Senior Process Control Engineer

Hydrogen Group; Augusta (GA); On-site; USD 110,000 - 155,000; Full time

Job summary

Hydrogen Group is seeking a Senior Process Control Engineer to provide technical leadership in process automation, control system design, commissioning, and continuous improvement within a manufacturing environment. This role serves as SME for process control systems and partners with engineering and production teams to improve reliability, efficiency, and overall process performance.

Strong PLC/DCS experience and project leadership are essential.

Qualifications

• Bachelor's degree in Engineering (Chemical, Electrical, Mechanical, or related discipline).
• 5-7+ years of experience in process controls, automation engineering, or related manufacturing environments.
• 5-7+ years of experience managing engineering projects, including planning, execution, and commissioning.
• Hands-on experience with PLC and/or DCS platforms such as Rockwell, Siemens, Emerson DeltaV, or Honeywell.
• Experience leading automation projects, including scope development, cost estimation, testing, and startup/commissioning activities.
• Strong understanding of process instrumentation, including flow, pressure, temperature, level, and analytical measurement systems.
• Experience with control loop tuning, troubleshooting, and optimization.
• Knowledge of GMP, quality systems, and regulatory compliance requirements.
• Strong communication skills with the ability to collaborate with both technical and non-technical stakeholders.
• Proven problem-solving skills with experience leading RCA investigations and implementing long-term solutions.
• Ability to work in a manufacturing environment, including equipment inspections, troubleshooting activities, climbing stairs/ladders, and wearing required PPE.
• Flexibility to support shutdowns, startups, and other critical operational activities as needed.

Responsibilities

• Serve as the site subject matter expert (SME) for process control systems, including PLC, DCS, HMI, SCADA, instrumentation, and automation platforms.
• Lead the design, configuration, testing, and commissioning of complex control systems for new and modified manufacturing processes.
• Develop and maintain control system standards, programming practices, documentation requirements, and automation architectures.
• Evaluate and recommend control hardware and software solutions to support operational and business objectives.
• Troubleshoot advanced process control issues, perform root cause analysis (RCA), and implement corrective and preventive actions (CAPA).
• Lead capital projects from initial scope development and cost justification through control design, FAT, and site commissioning.
• Develop project schedules, coordinate vendors and contractors, manage deliverables, and communicate project updates to engineering and site leadership.
• Review and approve engineering documentation, including P&IDs, control narratives, functional specifications, cause-and-effect matrices, and as-built documentation.
• Provide technical guidance and mentorship to Process Control Engineers and support team development.
• Provide senior-level automation support to production teams, including control system modifications, troubleshooting, and process optimization.
• Partner with Production and Process Development teams to improve automation, efficiency, data collection, reporting, and process reliability.
• Lead continuous improvement initiatives focused on reducing downtime, improving equipment performance, and increasing operational efficiency.
• Analyze process data and historian trends to identify control performance opportunities and recommend improvements to control strategies.

Skills

Process control systems

Automation engineering

Project management

Root cause analysis (RCA)

CAPA implementation

Communication

Problem solving

Team mentoring

Cross-functional collaboration

Education

Bachelor's degree in Engineering

Tools

Rockwell

Siemens

Emerson DeltaV

Honeywell

SCADA

OSIsoft PI

Job description

We are seeking a Senior Process Control Engineer to provide technical leadership in process automation, control system design, commissioning, and continuous improvement initiatives within a manufacturing environment. This role will serve as a subject matter expert for process control systems, support capital projects, troubleshoot complex automation issues, and partner with engineering and production teams to improve reliability, efficiency, and overall process performance.

Key Responsibilities

Technical Leadership & Process Controls Engineering

• Serve as the site subject matter expert (SME) for process control systems, including PLC, DCS, HMI, SCADA, instrumentation, and automation platforms.
• Lead the design, configuration, testing, and commissioning of complex control systems for new and modified manufacturing processes.
• Develop and maintain control system standards, programming practices, documentation requirements, and automation architectures.
• Evaluate and recommend control hardware and software solutions to support operational and business objectives.
• Troubleshoot advanced process control issues, perform root cause analysis (RCA), and implement corrective and preventive actions (CAPA).

Capital Projects & Engineering Support

• Lead capital projects from initial scope development and cost justification through control design, factory acceptance testing (FAT), and site commissioning.
• Develop project schedules, coordinate vendors and contractors, manage deliverables, and communicate project updates to engineering and site leadership.
• Review and approve engineering documentation, including P&IDs, control narratives, functional specifications, cause-and-effect matrices, and as-built documentation.
• Provide technical guidance and mentorship to Process Control Engineers and support team development.
• Provide senior-level automation support to production teams, including control system modifications, troubleshooting, and process optimization.
• Partner with Production and Process Development teams to improve automation, efficiency, data collection, reporting, and process reliability.
• Lead continuous improvement initiatives focused on reducing downtime, improving equipment performance, and increasing operational efficiency.
• Analyze process data and historian trends to identify control performance opportunities and recommend improvements to control strategies.

Training, Documentation & Compliance

• Develop and deliver training programs for operators on automated systems, control processes, and operational best practices.
• Ensure all control system activities comply with site GMP requirements, change control procedures, and applicable regulatory standards.
• Support safety, quality, and compliance initiatives through participation in investigations, corrective actions, and process improvement efforts.
• Maintain accurate engineering documentation in alignment with good documentation practices (GDP) and quality management systems.

Qualifications

• Bachelor's degree in Engineering (Chemical, Electrical, Mechanical, or related discipline).
• 5-7+ years of experience in process controls, automation engineering, or related manufacturing environments.
• 5-7+ years of experience managing engineering projects, including planning, execution, and commissioning.
• Hands-on experience with PLC and/or DCS platforms such as Rockwell, Siemens, Emerson DeltaV, or Honeywell.
• Experience leading automation projects, including scope development, cost estimation, testing, and startup/commissioning activities.
• Strong understanding of process instrumentation, including flow, pressure, temperature, level, and analytical measurement systems.
• Experience with control loop tuning, troubleshooting, and optimization.
• Knowledge of GMP, quality systems, and regulatory compliance requirements.
• Strong communication skills with the ability to collaborate with both technical and non-technical stakeholders.
• Proven problem-solving skills with experience leading RCA investigations and implementing long-term solutions.
• Ability to work in a manufacturing environment, including equipment inspections, troubleshooting activities, climbing stairs/ladders, and wearing required PPE.
• Flexibility to support shutdowns, startups, and other critical operational activities as needed.

Preferred Qualifications

• Experience with biotech, pharmaceutical, specialty chemical, or bioprocess manufacturing environments.
• Experience with bioprocess automation, fermentation systems, or BioFacility operations.
• Knowledge of SCADA systems, historian platforms (such as OSIsoft PI), and MES integrations.
• Familiarity with ISA-88 batch control standards and ISA-99/IEC 62443 industrial cybersecurity standards.
• Experience with 21 CFR Part 11 requirements for electronic records and electronic signatures.
• Experience with process simulation tools, operator training systems (OTS), or automation training platforms.
• Professional Engineer (PE) license or progress toward obtaining licensure.
• Previous experience mentoring engineers or leading technical teams.