Advance Process Control (APC) Engineer

Linde; Shah Alam; On-site; MYR 70,000 - 95,000; Full time

Job summary

A leading engineering firm located in Shah Alam, Malaysia, is seeking an experienced APC Engineer. The role involves designing, developing, and implementing advanced control strategies to optimize plant performance and improve product quality. Candidates should have a background in Chemical Engineering and at least 3 years of experience in APC modeling. This position offers the opportunity to work closely with operations and process engineering teams in a dynamic environment.

Qualifications

• 3+ years experience in APC modelling and controller design.
• Strong knowledge of DCS/PLC systems like Honeywell and Emerson.
• Familiarity with data analytics tools such as MATLAB and Python.

Responsibilities

• Develop and implement Model Predictive Control (MPC) for process optimization.
• Monitor APC controller performance and troubleshoot issues as needed.
• Collaborate with operators to ensure smooth operation of APC.

Skills

Process control fundamentals (PID, feedforward, cascade control)

Model Predictive Control (MPC)

Data analytics and statistical methods

Python for data analysis

Education

Bachelor’s or Master’s in Chemical Engineering

Process Control Engineering

Electrical Engineering (with APC experience)

Tools

Aspen Tech DMC+ / DMC3

Honeywell Profit Controller / RMPCT

MATLAB

Python

Job description

Purpose of the Position

The APC Engineer is responsible for designing, developing, implementing and maintaining advanced control strategies (both from LMPC and MPC) to optimize plant performance, improve product quality, reduce variability and increase production resulting in efficient operating cost in ROC RSE/KL. This role works closely with operations process engineering and automation team to ensure stable, reliable, efficient and optimized operations of manufacturing unit.

Principal Responsibilities

A. APC System Development

• Develop and implement Model Predictive Control (MPC), inferential models, and multivariable control schemes.
• Build dynamic process models for advanced control applications.
• Configure and tune APC applications using platforms such as Aspen DMC+/DMC3, Honeywell RMPCT, Yokogawa APC, or Emerson DeltaV Predict.

B. Process Optimization

• Improve plant KPIs including throughput, energy consumption, yield, stability, and product quality.
• Identify performance bottlenecks using historical data and online trends.
• Optimize process safety margins while maintaining operational constraints.

C. Monitoring & Maintenance

• Monitor APC controller performance daily/weekly.
• Troubleshoot performance issues and revise controller models or constraints.
• Manage APC application lifecycle updates and migrations.

D. Collaboration & Technical Support

• Work with operators to ensure smooth APC operation.
• Provide training and troubleshooting guidance for control room staff.
• Collaborate with process engineers to integrate APC strategies with process changes.

E. Data Analytics & Digitalization

• Use tools such as PI System, SQL, MATLAB, Python, Power BI for analytics.
• Develop soft sensors/inferential models for unmeasured quality parameters.
• Support digitalization initiatives such as predictive maintenance models or advanced optimization platforms.

F. Key KPIs for APC Engineer

• APC uptime (%)
• Energy reduction achieved (GJ/ton or kWh/ton)
• Throughput increase (%)
• Reduction in quality variability
• Economic benefit generated (annual savings)
• Number of APC loops/controllers online

Required Critical Behaviors

• Technical competence
• ASU Process & Performance experience (min 3 years)
• Familiar in coding and hands on experience (min 1 year)
• Understanding in process control and sequence
• Good team player

Required Key Skills (functional/technical)

Strong knowledge of:

• Process control fundamentals (PID, feedforward, cascade control)
• Model Predictive Control (MPC)
• Process modeling, system identification
• DCS/PLC systems (Honeywell, Emerson, Yokogawa, ABB, Schneider)
• Chemical engineering thermodynamics & mass balance
• Data analytics and statistical methods
• Software experience (depends on company):
• Aspen Tech DMC+ / DMC3
• Honeywell Profit Controller / RMPCT
• MATLAB, Simulink
• Python for data analysis

Required Qualifications/Experience

• Bachelor’s or Master’s in:
• Chemical Engineering (preferred)
• Process Control Engineering
• Instrumentation & Control
• Electrical Engineering (with APC experience)
• 3+ years (Engineer role) or 7+ years (Senior role) in:
• APC modelling and controller design
• Refinery, petrochemical, polymer, or chemical plant operations
• DCS configuration and troubleshooting
• Optimization projects

Typical Industries Experience

• Oil & Gas (upstream & downstream)
• Petrochemical
• Polymer manufacturing
• Specialty chemicals
• Pharmaceuticals
• Fertilizers
• Food & beverage continuous processes