Controls Engineer

Insight Global; Michigan; On-site; USD 120,000 - 160,000; Full time

Job summary

Insight Global is seeking a Senior Controls Engineer to support the deployment, commissioning, startup, and turnover of a distributed control system on a major power generation project. You will coordinate with engineering, construction, commissioning, operations, and vendors to ensure the control system is installed, tested, and brought online safely.

The role requires hands-on DCS troubleshooting, loop and graphics validation, and strong communication across multi-disciplinary teams.

Qualifications

• 8+ years of experience in controls engineering or related field.
• Experience with DCS platforms and industrial automation.
• Experience supporting commissioning and startup in industrial environments.
• Strong communication and coordination skills.

Responsibilities

• Support DCS installation, hardware checkout, cabinet inspections, network verification, and system startup activities.
• Coordinate with vendors, contractors, engineering teams, and operations personnel throughout commissioning and startup.
• Perform control logic checkout, graphics verification, alarm validation, historian checks, and field device integration.
• Execute loop checks, functional testing, interlock testing, permissive testing, sequence testing, and control tuning.
• Troubleshoot DCS hardware, software, communications, instrumentation interfaces, I/O, and industrial networks.
• Review control narratives, logic diagrams, I/O lists, drawings, and commissioning documentation.
• Support FAT, SAT, commissioning procedures, deficiency tracking, and punch list resolution.
• Provide field engineering support during energization, startup, synchronization, performance testing, and turnover activities.
• Maintain startup documentation, test records, issue logs, and turnover packages.
• Manage controls-related change management processes throughout commissioning.

Skills

DCS experience

Industrial automation

Power generation

Troubleshooting

Strong communication

Tools

Emerson Ovation

DeltaV

Honeywell Experion

ABB 800xA

Job description

Senior Controls Engineer (DCS Commissioning & Startup)

We're looking for an experienced Controls Engineer to support the deployment, commissioning, startup, and turnover of a Distributed Control System (DCS) on a major power generation project. This individual will play a key role in coordinating with engineering, construction, commissioning, operations, and vendor teams to ensure the control system is installed, tested, and brought online safely and successfully.

What You'll Do

• Support DCS installation, hardware checkout, cabinet inspections, network verification, and system startup activities.
• Coordinate with vendors, contractors, engineering teams, and operations personnel throughout commissioning and startup.
• Perform control logic checkout, graphics verification, alarm validation, historian checks, and field device integration.
• Execute loop checks, functional testing, interlock testing, permissive testing, sequence testing, and control tuning.
• Troubleshoot DCS hardware, software, communications, instrumentation interfaces, I/O, and industrial networks.
• Review control narratives, logic diagrams, I/O lists, drawings, and commissioning documentation.
• Support FAT, SAT, commissioning procedures, deficiency tracking, and punch list resolution.
• Provide field engineering support during energization, startup, synchronization, performance testing, and turnover activities.
• Maintain startup documentation, test records, issue logs, and turnover packages.
• Manage controls-related change management processes throughout commissioning.

Required Qualifications

• 8+ years of experience in controls engineering, commissioning, startup, industrial automation, power generation, or a related field.
• Strong understanding of Distributed Control Systems (DCS).
• Experience supporting commissioning and startup activities in industrial environments.
• Hands-on troubleshooting experience with control systems, instrumentation, networks, and field devices.
• Strong communication and coordination skills.

Preferred Qualifications

• Experience with Emerson Ovation, DeltaV, Honeywell Experion, ABB 800xA, or similar DCS platforms.
• Experience with loop checks, logic validation, graphics testing, and system integration.
• Experience supporting power plants, combined cycle facilities, utilities, refineries, chemical plants, or other process industries.
• Familiarity with PLCs, SCADA, industrial networking, instrumentation, and cybersecurity requirements.
• Knowledge of ISA, IEEE, NFPA, NERC CIP, or related industry standards.
• Hybrid schedule when project demands allow.
• Significant onsite support required during commissioning and startup phases.
• Travel typically 25-50%, with higher travel during critical project milestones.