Senior Process Control Engineer
Location: Theodore, AL
Work Arrangement: 100% Onsite
Employment Type: Direct Hire | Full-Time
Sirius Staffing is seeking an experienced Senior Process Control Engineer for a direct-hire opportunity with a leading chemical manufacturing facility in Theodore, Alabama.
This position serves as the facility’s technical expert for process control, automation, and safety systems. The engineer will be responsible for maintaining and improving the reliability, integrity, cybersecurity, and performance of the plant’s DCS, PLC, emergency shutdown, safety instrumented, data historian, and alarm management systems.
Key Responsibilities
- Maintain and troubleshoot DCS, PLC, ESD, SIS, data historian, alarm management, and industrial control-network systems.
- Develop preventive maintenance, inspection, backup, cybersecurity, and testing programs for automation hardware and software.
- Design, configure, simulate, test, implement, and document control strategies, sequences, interlocks, alarms, and system modifications.
- Perform and document annual and biannual safety-interlock testing.
- Analyze process and system data to identify reliability concerns, equipment issues, and improvement opportunities.
- Optimize PID loops, alarm configurations, process calculations, and advanced control strategies.
- Support Operations, Maintenance, Engineering, Environmental Health and Safety, and Laboratory personnel with troubleshooting and technical guidance.
- Participate in Process Hazard Analyses, Pre-Startup Safety Reviews, Safety Integrity Level reviews, incident investigations, and Management of Change activities.
- Design and execute automation, instrumentation, hardware, and software improvement projects.
- Coordinate contractors, consultants, vendors, capital projects, and plant-turnaround activities.
- Maintain system documentation, configuration records, backups, cybersecurity tools, and automation databases.
- Train plant personnel on automated systems, process controls, and operating philosophies.
Required Education and Experience
Candidates must meet one of the following:
- Bachelor’s degree in Engineering with at least five years of experience in an industrial environment; or
- Associate degree in a technical discipline with at least ten years of experience in industrial electrical systems, instrumentation, and process controls.
Required Technical Skills
- Strong knowledge of process control theory, process dynamics, PID tuning, advanced controls, and industrial instrumentation.
- Hands-on experience with DCS, PLC, HMI, emergency shutdown, and safety instrumented systems.
- Experience configuring and troubleshooting platforms such as Emerson RS3, Emerson DeltaV, or Honeywell Experion.
- Experience with Honeywell FSC, HIMA, or similar safety systems.
- Proficiency with Allen-Bradley or Siemens PLCs, including ladder logic or structured text.
- Experience with OSI PI, Process View, or similar historian and alarm management systems.
- Knowledge of Modbus, Profibus, SQL, and industrial communication networks.
- Ability to read and modify P&IDs, loop sheets, control drawings, and single-line diagrams.
- Knowledge of ISA, IEC, NFPA, and applicable process-safety standards.
Preferred Qualifications
- Process-controls experience within chemical, petrochemical, refining, or continuous-process manufacturing.
- Experience with advanced process control, alarm management, process simulation, plant turnarounds, and capital projects.
- Strong troubleshooting, communication, project-management, and cross-functional collaboration skills.
Working Environment
This position includes office and field work within an operating chemical manufacturing facility. Candidates must be able to work outdoors, climb ladders, work at elevated heights, and work around energized systems. Occasional after-hours or call-in support may be required.
Interview Process
- First round: Phone interview with Kevin Ellis
- Second round: In-person interview with the HR Manager and four team members
Sirius Staffing is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other protected status under applicable law.
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