Job Title: Process Control Engineer (Water Treatment)
Job Summary:
The Process Control Engineer Manager (Water Treatment) is responsible for leading the design, optimization, and overall management of process control systems used in water treatment facilities. This leadership role involves overseeing the integration, maintenance, and continuous improvement of SCADA, PLCs, and other automation systems to ensure optimal operation of water purification, chemical dosing, filtration, and water quality monitoring systems. The Process Control Engineer Manager will lead a team of engineers, work with cross-functional departments, and drive improvements to meet regulatory compliance, operational goals, and environmental standards in water treatment operations.
Key Responsibilities:
Leadership and Team Management:
- Manage and lead a team of process control engineers, providing mentorship, coaching, and support to ensure that the team meets operational and project objectives.
- Set team goals, track performance, and provide feedback and development opportunities to junior and mid-level engineers.
- Foster a collaborative and innovative environment within the team to drive continuous improvement and ensure efficient water treatment system operations.
Process Control System Strategy and Optimization:
- Oversee the design, configuration, and optimization of SCADA systems, PLCs, RTUs, and other control technologies used in water treatment plants.
- Lead efforts to optimize process control strategies, ensuring that key water quality parameters (pH, chlorine levels, turbidity) are consistently maintained within regulatory standards.
- Ensure efficient operation of water treatment systems, including filtration, chemical dosing, and disinfection, by continuously analyzing data and implementing process improvements.
System Integration and Troubleshooting:
- Ensure seamless integration of process control systems with other automation technologies, including sensors, pumps, and valves.
- Troubleshoot complex control system issues, manage corrective actions, and ensure minimal downtime in water treatment operations.
- Provide leadership in diagnosing and resolving control system failures, collaborating with senior engineers and maintenance teams to implement preventive and corrective actions.
Regulatory Compliance and Reporting:
- Ensure that water treatment processes comply with local, state, and federal regulations for water quality and environmental standards.
- Oversee the preparation and submission of compliance reports, including water quality testing results, regulatory audits, and system performance assessments.
- Ensure adherence to health, safety, and environmental guidelines, mitigating any risks related to water treatment processes.
Project Management and System Upgrades:
- Manage and lead process control system upgrades, ensuring that new systems are integrated seamlessly and meet both operational and regulatory requirements.
- Oversee the planning, budgeting, and scheduling of SCADA-related projects, ensuring resources are allocated effectively and project milestones are met.
- Ensure that process control projects are executed on time, within budget, and to the required standards of quality and performance.
Continuous Improvement and Innovation:
- Lead continuous improvement efforts for process control systems, leveraging data analysis and emerging technologies to optimize water treatment processes.
- Stay updated with the latest developments in process control technologies, automation, and water treatment systems to introduce innovative solutions.
- Implement new technologies and strategies to improve system reliability, reduce energy consumption, and enhance overall operational efficiency.
Collaboration with Cross-Functional Teams:
- Work closely with operators, maintenance, engineering, and IT teams to ensure that SCADA and process control systems are aligned with water treatment plant goals and operational objectives.
- Collaborate with external vendors and contractors for system upgrades, technical support, and integration efforts.
- Communicate effectively with senior management, providing updates on system performance, optimization efforts, and project status.
Data Management and Analysis:
- Oversee the collection and management of real-time and historical water quality data, ensuring that data is accurate, accessible, and used for decision-making.
- Analyze system data to identify trends, areas for improvement, and potential risks, using insights to drive process optimization.
- Generate and present reports on water treatment plant performance, including water quality, system uptime, and efficiency improvements.
Safety and Environmental Stewardship:
- Ensure that all process control systems operate safely and within the required environmental regulations.
- Develop and implement safety procedures and protocols for the operation and maintenance of water treatment systems.
- Ensure that the team is trained on safety protocols, emergency response plans, and environmental compliance practices.
Key Focus Areas:
- Process Control System Optimization: Oversee the optimization of SCADA, PLC, and automation systems to maintain efficient and compliant water treatment operations.
- Leadership and Team Development: Lead, mentor, and develop a high-performing team of engineers to ensure efficient water treatment operations.
- Regulatory Compliance and Reporting: Ensure water treatment systems meet all regulatory and environmental standards while preparing accurate compliance reports.
- Continuous Improvement: Drive process improvements through the integration of new technologies, data analysis, and innovative solutions.
- Project Management and System Upgrades: Manage process control system projects, ensuring successful execution and alignment with operational goals.
Skills and Knowledge Required:
- Strong experience with SCADA systems, PLCs, RTUs, and other process control technologies in water treatment or similar industries.
- In-depth knowledge of water treatment processes (e.g., filtration, chemical dosing, disinfection) and the role of process control systems in these processes.
- Strong troubleshooting skills, with experience in diagnosing complex control system issues and implementing solutions.
- Proven ability to manage projects, including budgeting, scheduling, and resource allocation, while ensuring compliance with quality standards.
- Deep understanding of water quality parameters (pH, chlorine, turbidity) and the importance of maintaining them within regulatory limits.
- Knowledge of environmental and regulatory standards (e.g., ISO 9001, EPA, state regulations) related to water treatment and process control systems.
- Experience with data analysis tools (e.g., Excel, Power BI, SQL) to drive process improvements and monitor system performance.
- Leadership abilities, with experience in managing teams and cross-functional collaboration.
Educational Qualifications:
- Bachelor’s or Master’s degree in Environmental Engineering, Chemical Engineering, Control Systems Engineering, Mechanical Engineering, or a related technical field.
- Certifications in SCADA systems, PLC programming, process control, or water treatment are advantageous.
Experience:
- 7+ years of experience in process control systems, automation, or water treatment engineering, with at least 3-5 years in a managerial or leadership role.
- Proven track record in managing SCADA systems, process control optimization, troubleshooting, and project management in a water treatment or industrial setting.
- Experience with regulatory compliance, environmental standards, and water quality management in water treatment processes is highly preferred.
Tools and Technologies:
- Expertise with SCADA platforms (e.g., Wonderware, Siemens WinCC, Ignition, Rockwell FactoryTalk).
- Proficiency with PLC programming languages and industrial control systems (e.g., Siemens, Allen-Bradley).
- Familiarity with water quality monitoring instruments (e.g., pH sensors, chlorine analyzers) and control systems.
- Knowledge of data analysis and performance monitoring tools (e.g., Power BI, SQL, Excel).
Other Requirements:
- Strong leadership and project management skills to drive the team toward operational success.
- Ability to work in a fast-paced environment, managing multiple projects and priorities simultaneously.
- Willingness to travel to different sites for troubleshooting, installations, and system upgrades.