Process Control Engineer

WestRock Company; Hopewell (VA); On-site; USD 110,000 - 150,000; Full time

Job summary

Smurfit WestRock in Hopewell, VA is seeking a Process Control Engineer to provide expertise in implementing new process control technology and equipment for paper production.

You will design and program changes to DCS/PLC/HMI, lead control system projects, and collaborate with maintenance and operations to ensure safe, efficient, and compliant operations.

A strong background in ABB, Honeywell, Rockwell and OSIsoft Pi is preferred.

Qualifications

• Five years of industrial experience in DCS, PLC, and HMI applications.
• Strong knowledge of field instrumentation and motor controls.
• Process control experience in paper industry preferred.
• Strong troubleshooting and root-cause analysis skills.
• Experience with ABB 800XA, Honeywell Experion, Rockwell PLC, GE Mark VI.
• Experience with Ethernet networks and VLAN configurations.
• Ability to read P&ID loops and electrical drawings.
• Excellent written and verbal communication; team player.
• Ability to drive large-scale control projects from concept to commissioning.

Responsibilities

• Design, implementation, and support for existing and new Process Control systems including DCS, PLCs, and custom controls.
• Assist project engineers/managers in capital project planning and execution.
• Plan short/long-term system upgrades and migrations.
• Coordinate control logic development with operations and suppliers; factory checkout prior to delivery.
• Assist with control system operator training.
• Emphasize process improvement and cost-saving initiatives.
• Develop control logic with safety, environmental, and maintenance requirements in mind.
• Collaborate with Maintenance and Operations to resolve issues.
• Lead troubleshooting of systems and mentor EI technicians.
• Manage consultants, contractors, and vendors on controls projects.
• Provide weekend/off-hour support for process control and IT needs.
• Adhere to safety rules and support safety programs.
• Maintain OSIsoft Pi historian and interfaces.
• Evaluate and maintain system hardware.
• Perform other duties as assigned.

Skills

DCS

PLC

HMI

ABB 800XA

Honeywell Experion

Rockwell PLC

GE Mark VI

Ethernet networks

Control loop tuning

P&ID reading

Electrical drawings

Project leadership

Safety focused

Troubleshooting

Team collaboration

Education

B.S. Degree in Chemical or Electrical Engineering

Pulp & Paper Engineering (plus)

Tools

OSIsoft PI

Windows OS

Job description

SUMMARY

The Process Control Engineer position: provides technological and engineering expertise for the implementation of new process control technology and equipment; evaluates and resolves problems with existing process control systems utilizing vendor and/or mill maintenance support when necessary; designs and programs changes to the existing process control systems as needed. This position ensures the control systems are properly deployed to provide the greatest return on investment regarding production, costs, quality as well as safe and environmentally sound operations. The Process Control Engineer reports to the Technical Support Manager.

HOW YOU WILL IMPACT SMURFIT WESTROCK

• Responsible for providing design, implementation, and support for existing and new Process Control systems. This includes Distributed Control Systems (DCS), Programmable Logic Controllers (PLC’s), as well as custom control applications used to meet manufacturing needs and production goals.
• Assists project engineers and managers in the planning, development, and implementation of capital projects.
• Engages in development of short and long-term planning of system upgrades and migrations.
• During project design, assists with coordinating the development of control logic and system configuration between the Operating Department and control system suppliers. Participate in factory checkout of equipment prior to delivery to confirm design and functionality.
• Assists with control system operator training.
• Maintains a strong emphasis on process improvement projects -- customer focused innovations, cost saving improvements, process optimization, etc.
• Utilizes a proactive approach and project skills to develop solutions to short and long- term issues.
• Designs and implements control system logic based on process knowledge, applicable safety and environmental requirements, operational need, and maintenance requirements that provide clearly defined benefits.
• Works closely with Maintenance and Operations to identify and resolve issues.
• Leads troubleshooting efforts of systems and processes. Helps promote technical skills in EI technicians.
• Manage and direct consultants, contractors, and vendors during controls related projects.
• As part of the Process Control team, shares in the responsibility of providing weekend and off-hour availability to support Process Control and IT mill needs as well as startup support from planned and unplanned shutdowns.
• Adheres to all mill safety rules, participates in, or may lead safety programs and meetings with the goal of improving safety at the mill. Supports the mill behavior-based safety program.
• Maintains mill-wide data historian (OSIsoft Pi) and related interfaces.
• Evaluates, troubleshoots, and maintains system hardware.
• Perform other duties as assigned.

WHAT YOU NEED TO SUCCEED

Required Experience

• A minimum of five years of industrial experience in DCS, PLC and HMI applications
• Strong knowledge of field instrumentation, control devices, and motor controls required.
• Process control experience within paper industry experience preferred.
• Strong troubleshooting skillset for evaluating root cause and addressing technical issues with long term solutions in mind.
• Experience with ABB 800XA, Honeywell Experion, Voith QCS, Rockwell PLC Systems, GE Mark VI, GE drive Systems.
• Experience with Ethernet networks including configuration of switches, routers and VLANs.
• Experience with control loop tuning and performance evaluation tools.
• Strong written and verbal communication skills.
• Results oriented individual capable of handling projects individually, yet able to work efficiently in a team-oriented environment.
• Ability to drive large scale control system projects from concept to commissioning.
• Ability to read and understand P&ID’s loop sheets, and electrical drawings.
• Additional skills needed: self-directed, flexible, self-learner, multitasking, results driven, safety focused.

Plus (Not Required)

• B.S. Degree in Chemical, Electrical, Pulp & Paper Engineering or other engineering degree with adequate DCS, PLC and HMI application experience.
• Experience in a 24/7 manufacturing environment
• Experience with Anti-Virus products such as McAfee and Symantec
• Experience with VDI (Virtual Desktop Infrastructure) environments utilizing Thin/Zero clients
• Expertise with all Windows operating systems (Server and Workstation)
• Knowledge of Microsoft Office365 application suite (Word, Excel, Outlook, PowerPoint, Access, Teams, SharePoint, OneDrive, etc.)
• Ability to support other devices such as Vehicle Mounted Units (VMUs), Uninterruptible Power Supplies (UPS), and Cameras
• Understanding of Industrial Communication Protocols such as Modbus TCP, Ethernet/IP, OPC, Wireless HART, etc.
• Experience with Ethernet networks including configuration of switches, routers and VLANs.

Keywords

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