Process Controls Engineer
Dixie Chemical

This position is the technical and project lead for the management and support of Dixie's DCS (distributive control system). This individual will be responsible for developing, installing and/or maintaining equipment which is used to monitor and control systems, machinery and processes throughout the plant. This involves oversight of the design and layout of the system, control strategies, operator graphics, historian (SCADA) and alarm management. The role works closely with Operations, Engineering, and Maintenance.
Summary of Essential Job Functions

• Design and manage all levels of Controls: DCS, PLCs, and associated small scale programmers (Yokogawa, Emerson, pH controllers, VFD's, MCC starters, etc.)
• Perform DCS programming, graphics implementation and updates, alarms and interlocks to existing DCS.
• Troubleshooting and performing root cause analysis on DCS, PLC controls and instrumentation.
• Support 24/7 plant operation including unplanned outages and troubleshooting
• Manage the design and layout of the DCS, infrastructure, and network communications. This includes serial, Modbus/TCP, Modbus/RTU, FOE, POE, Ethernet, and HART.
• Manage and maintain the Historian/SCADA systems
• Understand, maintain, and troubleshoot redundant DCS components and servers on a virtual environment.
• Create and manage technical and operational documentation related to DCS and instrumentation & controls.
• Assist the Engineering and Operations Manager in determining specifications and design requirements for replacing legacy control systems
• Support I&E and Operations teams in performing PMs, design optimization, and troubleshooting critical process instrumentation.
• Collaborate with multiple departments including engineering, operations, maintenance and procurement to execute capital and maintenance projects.
• Alarm management and rationalization.
• Evaluate and recommend reliability improvements.
• Identify and recommend spare part strategy / assess system risks.
• Write and develop preventative maintenance procedures.
• Analyze data and present findings in written/electronic reports.
• Adhere to PSM principles related to MOC and software change requests and documentation.
• EHS responsibilities include conducting inspections and audits related to the EHS program as assigned, participating in Hazard Reviews as needed, recommending safety improvements, completion of safety action items as assigned, completing required regulatory training, and compliance with all applicable regulations.
• All other duties and responsibilities as assigned.

Qualifications

Minimum Requirements

• Bachelor's degree in Engineering or comparable Controls Background
• 5-10 years of batch operation chemical plant experience is preferred
• 5-10 years of experience in a controls engineering role (or equivalent function) with significant hands on design, layout, and configuration of a DCS or PLC system
• Preferred experience with Allen Bradley PLC, Wonderware ArchestrA, Wonderware Historian, and Paragon
• Strong communication and interpersonal skills
• Demonstrated ability to organize, schedule, and manage multiple priorities and initiatives

Recommended Experience

• Design and commissioning expertise with Power Distribution and Control Systems up to 480VAC.
• Experience with batch sequencing and recipe management within a chemical processing plant DCS.
• Extensive knowledge of closed loop controls and tuning methodology.
• Ability to prioritize supporting multiple projects managed by the Engineering Team.
• AutoCAD or similar software experience preferred

Physical Demands & Environment
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Individuals may need to sit or stand as needed. This job may require the following: walking primarily on a level surface periodically throughout the day; climb ladders within operating units on occasion; reaching above shoulder heights and below the waist to lift as required to file documents or store materials throughout the workday and lift up to 25 pounds on occasion. Proper lifting techniques are required.

Primary environment: ambient room temperatures, lighting, and traditional office equipment as found in a typical office environment, approximately 50% of the time. The other 50% will require exposure to the manufacturing areas where certain areas require the use of personal protective equipment such as fire-retardant clothing, hard hats, steel-toed boots, safety glasses with side shields, and mandatory hearing protection.
Disclaimer
The above statements are intended to describe the general nature and level of work being performed by people assigned to this classification. They are not to be construed as an exhaustive list of all responsibilities, duties, and skills required of personnel so classified. All personnel may be required to perform duties outside of their normal responsibilities from time to time, as needed.

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