Process Controls Engineer

INEOS AMERICAS LLC; Alabama; Hybrid; USD 120,000 - 180,000; Full time

Job summary

INEOS Phenol in the United States is seeking a highly experienced engineer to ensure the integrity and reliability of DCS/PLC control systems, ESD, data historian, and alarm management within a chemical processing environment. The role requires broad knowledge of process controls, safety systems, industrial communications, and control theory.

You will design, configure, maintain, and optimize automation infrastructures, lead process control optimization, and develop preventive maintenance plans.

Qualifications

• Education: BS in Engineering with at least 5 years of industrial experience, or AAS Technical Degree with at least 10 years in industrial electrical, instrumentation & process controls.
• Technical Skills: In-depth understanding of control theory (PID, advanced control, SPC); expertise with DCS/PLC/HMI technologies, and safety instrumented systems (SIS).
• Experience configuring/troubleshooting DCS (e.g., Emerson DeltaV, Honeywell Experion), SIS (e.g., Honeywell FSC, HIMA), PLCs (Allen-Bradley, Siemens), and data acquisition/alarm systems (OSI PI, Process View).
• Proficiency in PLC programming languages and ability to read/modify P&IDs, loop sheets, and single-line diagrams.
• Strong knowledge of industrial communications protocols (e.g., Modbus, Profibus) and scripting/programming for automation and data analysis.
• Familiarity with industry standards (ISA, IEC) and ability to ensure safe, compliant operations.
• Experience with cybersecurity considerations for control networks.

Responsibilities

• Independently design, simulate, implement, test, maintain, and document reliable control networks and associated software systems.
• Lead engineering efforts for process control optimization, including loop tuning, alarm configuration, interlocks, and control sequence development/modification.
• Develop and implement long-term preventive maintenance and testing plans for DCS/PLC, ESD, data historian, and alarm management systems; manage documentation and data for audits (INEOS, insurance, OSHA, etc.).
• Coordinate maintenance and inspections with I&E, ensuring minimal operation disruption and accurate AMS databases when devices are added, replaced, or modified.
• Perform annual and bi-annual safety interlock checks to ensure compliance with mechanical integrity requirements.
• Analyze process data to identify improvement opportunities; develop and implement advanced control strategies and sequences to enhance safety, stability, efficiency, and reliability.
• Provide training to plant personnel on automated systems and support cross-functional departments (production, maintenance, ES&H, lab, engineering).
• Support management of change (TEC, procedure review, TPCC) and review proposed changes for feasibility and accuracy; store, modify, and control technical data for automation systems.
• Design and execute automation projects; participate in audits and reviews to meet internal and external requirements (e.g., INEOS 20 Principles, ISO, OSHA).

Skills

Control theory

DCS/PLC/HMI

Safety Instrumented Systems

Industrial communications

Scripting/Programming for automation

Cybersecurity for control networks

Data analysis

Education

BS in Engineering with 5+ years of industrial experience or AAS Technical Degree with 10 years

Tools

OSIsoft PI

Emerson DeltaV

Honeywell Experion

SIS (HIMA/Honeywell FSC)

PLC programming (Allen-Bradley & Siemens)

SQL/Access/Databases

Modbus/Profibus

Job description

INEOS Phenol is seeking a highly experienced engineer to ensure the integrity and reliability of DCS/PLC control systems, Emergency Shutdown systems, Data Historian, and Alarm Management systems. This role requires broad knowledge of process controls, safety systems, industrial communications, and control theory, with the ability to design, configure, maintain, and optimize automation infrastructures in a chemical processing environment.

Responsibilities

• Independently design, simulate, implement, test, maintain, and document reliable control networks and associated software systems.
• Lead engineering efforts for process control optimization, including loop tuning, alarm configuration, interlocks, and control sequence development/modification.
• Develop and implement long-term preventive maintenance and testing plans for DCS/PLC, ESD, data historian, and alarm management systems; manage documentation and data for audits (INEOS, insurance, OSHA, etc.).
• Coordinate maintenance and inspections with I&E, ensuring minimal operation disruption and accurate AMS databases when devices are added, replaced, or modified.
• Perform annual and bi-annual safety interlock checks to ensure compliance with mechanical integrity requirements.
• Analyze process data to identify improvement opportunities; develop and implement advanced control strategies and sequences to enhance safety, stability, efficiency, and reliability.
• Provide training to plant personnel on automated systems and support cross-functional departments (production, maintenance, ES&H, lab, engineering).
• Support management of change (TEC, procedure review, TPCC) and review proposed changes for feasibility and accuracy; store, modify, and control technical data for automation systems.
• Design and execute automation projects; participate in audits and reviews to meet internal and external requirements (e.g., INEOS 20 Principles, ISO, OSHA).

Qualifications & Experience

• Education: BS in Engineering with at least 5 years of industrial experience, or AAS Technical Degree with at least 10 years in industrial electrical, instrumentation & process controls.
• Technical Skills:
• In-depth understanding of control theory (PID, advanced control, SPC); expertise with DCS/PLC/HMI technologies, and safety instrumented systems (SIS).
• Experience configuring/troubleshooting DCS (e.g., Emerson DeltaV, Honeywell Experion), SIS (e.g., Honeywell FSC, HIMA), PLCs (Allen-Bradley, Siemens), and data acquisition/alarm systems (OSI PI, Process View).
• Proficiency in PLC programming languages and ability to read/modify P&IDs, loop sheets, and single-line diagrams.
• Strong knowledge of industrial communications protocols (e.g., Modbus, Profibus) and scripting/programming for automation and data analysis.
• Familiarity with industry standards (ISA, IEC) and ability to ensure safe, compliant operations.
• Experience with cybersecurity considerations for control networks.

Behavioral & Soft Skills

• Strong problem-solving ability with data-driven decision making; effective communication to technical and non-technical stakeholders.
• Ability to work cross-functionally with engineers, technicians, and operations personnel; meticulous and detail-oriented with a safety-first mindset.
• Adaptability to changing priorities, commitment to lifelong learning, and capability to manage multiple projects and contractors/consultants.

Work Environment & Tools

• Hybrid environment with field and office work; field tasks involve installation/upgrade, maintenance, testing, troubleshooting in variable weather and physical conditions.
• Office tasks include process/system simulation, change implementation, data analysis, project scoping, and support for Management of Change and incident investigations.
• Proficiency with Microsoft Office, SAP, OSIsoft PI, Visio, and databases (e.g., Access, SQL).

Additional information: The role involves collaboration on the Phenol Smart Manufacturing team, support for global initiatives, and interfacing with DCS interfaces (e.g., Loading operations, SAP, Profibus, Modbus, SQL). The company emphasizes safety, diversity, inclusion, sustainability, and community involvement. For more information, visit www.ineos.com.