Job Title: Process Control Engineer

Reports To Production Manager

Supervisory Responsibilities None

The Process Control Engineer provides day-to-day technical support for mill DCS/QCS (ABB) and PLC’s, including motor controls, drives, instrumentation, HMI development, and other associated interfaces. The Controls Engineer will provide process control engineering support for ongoing and new operations, control system configuration and monitoring, and functional implementation and start-up of controls strategies in a world-class Linerboard facility. He or she can be expected to work on and solve complex process control problems where analysis of situations or process data requires an in-depth evaluation of various factors. This position will support, and lead process control-oriented capital projects. This position will work collaboratively with New-Indy’s Enterprise IT/OT Teams, interfacing on a daily-basis with the mill-specific IT/OT representant, to support OT network standardization, governance and controls required to enhance NICB’s overall cybersecurity & resilience posture, and to support the execution of enterprise-wide OT strategies, policies and procedures to align OT solutions such as ABB DCS/QCS systems with overall focus on the optimization of overall equipment effectiveness (OEE – availability, performance and quality). The ideal candidate will have hands-on experience in industrial automation (ICS), with a strong background in DCS/QCS and PLC systems, a solid understanding of industrial communication protocols, and a proven ability to troubleshoot complex control system issues efficiently and independently, preferably with experience in the Pulp and Paper Industry – mainly containerboard.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Ensure all aspects of process controller (DCS/QCS, PLC,…) system management, including system reliability, compliance with mill and enterprise IT/OT standards including policies, controls, SOPs, system back-up’s, documentation, and change management protocols are followed and achieved.
• Develop and implement automation control enhancements, interfacing with Production Manager, Shift Coordinators and Operators, to improve the mill process control towards increased production, improved quality, improved reliability, and reduced costs.
• Providing process controls and supports ongoing and new operations; Serve as system technical support for maintenance and operations personnel in control-related problems.
• Develop operator interfaces to promote efficient operation, effective alarm management, and improved process monitoring.
• Interface with electrical, PLC, and Machine Drive specialists for holistic approach to process control.
• Support the development of E&I technicians and/or engineers.
• Assist areas with daily troubleshooting, gathering data and analysis of available process information including controls hardware for mill control systems
• Create controls system documentation that could include control schematics, operational narratives, loop sheets, requirements for software backups, and troubleshooting SOPs – Standard Operating Procedures.
• Support development of Capital Appropriation Requests as required for process control projects, working in collaboration with Enterprise OT Solutions Team.
• In alignment with Enterprise OT Solutions Team, specify DCS/QCS and other process control equipment to be used in production areas that meet all governing applicable industry and regulatory standards and protocols.
• Support training and usage of data historian management system (Pi)
• Provide technical support for process design functions by preparing standards, equipment specifications and verification of compliance with codes, standards, sound design principles, etc.
• Serve as DCS/QCS & controls engineering mill-representative on capital projects implemented throughout the plant including testing and startup assistance
• Participate as needed in Process Hazard Analysis
• Other duties as assigned.

PHYSICAL DEMANDS

• Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
• While performing the duties of this job, the employee is regularly required to:
  • Stand, walk, sit and use hands to handle or feel.
  • Sit at a desk for long periods of time, or sit while driving a car
  • Frequently use hands to type on a computer keyboard, answer the telephone and file documents
  • Frequently walk within the office and occasionally the distance of a large manufacturing facility
  • Occasionally reach with hands and arms above the shoulders
  • Vision abilities required are close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus
  • Frequently to talk or hear.
  • Occasionally to reach with hands and arms, use hands to handle or feel
  • Regularly lift and/or move up to 10 pounds and occasionally lift and/or move up to 50 pounds.

WORK ENVIRONMENT

• The noise level within the office is usually quiet and the temperature is regulated to be comfortable.
• The noise level in the work environment can be loud at times. Usually loud (80+dB).
• Regular exposure to loud, moving mechanical parts and equipment.
• May be exposed to wet, hot and/or humid conditions.
• Occasionally exposed to high, precarious places, fumes or airborne particles; vibrations.

CERTIFICATES, LICENSES, REGISTRATIONS

• No license requirement.

[ Employees are required to wear Personal Protective Equipment [PPE] such as: hard hat, steel toed boots, gloves, safety glasses and hearing protection].

• B.S. in Electrical or Chemical engineering or technical discipline
• Five (5) or more years’ experience in a related position with two (2) years in a process industry.
• Must be familiar with DCS/QCS standards and protocols
• Proven experience with ABB 800xA; Experience with Honeywell Experion or Emerson DeltaV would be valuable addition.
• Proven experience with Allen Bradley/Rockwell, GE, or Siemens family of PLCs preferred.
• Experience with all phases of automation project implementation.
• Technical knowledge of various communication methods such as OPC, Modbus TCP, Ethernet IP and Serial.
• Functional experience with all components of an instrument-based control loop.
• Excellent written and oral communication skills, including an ability to work collaboratively across multiple functions.
• Excellent analytical, problem-solving skills and ability to think outside the box.
• Demonstrated ability to balance priorities that meet short and long-term objectives; uses organized and efficient work methods.
• Demonstrated ability to learn and continue to develop knowledge and skills.

Pay Transparency: The starting annual salary for this position ranges from $115,000 to $125,000 annual. New-Indy provides a variety of benefits to employees, including medical, dental and vision insurance coverage, life and disability insurance, retirement savings plan, paid holidays, and paid time off (PTO). Please note that the compensation information is a good faith estimate for this position and assumes a rate based on location and experience.