) and Safety Instrumented Systems (SIS), specifically the potentials for domino effect problems, loss of view, loss of control, incorrect logic, and the interconnected nature of the system
• Assist contract DCS programmers, as needed, for larger projects
• This position is the site automation engineer for Bay 3, which utilizes Emerson DeltaV, however, Honeywell Distributive Control Systems will be introduced, eventually, as this site utilizes both systems.
  
  
  

Maintenance Responsibilities

• Maintain DCS, ESD, SIS, and PLC systems (primarily DeltaV)
• Perform hardware and software updates for automation systems while on-line
• Install, set-up, upgrade, and edit program logic control (PLC) statements without bringing system down
• Set-up new equipment and change how equipment is viewed on the DCS
• Investigate, repair, and provide preventative maintenance on plant APC, DCS, SIS, and PLC hardware and software
• Guide instrument technicians and electricians in the field to identify equipment malfunctions
• Partner with engineers to program alarms and operational limits
• Partner with capital support for new APC and DCS installations
• Interpret and follow Baystar guidelines for industrial control system security
• Build various density, pressure, temperature, flow, auto/manual, valve position trends
• Maintain documentation, instructions, and procedures
• Participate in functional acceptance testing of APC and DCS applications
• Manage vendor testing to ensure operating to Company specifications
  
  
  

CORE VALUES

Must exhibit and demonstrate our 5 Core Values

• Caring: Dedicated to Safety, Employees, Customers, Community and Environment
• Trustworthy: Living a Culture of Openness, Honesty and Collaboration
• Focused: Creating Value by Delivering the Right Solutions
• Innovative: Daring to be different by finding New Ways
• Fun: Embracing our Diverse Family and Celebrating our Success
  
  
  

COMPETENCIES

• Job Knowledge - Understands facets of job, aware of duties and responsibilities, keep job knowledge current
• Productivity - Manages workload, works efficiently, meets goals and objectives
• Quality - Strives to eliminate errors, accurate work is a priority, seeks opportunities to improve product/services
• Safety – HSSE - Works in a safe manner, uses PPE, recognizes hazards, makes safety suggestions and observations, current on Training Mine
  
  
  

Qualifications / Experience Required

• B.S. in Electrical Engineering (other engineering/technical degrees will be considered depending on experience).
• 5 or more years manufacturing experience in instrumentation or IT
• 5 or more years’ experience with Emerson DeltaV systems and/or Honeywell TDC300 and Experion.
• 2 or more years’ Advanced Process Control experience
• Computer proficient: Windows 10, Server 2016, MS Office, SAP
• Excellent verbal/written communication
• Ability to manage multiple issues/projects simultaneously
• Candidates will be required to successfully complete extensive testing and an extended training period
  
  
  

Preferred Qualifications / Experience

• Master’s Degree in Electrical, Electronics or Controls/Automation Engineering
• 8 or more years of manufacturing experience