Senior Controls Engineer

Messer Americas; Bridgewater Township (NJ); On-site; USD 110,000 - 146,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

Short-term disability

Life insurance

Paid time off

401(k) plan

Bonus program

Job summary

Messer Americas is seeking a seasoned Controls & Automation Engineer to drive full lifecycle projects for Capital and Re-Life initiatives in the United States. You will design, implement, and optimize advanced control systems with emphasis on safety, reliability, and efficiency.

Collaborate with cross-functional teams, manage vendors, and ensure timely delivery. You will lead safety assessments, develop standards, and produce comprehensive design narratives and documentation.

Qualifications

• Bachelor's degree in engineering is required.

Responsibilities

• Lead design, development, and implementation of advanced controls and automation systems.
• Develop in-house standards, methods, and practices for long-term sustainability.
• Lead safety assessments (LOPA, HAZOP, SIL) and ensure compliance with safety standards.
• Create Control System Architecture drawings and related design documents (P&IDs, Interlock and Trip docs).
• Manage vendor relations, project schedules, and resources to deliver on time and within budget.
• Provide high-level technical support in DCS/PLC programming, HMI, and network security.
• Develop and maintain standard documentation and design guides across projects.
• Develop simulation logic and FAT/SAT procedures; coordinate multidisciplinary validation.
• Lead commissioning, loop checks, and on-site support; ensure successful handover.

Skills

DCS/PLC systems

HMI systems

Industrial networking

Programming: Python/Java/C++

SQL databases

Security & virtualization

Education

Bachelor's degree in engineering

Tools

Siemens PCS7

Yokogawa Centum VP

DeltaV

Foxboro

Honeywell

Allen-Bradley ControlLogix

WinCC

AVEVA Wonderware

Inductive Automation

Job description

Position Overview

In this role, you will be responsible for the full lifecycle of controls and automation systems for Capital and Re-Life projects. Your expertise will be crucial in ensuring that our systems are designed with the highest standards of safety, reliability, and efficiency. You will collaborate with cross-functional teams to develop and implement advanced controls strategies, manage vendor relationship, and ensure successful project execution.

Key Responsibilities

• Controls and Automation System Expertise
  • Lead the design, development, and implementation of advanced controls and automation systems, focusing on safety, reliability, efficiency, and customer satisfaction.
  • Develop in-house standards, methods, and practices that ensure long-term sustainability and adaptation to rapidly evolving technologies.
  • Leverage advancements in hardware, software, security, and control concepts to stay ahead in the field of industrial automation.
• Concept Development
  • Identify, define, estimate, budget, and plan controls and measurement system projects.
  • Responsible for future casting and developing innovative solutions that set the standard for controls and automation within the industry.
• Safety Leadership
  • Play an integral role in the safety design process, participating in LOPA, HAZOP, and SIL assessments.
  • Ensure all controls and automation systems comply with safety, health, environmental, and quality standards.
  • Foster a culture of safety within the project team and across the organization.
• Design & Documentation
  • Assist in the development of P&IDs.
  • Create detailed Control System Architecture drawings, illustrating the interconnectivity of control system components, including DCS, PLC, networks, and field devices.
  • Generate IO and alarm lists, develop Interlock and Trip documents, produce Control Narratives and Functional Design Standards.
  • Develop comprehensive scopes of work for controls and automation projects and participate in contract awards.
• Project Management
  • Maintain strong relationships with key vendors and system integrators, ensuring clear communication and alignment on project goals.
  • Oversee programming development, providing technical feedback and direction to vendors to ensure successful outcomes.
  • Manage project schedules and resources, ensuring important milestones are met and projects are delivered on time and within budget.
• Programming & Technical Support
  • Provide high-level technical assistance, troubleshooting, and design expertise in DCS/PLC programming, HMI architecture, database design, and network security.
  • Develop and maintain documentation that details our standard methodologies and design guides, ensuring consistency across projects.
  • Lead the programming efforts for control systems, ensuring that all software components are robust, secure, and optimized for performance.
• Simulation & Testing
  • Develop simulation logic, standards, and methods to streamline program development and testing.
  • Focus on modular design and flexibility to ensure that systems can be easily adapted to changing requirements.
  • Design and execute FAT and SAT procedures, coordinating with multidisciplinary teams to ensure compliance and validation.
• Execution & Commissioning
  • Lead the commissioning process, including loop checks, functional tests, and on-site support, ensuring that control systems are fully operational and meet all project specifications.
  • Provide comprehensive project handover documentation, including as-built drawings, manual, and maintenance guides.
  • Support Area Operations and Reliability teams with controls-related troubleshooting and ongoing engineering assistance.

Required Skills

• Travel: Ability to travel up to 20%-40% on an annual basis
• Technical Skills:
  • Proficiency in DCS/PLC systems, including Siemens PCS7, Yokogawa Centum VP, Delta V, Foxboro, Honeywell, and Allen‑Bradley ControlLogix.
  • Experience with HMI systems such as Siemens WinCC, AVEVA Wonderware, and Inductive Automation.
  • Strong understanding of industrial device networking, including Ethernet, Serial (RS232/485), ProfiNET, ProfiBUS, EthernetIP, ModbusTCP/RTU.
  • Knowledge of computer hardware, software, and security, including MS Windows Server, Active Directory, and virtualization technologies like VMWare.
• Safety Leadership: Demonstrated exceptional operational safety leadership.
• Controls & Measurement Systems: Proven experience in the installation, maintenance, and troubleshooting of controls and measurement systems, including Remote Operations, Plant Auto Start, Supervisory Control, LMPC Control, Historian, Expert Systems, Metering and Monitoring Systems, Automated Data Collection, Pipeline Demand Management, and Batching Systems.
• Software Proficiency: Experience with programming languages like Python, Java, VB, and C++.
• Database Management: Familiarity with SQL databased (MS SQL, MySQL, Oracle).

Basic Qualifications

• Education: Bachelor's degree in engineering
• Experience: 5-7 years of experience, with a minimum of 5 years in an operations or project engineering environment focused on controls and automation

Preferred Skills

• Instrumentation & Analyzers: General expertise in instrumentation and analyzers.
• Regulatory & Industry Standards: Proven understanding of regulatory and industry standards and codes.
• Cryogenics: Experience and knowledge in cryogenics.
• Engineering Tools: Familiarity with COMOS, Smart Plant, and AVEVA Engineering.

Salary and Benefits

The salary range for this position is $110,000 - $146,000. Messer provides medical, dental, vision, short term disability, life insurance and paid time off as well as other voluntary benefits, such as, long term disability in accordance with the terms and conditions of these Plans. Employees are eligible to enroll in Messer's 401(k) Plan. Employees may be eligible to participate in the company's bonus program.

Equal Opportunity Employer / Veterans / Individuals with Disabilities

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