Process Automation Engineer

PGM TEK, Inc.; Aurora (IL); On-site; USD 100,000 - 150,000; Full time

Job summary

A leading company in the petrochemical industry is seeking an Engineering Authority in Automation to oversee technical support and process improvements in their Aurora facility. The role requires extensive experience in automation, control systems, and safety compliance, with a strong focus on project management and team leadership.

Qualifications

• Minimum 10 years experience in process control or automation in petrochemical industry.
• Advanced degree preferred; experience in R&D environment is a plus.
• Certifications in project management (PMP or equivalent) are beneficial.

Responsibilities

• Provide automation improvements and maintenance for control and safety systems.
• Support and lead capital projects for automation initiatives.
• Ensure compliance with safety regulations and promote a safety culture.

Skills

Automation expertise

Control theory

Data analysis

Project management

Communication

Education

BS degree in Engineering

AAS Technical Degree

Tools

DCS

PLCs

HMIs

Simulation tools

Job description

The Technology and Engineering group is located in Aurora, Illinois and has global responsibility for manufacturing site technical support, including problem solving, process improvements, and major project support. Also provide catalyst sales and licensing technical support, including delivery of the technical aspects of new licensee projects from design through start-up and technical support.

This role is an engineering authority in the Research, Development, and Technology (RD&T) team. This role is an experienced technical position in the Process Technology and Engineering (PT&E) group reporting to the Process Technology and Engineering Lead.

The incumbent provides automation expertise to the RD&T team in Aurora and implements automation improvements to advance safety, efficiency, decrease manual actions, and enhance centralized data collection and analytics. Improvements include managing and implementing capital projects and routine software, automation and controls upgrades. The incumbent is responsible for maintenance of the controls and automated safety systems testing in Aurora.

Responsibilities AND Accountabilities

SHE Stewardship

• Maintain safety as the highest priority and abide by all safety policies and procedures.
• Understand and promote the "20 Principles of Safety", ensuring that personnel are aware of safe working practices and promote the safety concepts of "Coaching for Safety" and "Stop Work".
• Promote safety and safe actions through communication such as discussing safety with employees / contractors before job tasks, during meetings, and as opportunities arise to promote safety to the fullest extent possible.
• Ensure compliance with all safety and environmental regulatory requirements and strive to meet internal SHE objectives.
• Ensure that work performed by self or others being directed is performed in accordance with site procedures. All deviations and incidents are to be reported to management.
• Ensure that the design and implementation of technical work has been thoroughly reviewed and executed correctly.
• Ensure safety system testing is performed and documented as defined in the mechanical integrity procedures.
• Develop automation scope to improve safety.

Reliability :

• Meet monthly reliability targets with a focus on continuous improvement. Ensure that automation systems (control, safety, reporting, historian, etc.) are properly maintained and upgraded to provide ongoing site pilot and lab reliability.
• Responsible for the Aurora RD&T DCS, BAS and PI maintenance, update and creation of graphics, programming of control loops, and interface with the data historian.

Engineering Authority :

• Engineering Authority of the Aurora Site. Support the site Process Safety program. Review MOC's, etc.
• Support Aurora RD&T Process Safety Program, including attend risk assessments, SIL verification studies
• Support continuous improvement initiatives. Execute and support changes that will improve the efficiency and operations of the Aurora facility. Automatic control of pilot plant equipment and online data collection. Automatic data transfer of analytical data from lab instruments to central database. Support the global Smart Manufacturing initiatives.
• Develop scope, implement and manage capital projects for automation initiatives in RD&T
• Develop plans for central online data acquisition from pilot plant equipment and lab instruments for future AI infrastructure and initiatives, then implement.

Capital Spending :

• Control projects with budget. Support the budgeting and execution of projects to minimize impacts to the timeline and total cost

Financial Performance :

• Support cost improvement initiatives. Execute and support process changes that will improve the operating costs of the Aurora facility
• Providing training to site personnel (scientists, technicians, engineers, maintenance, laboratory, etc.) as needed to ensure understanding of automation systems.

