Controls and Automation Engineer

Job Purpose

The Controls and Automation Engineer is responsible for all developing functional specifications for capital projects, implementing PLC programs, integration, and commissioning at the manufacturing site in Newark NJ.

Responsible for setting standards for equipment, software, and instrumentation for the Newark site, training and supporting the onsite instrumentation technicians.

Essential Duties and Responsibilities (to include but not limited to)

Reporting to the Project Engineering Manager. Working cross functionally with operations, maintenance, and IT the Controls and Automation Engineering will be responsible for the design, development, and operational success of the automation portfolio In Newark.

Will work with key system integrators on the deployment of automation solutions, including Emerson PLC’s, GE Cimplicity, Ignition Vision and Perspective SCADA systems.

Will assist the engineering team to create and present automated solutions. Challenge is to integrate and maintain world class automated solutions while managing the integrator relationships and meeting the business needs, both efficiently and on budget.

Safety & Environmental Performance

• Lead the safety effort by personal example.
• Support Richmond compliance with safety rules to further our goal of 0 accidents.
• Support 0 contractor accidents during major construction or anytime contractors are on site.
• Identify high-risk safety/ productivity issues and help remedy them.
• Adhere to SOPs and other work procedures as required to assure safe efficient and operable facility.

Work Requirements

• Develop functional specifications, control narratives, cause-effect charts leading to programming PLC logic for capital projects.
• Development of the documentation for the existing control systems on site. Documentation includes schematics and panel layouts created in AutoCad Electrical, Bills of Materials, PLC code flow charts, Cause and Effect tables, tag lists, control narratives.
• Upgrade of the existing PLC panels with the more modern PLC’s, wiring components and remote IO’s,
• PLC Code update with the use of OPC-UA communication protocols, User-Defined Tags (UDT’s), Function Blocks, State Machine programming technique. Updating the existing documentation according to the required changes.
• Development of HMI screens in Ignition Vision and Perspective platforms,
• Creating Ignition SFC for the high-level controls and process synchronization between PLC’s and control nodes,
• SCADA Users management,
• Troubleshooting of the equipment malfunctioning and providing the recommendations on short- and long-term fixes.
• Develop and maintain start-up procedures, Site acceptance tests and commissioning, qualification and verification documentation for automation projects.
• Supervise and support the Installation, calibration and programming of temperature, level, pressure, and flow instruments for capital projects.
• Work with IT team to protect our control systems form external influence.
• Create and manage revision control for all the companies control systems and associated programs.
• Design control panels: design and implement controls upgrades.
• Install and troubleshoot motor controls, VFDs, and Soft-Starts.
• Audit, update and maintain all documentation for the automation systems within the facilities creating panel P&IDs and ladder logic diagrams, etc.
• Map all control systems and clearly document current state and future strategies.
• Execute work in a safe and expedient manner according to the following priorities:
• Execution of engineering and maintenance capital projects and manage automation integrators,
• Emergency corrective maintenance either on site or remotely to support on site Instrument technicians
• Audit preventive/ predictive maintenance
• Provide practical solutions to operations/ controls / IT problems.
• Assist IT integrate with OT infrastructure.
• Scope, estimate and execute all automation capital projects along / project managers/ operations, etc.
• Train other employees considering their needs and company needs.
• Oversee the work by contractors as required on site to assure safe and quality performance.
• Look for opportunities to help work get done safer, faster and more cost effective.
• Participate in company activities such as Safety Committee, Audit committees, employee task forces, etc.
• Specifying new technologies and run trials to prove effectiveness.
• Assist in the planning and direction of strategic improvements to keep plant process controls up to date using current best practice and latest technologies.
• Develop and maintain the site calibration system for all sites to meet all current standards.

Cost Control

• Contribute to the effort in controlling costs and minimizing wastage in pursuit of your work.
• Support goal of minimum part sparing consistent with US Operations goals and local vendor support services.
• Work to support cost reduction and improved efficiencies in all departments.

Qualifications

• Engineering degree in Automation or Electrical Engineering and equivalent experience accepted.
• Such experience would be equal to at least 10 years in a similar role, Automation project management, equipment specification and cost control experience.
• 3 years min. experience in the development and commissioning of control systems based on PLC’s, HMI’s and SCADA.
• Proficient in MS office suite, AutoCAD Electrical,
• Knowledge of Python scripting, MS SQL Server, Ignition Vision and Perspective, GE Cimplicity, Emerson PLC’s are a plus.

Working Conditions

The job is performed in an office and manufacturing environment. Exposure to loud noises, dust, dirt, heat, sparks, oil, and smoke may occur. Protective safety equipment is required including appropriate clothing, shoes, gloves, hardhat, and goggles as needed. Activities include extended periods of standing and extensive work with various devices and heavy machinery.

Travel will be expected occasionally dependent on the location of the project being executed.

Physical Requirements

Ability to communicate (verbal and written) with management and other co-workers is important. Regular use of a variety of measuring tools, the telephone and e-mail for communication is essential. Standing or sitting for extended periods is common. Hearing and vision within normal ranges is important for conversations, to receive ordinary information. Heavy lifting is required intermittently. Exertion of up to 50 lbs. of force occasionally is required. Good manual dexterity for the use of common office equipment.

Ability to work at heights when needed.

Direct Reports

Contractors