Process Control 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

The Process Controls Engineer provides technical leadership for the facility’s distributed control systems (DCS), safety instrumented systems (SIS), and operational technology infrastructure. Working closely with Operations, Maintenance, Instrumentation and Electrical, Engineering, and external partners, this individual helps ensure that process automation systems operate safely, reliably, and consistently.

The role also supports capital projects from early planning and design through commissioning and startup. The ideal candidate combines hands-on controls expertise with strong project coordination skills and a practical understanding of process safety requirements within a refinery or similar industrial environment.

Key Responsibilities

• Maintain, improve, and support existing process automation and control systems.
• Troubleshoot control system performance, equipment configuration, production automation, and instrumentation-related issues.
• Assist Instrumentation and Electrical personnel with PID loop tuning, control strategy optimization, and operating-data analysis.
• Serve as the primary interface between project teams, site controls personnel, system integrators, vendors, panel shops, and contractors.
• Support small-, mid-, and large-scale capital projects from front-end planning through design, construction, commissioning, and startup.
• Coordinate DCS, SIS, HMI, and process controls activities across multiple concurrent projects.
• Develop process control deliverables, including control narratives, I/O assignments, system architecture documentation, and updates to P&IDs.
• Participate in Process Safety Management activities, including Management of Change, PHA, HAZOP, LOPA, What-If reviews, and alarm rationalization.
• Support HMI development and participate in Factory Acceptance Testing, Integrated Factory Acceptance Testing, and Site Acceptance Testing.
• Coordinate control panel design and fabrication with panel shops and other third-party partners.
• Develop and execute control panel checkout procedures and witnessed or unwitnessed factory acceptance tests.
• Review project specifications and collaborate with internal stakeholders to ensure control system designs satisfy functional, operational, and contractual requirements.
• Review and approve SIS documentation, including Safety Requirements Specifications, cause-and-effect matrices, test procedures, and engineering drawings.
• Complete Functional Safety Assessments for new or modified safety instrumented systems in accordance with ISA 84 and applicable site practices.
• Serve as a subject matter expert for the facility’s DCS and SIS platforms, helping establish, document, and communicate technical standards and best practices.
• Support continuous improvement initiatives related to system reliability, cybersecurity, standardization, and lifecycle management.
• Maintain current knowledge of relevant automation technologies, process safety standards, and industry practices.
• Perform other related responsibilities as operational or project needs require.

Required Qualifications

• At least two years of experience applying IEC 61511 and ISA 84 requirements to safety instrumented systems.
• Three or more years of controls engineering experience involving system design, programming, testing, commissioning, and startup.
• Three or more years of experience programming Allen-Bradley Logix controllers using Studio 5000.
• Three or more years of SCADA and HMI development experience, including FactoryTalk View SE distributed applications and historian integration.
• Strong understanding of industrial process controls, automation architecture, instrumentation, and control system troubleshooting.
• Proficiency with industrial networks, computers, and operational technology systems.
• Clear and effective written, verbal, and digital communication skills.
• Ability to collaborate effectively with Operations, Maintenance, Engineering, vendors, contractors, and project stakeholders.
• Strong organizational, prioritization, and time-management skills, with the ability to support multiple initiatives simultaneously.
• Commitment to ongoing technical development and continuous learning.

Preferred Qualifications

• Experience with industrial communication protocols and fieldbus technologies, including Modbus, Foundation Fieldbus, HART, and EtherNet/IP.
• Experience with AVEVA PI System, formerly OSIsoft PI, and PI Vision.
• Familiarity with Schneider Electric motor-control and configuration software, including SoMove and Easergy.
• Experience developing or maintaining Rockwell Automation PlantPAx applications.
• Prior experience supporting process controls in a refinery, chemical plant, renewable fuels facility, or other continuous-process industrial environment.