Lead Process Controls Engineer

Ellaway Blues Consulting; Kansas; On-site; USD 90,000 - 130,000; Full time

Job summary

Ellaway Blues Consulting in the United States is seeking a Process Controls Engineer to lead and optimize distributed control and safety instrumented systems across refinery-like operations. You will coordinate with Operations, Maintenance, Instrumentation, Electrical, and external partners throughout design, commissioning, and startup.

The role requires hands-on controls expertise, process safety understanding, and strong project coordination.

Qualifications

• Two+ years applying IEC 61511/ISA 84 to safety instrumented systems.
• Three+ years controls engineering with design, programming, testing, commissioning, startup.
• Experience programming Logix controllers using Studio 5000 (Allen-Bradley).
• SCADA/HMI development and historian integration (FactoryTalk View SE).
• Strong understanding of industrial process controls, instrumentation, and troubleshooting.
• Proficiency with industrial networks, OT systems, and cybersecurity basics.
• Clear written and verbal communication; able to coordinate with multiple stakeholders.

Responsibilities

• Maintain, improve, and support existing process automation and control systems.
• Troubleshoot control system performance and instrumentation issues.
• Assist with PID tuning, control strategy optimization, and data analysis.
• Interface between project teams, site personnel, integrators, vendors, and contractors.
• Support capital projects from planning through commissioning and startup.
• Coordinate DCS, SIS, HMI, and process controls across multiple projects.
• Develop control narratives, I/O assignments, and system architecture docs.

Skills

IEC 61511/ISA 84

Control system design

Studio 5000 (Logix)

SCADA/HMI (FactoryTalk View SE)

DCS/SIS knowledge

PID tuning & control strategy

Process safety analysis

Vendor/project coordination

Cybersecurity & lifecycle mgmt

Communication & teamwork

Tools

Studio 5000

FactoryTalk View SE

AVEVA PI System

PI Vision

Rockwell PlantPAx

SoMove

Easergy

Job description

Ellaway Blues Consulting in the United States is seeking a Process Controls Engineer to lead and optimize distributed control and safety instrumented systems across refinery-like operations. You will coordinate with Operations, Maintenance, Instrumentation, Electrical, and external partners throughout design, commissioning, and startup.

The role requires hands-on controls expertise, process safety understanding, and strong project coordination.