Senior Controls System Engineer

AM Global; Thornaby-on-Tees; On-site; GBP 55,000 - 75,000; Full time

Job summary

AM Global in the United Kingdom seeks an experienced Control Systems Engineer to design, develop, and maintain PCS7 and S7 PLC-based control systems within our EC&I team.

You will troubleshoot issues to minimize downtime, collaborate across functions to optimize processes, and lead commissioning activities with start-up support.

The role emphasizes compliance with COMAH and IEC standards, with opportunities to coach technicians and engineers.

Qualifications

• Degree, HNC/HND, apprenticeship, or equivalent qualification and/or relevant industry experience in Electrical Engineering, Control Systems Engineering, Instrumentation, or a related discipline.
• Extensive experience with Siemens PCS7 and S7 PLCs.
• Strong knowledge of COMAH regulations and safety standards.
• Excellent communication and teamwork skills.

Responsibilities

• Design, develop, and maintain control systems using Siemens PCS7 and S7 PLCs.
• Troubleshoot and resolve control system issues to minimize downtime and ensure continuous production.
• Collaborate with cross-functional teams to optimize process control and improve operational efficiency.
• Develop and implement control strategies for new and existing processes.
• Provide technical support, coaching and knowledge sharing to engineers, technicians and plant operators.
• Participate in HAZOP studies and risk assessments, including LOPA.
• Maintain accurate documentation of control systems and modifications.
• Implement and manage OT cybersecurity measures to protect control systems per IEC 62443.
• Develop and maintain safety programming on PCS7 per IEC 61511.
• Manage alarm systems per IEC 62682 for effective operator response.
• Lead commissioning activities, system testing, validation, and start-up support.
• Carry out other duties as directed by EC&I Engineering Leader

Skills

Siemens PCS7

S7 PLCs

Troubleshooting

Communication

Teamwork

Problem solving

Independent working

Education

Degree or equivalent in Electrical Engineering / Control Systems

Job description

Purpose

As a key member of the EC&I Team, ensuring new and repeat batch processes are brought online on time and within budget. Provide technical support to the maintenance technicians. Support the Manufacturing facilities in production. Contribute and deliver capital projects. Ensure regulatory compliance.

Main Tasks and Responsibilities

Key Accountabilities

Design, develop, and maintain control systems using Siemens PCS7 and S7 PLCs.

Troubleshoot and resolve control system issues to minimize downtime and ensure continuous production.

Collaborate with cross-functional teams to optimize process control and improve operational efficiency.

Develop and implement control strategies for new and existing processes.

Provide technical support, coaching and knowledge sharing to engineers, technicians and plant operators.

Reason: This better reflects collaborative working and development across the workforce rather than focusing solely on hierarchical job levels.

Participate in HAZOP (Hazard and Operability) studies and risk assessments, including Layers of Protection Analysis (LOPA).

Maintain accurate documentation of control systems and modifications.

Implement and manage OT cybersecurity measures to protect control systems from cyber threats, ensuring compliance with IEC 62443 standards.

Develop and maintain safety programming on PCS7, ensuring compliance with IEC 61511 standards.

Manage alarm systems in accordance with IEC 62682 standards to ensure effective alarm management and operator response.

Write and contribute to the development of process control narratives, User Requirement Specifications (URS), and Functional Design Specifications (FDS) documents

Lead and participate in commissioning activities, including system testing, validation, and start-up support

SHEQ Management

Ensure compliance with COMAH regulations and other relevant safety standards.

Team Building & Incentive

Assist in the generation, data collection and monitoring of key performance indicators (KPIs).

Organize and deliver SHE related training modules for staff.

Communication

Verbal and written communication within Engineering Team.

Participate in interdepartmental communications.

Confidentiality

Follow company policies and procedures to keep confidentiality on sensitive information.

Others

Carry out other duties as directed by EC&I Engineering Leader

Key Interactions

Direction From

EC&I Engineering Leader

Head of Engineering and Maintenance

Peers

Control Systems Engineer

Instrument Engineer

Senior Instrument Engineer

Electrical Engineer

Skills & Qualifications

Education

Essential

Degree, HNC/HND, apprenticeship, or equivalent qualification and/or relevant industry experience in Electrical Engineering, Control Systems Engineering, Instrumentation, or a related discipline.

Key Skills - Essential

1. Extensive experience with Siemens PCS7 and S7 PLCs.
2. Strong knowledge of COMAH regulations and safety standards.
3. Proven ability to troubleshoot and resolve complex control system issues.
4. Excellent communication and teamwork skills.
5. Strong analytical and problem-solving abilities.
6. Ability to work independently and manage multiple projects simultaneously.