Process Control Engineer

INEOS Olefins & Polymers USA, LLC; Alvin (TX); On-site; USD 125,000 - 179,000; Full time

Job summary

INEOS Olefins & Polymers USA is seeking a Technical Process Control Engineer for the Chocolate Bayou Alvin site in Texas. You will lead unit process control engineers, support DCS applications, and drive projects from front-end design through startup, partnering with Instrumentation, Operations and IT teams.

Strong knowledge of Honeywell Experion DCS, alarm management and loop tuning is required, along with a Bachelor’s degree in a relevant field and 10–15 years of experience.

Qualifications

• Bachelor’s degree in chemical/electrical/instrumentation/control systems.
• 10–15 years of relevant experience in process control engineering.
• Strong knowledge of Honeywell DCS and alarm management.
• Ability to lead projects and mentor engineers.

Responsibilities

• Lead process control engineers and mentor staff.
• Provide technical leadership on DCS projects and lifecycle maintenance.
• Ensure safety and regulatory compliance across the site.
• Coordinate with operations, instrumentation and IT for project delivery.
• Develop and maintain site process control procedures and runbooks.

Skills

Client Service Oriented

Teamwork

Analytical thinking

Problem solving

Education

Bachelor’s degree in Chemical/ Electrical / Instrumentation/ Control Systems

Tools

Honeywell Experion (TDC & Experion)

Honeywell DCS (TPS, EPKS)

PSI alarm management

Networking / Virtualization

Job description

Company

INEOS Olefins & Polymers USA

Job Title

Technical Process Control Engineer

Offer Range

$125,000 - $178,500 (commensurate with experience)

Location

Chocolate Bayou Works - Alvin, TX

Organizational Context and Job Purpose

The Olefins & Polymers USA division of INEOS is one of the largest producers of olefins and polyolefins in North America. From its manufacturing locations at Chocolate Bayou and the Battleground Manufacturing Complex, it is a merchant marketer of butadiene, ethylene, polypropylene and high density polyethylene with annual revenue of over $4b. The Chocolate Bayou Site is located in southeastern Texas about 40 miles south of Houston and consists of two Olefins units that produce approximately 4bn pounds/year of ethylene, 2 Polypropylene units that produce approximately 1bn pounds/year of polypropylene, and the Light Ends storage & transfer facilities at Stratton Ridge.

How the Role Fits In

Lead Process Control Engineer role is part of the Process Control and Operational Technology team, part of the Central Applied Technology organization. Engineers in this group support daily unit operations, advanced applications, process control infrastructure systems, and projects across O&P USA. This role will lead unit process control engineers, support advanced DCS applications and perform hands-on projects for Chocolate Bayou site and pipeline supply organization (PSO).

Responsibilities and Accountabilities

• Accountability: SHE Stewardship – meet all SHE objectives and comply with all governmental laws and policies for a manufacturing site. Supporting activities: Accountable for understanding and putting into practice the INEOS 20 Principles. Ensure process hazards are systematically identified, risk assessed, reviewed and managed. Always place safe operation or shutdown of the asset ahead of production. When in doubt ensure the asset is always taken to its safest state. Ensure assets operating envelopes and protective systems are in place to deliver safe operation and maintain asset integrity. Identify and establish operating, maintenance, and CAPEX strategies to drive asset integrity and environmental compliance. Promote, ensure and sustain commitment to operating assets with no harm to people and to the environment by visibly demonstrating Safety Leadership. Ensure that a comprehensive SHE management process delivers and improves safety performance through incident reporting, behavioural awareness, compliance to policies, audits, and corrective action tracking/resolution and incident investigation. Organize, lead and support site safety committees and emergency response teams.
• Accountability: Projects – technical assurance for the timely front end engineering design for capital projects, including lead assigned projects from early FEL to completion. Responsible for interface with project management to ensure projects success in terms of functionality, budget and scope. Manage project scope and provide technical guidance to process control engineers’ / control system engineers. Work seamlessly with other pertaining groups such as instrumentation/ analyzers & operations to identify interfaces and solving any potential hurdles for project execution. Responsible for all project pertaining documentations and related MOC’s that are assigned. Interface with site leadership & operations to ensure projects installed are turned over to operations and functional as designed. Provide process control engineering quality assurance of the EPC deliverables. Ensure process control standards are followed in all assigned projects; work with technical authority and team leads to address any standard deviations. Complete all related documentation from project inception to startup. Update all drawings pertaining to PSIM (P&ID’s, loop drawings, CFD’s, drawings etc.) and expected post project plant support for all projects. Support all phases of assigned capital projects including equipment selection, installation, configuration, start-up, checkout, and supervision of personnel contracted for specialized equipment installation. Responsible for identifying reliability issues and recommending solutions for system improvements.
• Accountability: Technical Leadership – serve as a technical leader and keep to date technologies and work with Team Leaders and technical authority to create roadmaps. Provide technical guidance and mentorship to recent graduates and site process control engineers. Assign activities to recent grad process control engineers in the team and ensure successful outcomes are achieved.
• Accountability: Site Resource – act as the site SME DCS and process control resource. Source of knowledge and expertise in the application of process control technology and communication protocols. Drive optimization effort and improvement with unit process control engineers (alarm management, loop tuning etc.). Key resource for site engineers for advice on specification and guidance issues. Develop, maintain and review site process control related procedures, standards and runbooks. Knowledge of engineering tools, systems, practices commonly used in the petrochemical and pipelines industries. Utilize this background to peer assist sites and specific projects as appropriate.

Education and Experience

Education: Bachelor’s degree + 10-15 years (Chemical/ Electrical / Instrumentation/ Control Systems). Strong knowledge of Honeywell Experion Systems (TDC & Experion). Strong knowledge of alarm management and loop tuning systems (Hexagon Plant PAS State Integrity (PSI) and control wizards are preferred solutions). Key skills and competencies are:

• Client Service Oriented
• Skill in partnering with internal customers at all levels to define problems, identify solutions, and facilitate change
• Impact and influence, able to persuade others to a particular course of action
• Teamwork shares accountability for team results and utilizes interpersonal skills to improve team performance
• Analytical and conceptual thinking, able to understand both the details and the underlying systemic issues in order to plan and implement creative and effective solutions to business challenges
• Innovative and information seeking, monitors internal and industry trends to identify new opportunities.
• Organizes work effectively and uses available resources
• Anticipate problems and adjust accordingly
• Demonstrated ability to manage progress and deliver multiple and competing priorities.
• Ability to manage multiple projects, activities and tasks simultaneously
• Strong estimating skills and practical understanding of costs (capital, operating & lifecycle)
• Strong knowledge of Honeywell DCS (TPS, EPKS), architecture, networks etc.
• Strong understanding of the Control systems Architecture, data mapping (data flows) between DCS and the MES
• Strong understanding of Networking, Virtualization infrastructure, LCN infrastructure, fiber optic networks.
• Experience in migrating from LCN to ELCN is preferred.
• Knowledge of PLC’s (AB / Triconex/ HIMA) and their operations is desirable.
• Ability to perform communication between the DCS and the 3rd party systems is required.

Company Culture

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. INEOS is a world class chemical company whose products touch every aspect of modern day life. Our company is comprised of 36 businesses with 194 sites in 29 countries throughout the world. We also have interests in consumer brands and sports on a global level. Safety is our number one core value. We also take pride in our culture of diversity, inclusion, sustainability and giving to the communities in which we live. To learn more about our company and the story of our heritage, go to www.ineos.com.