Advanced Process Control Engineer - Irving TX

JOB SUMMARY

The Advanced Process Control (APC) Engineer role is based out of the Irving, Texas office. Their primary responsibility is for the design, implementation, and maintenance of advanced process control strategies (MPC) and AI-driven models to optimize manufacturing performance, yield, and energy efficiency for a fleet of Air Separation Units (ASU). Additionally, this role maintains responsibility for PLC programming, HMI development, and troubleshooting to ensure reliable, high-level automation functionality.

·         Lead the design, develop, implement, and maintain Model Predictive Control (MPC) and AI-based empirical models to optimize process variables and reduce variability.

·         Apply AI and machine learning techniques (e.g., reinforcement learning, neural networks) to process data for predictive analytics, digital twins, and autonomous control adjustments.

·         Lead commissioning work with operations and instrumentation engineers to commission and tune AI/APC applications on-site, ensuring seamless integration with the existing DCS.

·         Continuously analyze system data to identify bottlenecks, meet production targets, reduce energy consumption, and increase throughput, yield, and profitability.

·         PLC Coding: Develop and troubleshoot PLC programs (Ladder Logic, Structured Text) on ControlLogix or Siemens platforms to support new or existing machinery.

·         HMI/SCADA: Configure and maintain HMI screens (FactoryTalk View, Wonderware) to ensure effective operator interfaces.

·         System Integration: Integrate APC/AI software layers with underlying PLCs to ensure seamless communication (Ethernet/IP, OPC UA).

·         Maintenance & Troubleshooting: Perform on-site troubleshooting of PLC faults, field instruments, and motor drives.

·         Data: Global Historian, standardize trending, KPI development & data visualization with Power BI

·         Documentation: Maintain up-to-date control narratives, P&IDs, electrical schematics, and functional specifications.

·         Provide technical training and documentation to ensure high APC uptime and proper response to system constraints.

·         Utilize process simulation tools (e.g., Aspen HYSYS) to validate control models against actual plant data

·         Identify opportunities to modernize legacy control systems and integrate "smart" automation features into our standard operating procedures.

·         Follow all aspects of change management (P&IDs, EMOC, etc.)