Engineer-Process Controls Lead

Primary Purpose:

The Lead Process Controls Engineer is responsible for leading the designing, implementing, and maintaining control systems that ensure safe, efficient, and reliable operation of power generation equipment systems. This role involves working closely with project teams, process engineers, operations, and maintenance teams to ensure safe, efficient, and reliable power plant operations through effective control strategies and system integration.

Essential duties and responsibilities:

• Lead and manage the process controls engineering team throughout the Engineering/design, Procurement, and Construction (EPC) process, adapting I&C plans according to the assigned budget, schedule, engineering/design standards.
• Oversee the design, develop, and maintain control systems for power plant equipment including turbines, boilers, generators, and balance of plant systems.
• Configure and program Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), and Human-Machine Interfaces (HMI) specific to power generation processes.
• Lead troubleshooting and resolution of complex control system issues during design and commissioning phases.
• Develop and optimize control logic to improve plant efficiency, reduce emissions, and ensure compliance with regulatory requirements.
• Collaborate with process and mechanical engineers to translate operational requirements into control system specifications.
• Perform system testing, commissioning, and troubleshooting during startup and ongoing operations.
• Monitor control system performance and implement improvements to enhance reliability and availability.
• Develop and maintain detailed documentation such as control narratives, logic diagrams, functional specifications, and test procedures.
• Ensure all control systems comply with industry standards (e.g., ISA, IEEE, IEC), safety regulations, and environmental guidelines.
• Support power plant-wide automation projects and upgrades, including integration of new technologies.
• Provide technical support and training to plant operators and maintenance personnel.
• Participate in root cause analysis and corrective action for control system-related issues.
• Assist in emergency response and plant outage activities as needed.
• Provide leadership, guidance and mentoring to other engineers or project staff as assigned to support the process engineering efforts of major process facility projects.
• Manage client and team relationships on multiple assigned projects to help ensure that the process design basis (PDP) is technically sound and meets the client project objectives. Provide technical oversight of assigned projects from early Front-End Planning (FEP) through detailed design and construction.
• Lead the production of controls design deliverables, including I/O list, Process Control Narratives, Graphic Sketches, Cause & Effect Diagrams, Alarm Rationalization, and manage third-party control system suppliers to comply with the control system design requirements, including participating in Factory Acceptance Tests (FAT).
• Lead the production of I&C purchase specifications, review bids, make technical recommendations and manage the overall purchase, review of I&C packages, and review of vendor documentation.
• Responsible for compliance with company and project site safety policies.

Minimum requirements:

Education:

• Bachelor of Science in Instrumentation and Controls Systems Engineering, Chemical Engineering, Electrical Engineering, Control Systems Engineering, Instrumentation. 15 years of engineering experience. Experience in process control engineering within power generation facilities. Coal, gas, combined cycle renewable energy.

Experience/Specific Knowledge:

• 15 years of engineering experience. Experience in process control engineering within power generation facilities (coal, gas, combined cycle, renewable).
• Strong knowledge of power plant control systems such as DCS (e.g., ABB, Honeywell, Emerson DeltaV, Siemens PCS7), PLCs, and SCADA.
• Familiarity with turbine control systems, boiler control, and balance of plant automation.
• Understanding of power plant processes including steam generation, combustion, emissions control, and electrical generation.
• Knowledge of industry standards and regulatory requirements related to power plants.
• Proficient in control system troubleshooting, commissioning, and performance optimization.
• Excellent communication and teamwork skills.
• Ability to work in both office and plant environments, including site visits and shift work if required.
• Experience with power plant performance monitoring and optimization tools.
• Knowledge of cybersecurity practices for industrial control systems.
• Familiarity with environmental control systems (e.g., SCR, FGD).
• Project management and vendor coordination experience.
• Familiarity with OSHA 1910.119 Process Safety Management ANSI/ISA-61511 Other similar industry standards
• Safety Integrity Level (SIL) Calculations
• Strong knowledge of electrical equipment design ANSI and IEEE Standards.
• Strong proficiency in MS Office applications that may include but are not limited to Excel, Word, SharePoint, PowerPoint, and Outlook.

Certifications, Licenses & Registrations:

• Must possess and maintain a valid driver’s license and a driving record satisfactory to the company and its insurers (for travel).
• Knowledge of industry’s regulatory compliance issues and standards.

Competencies, Skills & Abilities:

• Must be able to take direction from supervisor(s), keep required work schedule, focus attention on details, and follow work rules.
• Ability to lead execution of work and resolve issues in a team environment.
• Strong attention to detail, facilitation, team building, collaboration, organization and problem-solving skills.
• Ability to perform quality reviews for detailed engineering documents and specifications.
• Ability to travel. accredited program.
• Ability to take on additional tasks and shift priorities on short notice.
• Excellent verbal and written communication skills.
• Strong focus on safe work practices.
• Able to complete work assignments with moderate supervision in an acceptable timeframe.
• Strong analytical and problem-solving skills.
• Aptitude and interest in learning and leveraging new programs to accomplish tasks.
• Must be able to perform all essential and marginal functions of the job.
• Must be able to work with a team.
• Ability to successfully perform multiple tasks with strict deadlines.
• Ability to organize and prioritize daily work.
• The individual must possess the ability to associate and communicate with a wide variety of people with tact, courtesy, and professionalism.

Physical Demands:

All of the physical requirements listed below are those that may be necessary for an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Sitting; standing; walking or moving throughout facility; driving; talking; seeing (specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus); hearing; feeling; bending or stooping; squatting or crouching; reaching; kneeling; pushing; pulling.
• Must be able to climb to and work from elevated platforms, ladders and walkways
• Must be able to work outdoors in adverse weather conditions, climb vertical access ladders and stairwells, carry up to 50 pounds and to see, hear, walk and talk effectively.
• Must be able to sit for prolonged periods of time.
• The employee is regularly required to use hands to type, touch, handle, or feel. The employee is required to talk and hear. The employee is frequently required to stand and reach with hands and arms. The employee is occasionally required to walk and climb or balance. The employee must regularly lift and/or move up to 10 pounds and occasionally lift and/or move up to 25 pounds.

Working Conditions:

• This is a full-time position.
• Essentially indoors but must be able to work outdoors in project & maintenance activities.
• Travel from 40% of time to engineering offices, field sites and company offices with occasional overnight stays.
• May be required to carry a cell phone and be available to respond during working and non-working hours.
• The successful candidate will be required to clear a drug screen and a complete background check, including credit report for certain positions, after an offer has been extended and prior to being employed.

Supervisory Responsibility:

• No

Preferred Education, Experience, Certifications, Competencies, Skills & Abilities:

Above the minimum requirements, not required but advantageous in this position:

• Master of Science degree in I&CS Engineering a plus.
• Professional Engineering License (PE) preferred.

Other responsibilities:

The above statements describe the general nature and level of work being performed. This position may perform other duties as assigned.

Compensation: $185,500 - $202,200