Job Title: Control Systems Engineer (Electrical)

Job Summary:

The Mid-Level Control Systems Engineer (Electrical) is responsible for the design, programming, installation, maintenance, and optimization of electrical control systems used in industrial, commercial, and manufacturing environments. This role involves working independently on more complex tasks, ensuring that control systems such as PLCs, SCADA, and automation systems perform efficiently. The engineer will manage projects, troubleshoot complex system issues, and provide technical support to junior engineers. The role also requires ensuring that all systems meet safety and quality standards, while also driving improvements in system performance and reliability.

Key Responsibilities:

1. Control System Design and Programming:

   • Lead the design and programming of electrical control systems, including PLCs, SCADA, HMI (Human-Machine Interface), and automation systems.
   • Write, test, and debug PLC programs (e.g., Ladder Logic, Function Block Diagram, Structured Text) for controlling machinery and processes.
   • Develop system specifications, including control strategies, system layouts, and integration with other electrical and instrumentation components.
   • Ensure that designs and programs are aligned with operational requirements, safety standards, and industry regulations.

2. System Integration and Commissioning:

   • Manage the integration of control systems with other electrical, mechanical, and instrumentation systems, ensuring seamless functionality across platforms.
   • Oversee the commissioning process, including the setup, testing, and validation of control systems to verify that they meet design specifications and customer requirements.
   • Coordinate with cross-functional teams to ensure proper system startup and troubleshoot any issues during the integration phase.

3. Maintenance and Troubleshooting:

   • Lead troubleshooting efforts for complex control system failures, identifying root causes and implementing corrective actions.
   • Perform regular maintenance, calibration, and system optimization to ensure that control systems are functioning at peak performance.
   • Diagnose faults in electrical, PLC, SCADA, and automation systems and implement solutions to minimize downtime and prevent future issues.

4. Project Management:

   • Lead or assist in the management of control systems projects, including timelines, resources, budgets, and deliverables.
   • Coordinate with project managers and senior engineers to ensure that control systems meet project goals, deadlines, and regulatory standards.
   • Prepare project documentation, including detailed reports, progress updates, and technical specifications, for internal teams and clients.

5. System Optimization and Performance Tuning:

   • Analyze and optimize the performance of control systems to improve operational efficiency, energy savings, and reduce system downtime.
   • Identify and implement improvements to existing systems, including updates to software, hardware, or control strategies to increase system reliability and performance.
   • Work with production and operations teams to continuously improve control systems in line with changing needs or operational conditions.

6. Safety and Compliance:

   • Ensure that all control systems meet local and international safety standards, electrical codes, and industry regulations (e.g., NEC, IEC).
   • Follow safety procedures and protocols when working with electrical systems, PLCs, and automation equipment to ensure a safe working environment.
   • Conduct risk assessments, safety audits, and compliance checks to ensure the safe operation of control systems.

7. Training and Mentoring:

   • Mentor junior engineers and technicians, providing guidance on control system design, troubleshooting, and best practices.
   • Provide training to team members and operators on how to operate, maintain, and troubleshoot control systems effectively.
   • Support the development of training materials, including technical documents, manuals, and system documentation for both internal and external use.

8. Documentation and Reporting:

   • Maintain detailed records of control system designs, modifications, troubleshooting actions, and maintenance activities.
   • Prepare comprehensive reports on system performance, issues identified, corrective actions, and improvements made.
   • Ensure that documentation is up-to-date and easily accessible for audits, future reference, or regulatory compliance.

9. Collaboration with Cross-Functional Teams:

   • Collaborate with other engineering disciplines, including electrical, mechanical, and instrumentation teams, to ensure control systems meet overall project goals.
   • Work with operations teams to gather feedback and make adjustments to control systems as necessary to meet operational objectives.
   • Engage with clients, vendors, and suppliers to source components, provide technical support, and ensure the successful implementation of control systems.

Skills and Knowledge Required:

• Strong knowledge of electrical control systems, PLCs (Siemens, Allen-Bradley, Rockwell), SCADA systems, HMI, and automation technologies.
• Proficiency in PLC programming languages (Ladder Logic, Structured Text, Function Block Diagram).
• Experience in designing, programming, and troubleshooting complex control systems, including sensor integration, actuators, and electrical components.
• Strong understanding of electrical safety standards, codes (e.g., NEC, IEC), and industry regulations.
• Ability to analyze and optimize control systems to improve performance, energy efficiency, and reliability.
• Strong problem-solving and diagnostic skills, with the ability to troubleshoot complex electrical and automation issues.
• Excellent communication skills, with the ability to explain technical information clearly to non-technical team members or clients.
• Strong project management skills, including the ability to manage timelines, budgets, and resources effectively.

Educational Qualifications:

• Bachelor’s degree in Electrical Engineering, Control Systems Engineering, Electronics Engineering, or a related technical field.
• Relevant certifications in PLC programming, control systems, automation, or project management (e.g., Six Sigma, PMP) are a plus.

Experience:

• 3-5 years of professional experience in control systems engineering, electrical systems, PLC programming, and automation.
• Hands-on experience with electrical control systems, PLCs, SCADA, and HMI integration.
• Experience working in industrial or commercial settings with a focus on automation and control systems.

Tools and Technologies:

• Proficiency with PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000, Allen-Bradley).
• Experience with SCADA software (e.g., Wonderware, Ignition, Siemens WinCC) and HMI development.
• Familiarity with electrical design software and simulation tools (e.g., AutoCAD, MATLAB, LabVIEW).
• Experience with system integration tools and automation equipment (e.g., industrial robots, drives, sensors).

Other Requirements:

• Strong organizational skills with the ability to manage multiple projects and priorities.
• Ability to work independently and as part of a team, ensuring collaboration and efficiency.
• Willingness to travel to client sites, project locations, or supplier facilities as required.
• Proactive, self-motivated, and enthusiastic about learning new technologies in the control systems and automation fields.