Senior Controls Engineer
The Senior Controls Engineer is responsible for shaping and delivering complete control system solutions from concept through commissioning. This position leads the development of control strategies, system architectures, and device selection while supporting programming, startup, and site implementation. The role works closely with cross‑functional teams to produce systems that are safe, compliant, reliable, and user‑friendly, while ensuring alignment with customer requirements and applicable industry standards.
Key Responsibilities
Controls System Design
- Interpret process documentation such as PFDs and P&IDs to define system architecture, control panel layouts, network structure, and I/O assignments.
- Provide technical support for custom control panel design and fabrication, including preparation of documentation compliant with UL508A when required.
- Select and specify instrumentation and final control elements including transmitters, analyzers, flow measurement devices, and control valves.
- Design supporting systems such as gas detection, heat tracing, and industrial wireless telemetry using approved commercial platforms.
Programming, Startup, and Commissioning
- Develop PLC, safety logic, and combustion or burner management applications using platforms such as Honeywell and Allen‑Bradley.
- Configure SCADA and HMI applications using modern visualization platforms.
- Produce functional documentation including control narratives, alarm strategies, interlock descriptions, cause‑and‑effect matrices, and I/O databases.
- Implement combustion control strategies ranging from basic jackshaft systems to fully metered, cross‑limited air‑fuel control with oxygen trim.
- Execute system validation activities including I/O checkout, loop tuning, FAT, SAT, startup, and live commissioning.
- Deliver operator training and provide system handover documentation upon project completion.
Field Support and Lifecycle Services
- Support installed systems through on‑site and remote troubleshooting, tuning, warranty support, and performance optimization.
- Assist customers with long‑term system enhancements and upgrades.
Safety, Quality, and Compliance
- Apply industry best practices for combustion safety and functional safety throughout system design and implementation.
- Ensure accurate version control, change tracking, and maintenance of as‑built documentation.
- Develop customer-facing documentation including test plans, commissioning reports, and training materials.
Collaboration and Leadership
- Partner with Project Managers to align technical execution with scope, schedule, and risk management.
- Contribute to proposal development through conceptual designs, technical input, and effort estimates.
- Provide technical guidance to panel shop personnel during fabrication.
- Support field technicians during installation and startup activities.
- Mentor and provide technical oversight to junior controls engineers.
Knowledge, Skills, and Experience
- Strong understanding of burner management systems and combustion safety standards such as NFPA 85 and NFPA 86, along with functional safety concepts aligned with ISA 84 or IEC 61511.
- Proficiency with electrical and controls design standards including NEC and UL508A.
- Experience specifying and sizing instrumentation and control valves for gas and liquid fuel applications.
- Demonstrated expertise in combustion control methods including oxygen trim, air‑fuel ratio tuning, and cross‑limited metering.
- Familiarity with gas detection systems, heat tracing technologies, and industrial wireless communications.
- Ability to create and interpret P&IDs, electrical schematics, and control network diagrams.
- Strong hands‑on troubleshooting skills in startup and field service environments.
- Experience managing software version control and deployment for automation projects.
- Hands‑on experience with at least two major control platforms such as Honeywell HC900, Honeywell ControlEdge, or Allen‑Bradley CompactLogix/ControlLogix.
- Experience configuring HMI/SCADA platforms such as ICONICS, Ignition, or Red Lion Crimson.
- Proficiency in ladder logic and at least one additional programming methodology such as function block or structured text.
- Proven commissioning experience on combustion or high‑temperature process systems, including permissives, interlocks, purge sequences, light‑off, and flame supervision.
- Strong documentation discipline with attention to revisions, testing records, and compliance.
- Willingness and ability to travel for factory testing, site commissioning, training, and service support as required.
Education and Background
- Associate degree in a relevant technical discipline or equivalent practical experience.
- Bachelor's degree in Mechanical Engineering, Electrical Engineering, or a related field preferred.
- Approximately seven (7) or more years of progressive experience in controls engineering, automation, or combustion systems.
Compensation and Benefits
Full‑time employees are offered a comprehensive benefits package, which may include:
- Medical, dental, and vision insurance
- Health Savings Account (HSA) and Flexible Spending Accounts (medical and dependent care)
- 401(k) retirement plan with employer matching and immediate vesting
- Employer‑paid short‑ and long‑term disability coverage
- Employer‑paid basic life and AD&D insurance, with optional supplemental coverage
- Paid time off and paid holidays
- Tuition reimbursement and professional development support
FAQs
Congratulations, we understand that taking the time to apply is a big step. When you apply, your details go directly to the consultant who is sourcing talent. Due to demand, we may not get back to all applicants that have applied. However, we always keep your CV and details on file so when we see similar roles or see skillsets that drive growth in organisations, we will always reach out to discuss opportunities.
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