Process Safety Handbook Development :

• Support the advancement of the Process Safety Handbook

Business :

• Support the ongoing needs of the business.

Education / Experience

BS degree in Engineering field required with minimum 10 years successful petrochemical industry work experience in process control or AAS Technical Degree with minimum 10 years of experience in industrial electrical, instrumentation & process controls

Advanced degree, and experience in an industrial chemical R&D / Pilot Plan environment a plus.

Certifications in projects management a plus (PMP or equivalent)

Technical skills

• In depth understanding of control theory, including PID control, advanced control strategies (model predictive control adaptive control), and statistical process control (SPC)
• Expertise in a variety of instrumentation technologies (pressure, temperature, flow, level, etc.) distributed control systems (DCS), programmable logic controllers (PLCs), and human-machine interfaces (HMIs)
• Able to configure and troubleshoot distributed control systems (Emerson RS3, Emerson DeltaV, Honeywell Experion)
• Able to configure and troubleshoot safety instrumented systems (Honeywell FSC, Hima, Triconex, Delta V SIS)
• Proficient in PLC programming languages (e.g., ladder logic, structured text) and able to configure and troubleshoot field industrial controllers (Allen Bradley PLCs, Siemens PLCs, Local HMIs)
• Able to configure and troubleshoot data acquisition and alarm management systems (e.g. OSI PI, Process View, Vision, etc.)
• Proficient in using simulation tools to model and analyze complex chemical processes
• Able to collect, analyze, and interpret large datasets to identify trends, anomalies, and opportunities for improvement
• Knowledgeable in industrial communications configuration protocols (e.g., Modbus, Profibus) and capability to configure and troubleshoot
• Knowledge of programming languages and scripting languages for automation, data analysis, and control system development.
• Understanding of industry standards (e.g. ISA and IEC) to ensure safe and sustainable operations
• Able to understand and perform Safety Integrity Level (SIL) evaluations of Safety Instrumented Systems (SIS) (e.g. exSILentia Exida, SILcet, or equivalent)
• Able to configure and troubleshoot smart instrumentation
• Able to read, generate, and modify P&IDs, loop sheets, and single line diagrams associated with instrumentation and controls connections to skid packages, distributed control systems (DCS), and safety instrumented systems (SIS)
• Knowledgeable in automation of computer tasks and / or programming (VBA, Python, Java scripts, or equivalent).
• Knowledgeable in analytical instrumentation or online analyzer technology (e.g. GC, IR)
• Able to leverage Artificial Intelligence (AI) tools (MS Copilot or equivalent).
• Proficient in the entire lifecycle of project management from concept and scope development, detailed design, construction, and final commissioning.
• Demonstrated successful project management of capital projects of approximately $250k or higher.
• Provides Safety Leadership by Example
• Able to identify and troubleshoot complex technical issues, develop innovative solutions, and make data-driven decisions
• Able to effectively communicate with technical and non-technical stakeholders, including clear and concise written and verbal communication, presentation skills, and active listening
• Able to work effectively in cross-functional teams, collaborate with scientists, engineers, technicians, and operations personnel, and build strong relationships
• Meticulous approach to ensure accuracy and precision in all work, including control system design, configuration, and troubleshooting
• Strong commitment to safety and environmental compliance, including adherence to safety procedures and risk assessments
• Commitment to lifelong learning and professional development to stay up to date with the latest technologies, industry standards, and best practices in mechanical integrity and inspections
• Goal oriented, self-starter, able to manage priorities effectively, quality, and timelines of self and contractors / consultants
• Maintains well developed outside contacts among other sites, technology providers, equipment suppliers, engineering firms, professional associations, and industry peers to share expertise and implement best practices
• Capacity to adapt to changing priorities, learn new technologies, and work under pressure in a dynamic environment
• Capacity to embrace change and positively challenge the "status quo"

Line Management Responsibilities

• Supervise internal personnel and external contractors, and vendors as needed when implementing work, maintenance, or projects.
• See Organizational Chart

Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance. On our team, people are acknowledged for embracing new practices that help create real value for customers.