Senior Process Control Engineer

Vulcan Materials Company; Macon (GA); On-site; USD 90,000 - 130,000; Full time

Job summary

Vulcan Materials Company in Macon, GA is seeking a Process Control Engineer to design, implement, and maintain control systems for aggregate production, aiming to improve efficiency, safety, and quality. The role involves data analysis, troubleshooting, and collaboration with engineers and plant personnel.

You will work with Allen-Bradley/GE PLCs, HMIs, and historian software to optimize operations, develop asset models, dashboards, and technical specs.

Qualifications

• Minimum 5 years in heavy industrial control system design and installation.
• B.S. or A.S. in Engineering preferred.
• Strong knowledge of Allen-Bradley/GE PLCs, HMIs, Historian software.
• Experience with asset modeling and dashboards.
• Ability to manage multiple projects and meet deadlines.
• Willingness to work in industrial plant environments and safety rules.

Responsibilities

• Optimize PLC code and develop new PLC programs.
• Design and implement process control systems for aggregate processing.
• Provide cost estimates and project schedules for capital projects.
• Review projects for feasibility, cost, and design correctness.
• Build asset models to support dashboards and production reports.
• Develop plant dashboards and reports for operations management.
• Develop asset model standards.
• Prepare technical specifications and purchase requisitions.
• Diagnose and resolve control system issues.
• Provide project management for plant projects with internal and external teams.
• Analyze process data to identify improvements and optimize controls.
• Evaluate future plant control systems and apply new tech.
• Assist in maintenance of existing automation systems.
• Assist IS in installation/config of plant networks.
• Assist in development of corporate standards.
• Other duties as assigned.

Skills

Allen-Bradley PLCs

GE PLCs

Wonderware HMIs

FactoryTalk HMIs

Historian Software

SQL Server

Industrial controls

PLC programming

Education

B.S. or Associates Degree in Engineering

Job description

JOB DESCRIPTION

A process control engineer in an aggregate plant designs, implements, and maintains control systems to optimize production processes, ensuring efficiency, safety, and quality. They analyze data, troubleshoot issues, and collaborate with other engineers and plant personnel to improve operations. Their work involves utilizing control systems, programming, and various tools to achieve optimal plant performance.

Essential Functions

• PLC Coding. Optimize existing PLC code, including loop tuning and program enhancements. Develop new PLC code and modify existing code, as needed.
• Designing, developing, and implementing process control systems for aggregate processing, including control strategies, sensor selection, actuator integration, and control algorithm programming.
• Provide cost estimates and project schedules for capital and expense projects, as needed.
• Participate in the review of capital and expense projects pertaining to design correctness, feasibility, and cost for the sections of the project related to process control.
• Build asset models to support the development of dashboards and production reports.
• Develop plant level dashboards and reports to support operations management and drive operational improvements.
• Participate in the development of asset model standards.
• Develop technical specifications and purchase requisitions for process control equipment.
• Diagnosing and resolving issues related to process control systems, including equipment malfunctions, software bugs, and communication errors.
• Provide project management for plant projects working with internal personnel as well as outside contractors, developing schedules and goals to meet milestone requirements.
• Analyzing process data, identifying areas for improvement, and optimizing control systems to enhance efficiency, reduce waste, and minimize downtime.
• Analyze future plant control systems and apply new technology and original innovation to attain competitive superiority, where possible.
• Assist in the maintenance and improvement of existing plant automation systems.
• Assist Corporate IS Department in the installation and configuration of plant networks, wireless systems, and firewalls.
• Assist in the development and enforcement of Corporate Standards, Specifications, and Policies.
• Other duties as assigned.

Critical Competencies

• Attention to Detail - Ability to thoroughly and accurately complete tasks; meticulous and precise when handling information, and is critical in ensuring the quality, accuracy, and integrity of the results.
• Analytical Thinking - Ability to break down complex problems, situations, in order to understand underlying patterns, identify key issues; examine information logically, question assumptions, and draw conclusions based on evidence.
• Communication - Communicates clearly and effectively, both verbally and in writing, while actively listening and adapting the message to the audience.
• Critical Thinking - Ability to analyze information objectively, evaluate different perspectives, and make well-informed decisions.
• Decision Making - Makes informed, effective, and timely decisions by evaluating available information, considering potential outcomes, and choosing the best course of action; analyzes options, weighs risks and benefits, and uses sound judgment to reach decisions that align with organizational goals and values.

Education

• B.S. or Associates Degree in Engineering desired.

Experience

• Minimum of 5 years of experience in the design and installation of heavy industrial control systems is desired, preferably in aggregates or a related industry.

Knowledge, Skills, And Abilities

• Strong knowledge of Allen Bradley and GE PLCs, Wonderware and FactoryTalk HMIs, and Historian Software systems is strongly desired. Knowledge of SQL Server and other reporting software is a plus.
• Knowledge of industrial controls systems, PLC, and HMI programming.
• Identifying electrical problems, troubleshooting, and field installation experience.
• Detailed knowledge of asset modeling to support corporate-wide initiatives.
• Must have the ability to plan, prioritize, and coordinate multiple projects and priorities at one time.
• Must have the ability to work in a stressful, deadline‑oriented environment that requires complex, technical information and decision making.
• Ability to work independently with minimal supervision; self‑directed and motivated; highly organized.
• Excellent written and oral communication skills.
• Able to present complex information in a clear, concise, and positive manner.
• Maintain awareness and knowledge of technology trends, best practices, and code standards including NEC, NFPA, IEEE, and NEMA relating to assigned work in the electrical and instrumentation industry and the application thereof by competition and others.

Other Requirements

• Observes all safety rules such as wearing of welding hood, goggles, gloves, rain suit, helmet, etc.
• Willingness to work inside and outside, perform dirty and greasy tasks, in all kinds of weather conditions and tolerate being exposed to loud noises.
• Willingness to work overtime, as scheduled, and adjust personal plans accordingly.
• Must have the ability to drive a pickup truck/car on a daily basis.
• Knowledge of computer networking is desired but not required.

Vulcan Materials Company is an equal opportunity employer.