Description
The Senior Automation & Controls Engineer leads and executes Automation and Controls Engineering design activities for small to large-scale Engineering, Procurement, and Construction (EPC) projects across food, consumer products, pharmaceutical, life science, aerospace, and industrial facilities. This role is responsible for delivering automation and controls solutions throughout all project phasesfront end, detailed design, construction, and start-up. Projects may range from direct client controls work to full-scale self-performed Automation and Controls EPC projects.
Key Responsibilities
Ensure compliance with company and project site safety policies.
Lead design efforts for all Automation and Controls scope on assigned projects.
Manage and mentor a team of Automation and Controls Engineers, Specialists, and Designers.
Collaborate with internal teams including project management, electrical, estimating, procurement, construction, and other engineering disciplines.
Lead development of software design deliverables (PLC and HMI programming, Batch, MES, servers, virtualization) and oversee commissioning/start-up.
Prepare and review controls design deliverables (instrument/device lists, I/O lists, controls narratives, control panel/hardware designs, device location drawings, and installation details).
Lead vendor specification, design, procurement, FATs, and manage vendor progression.
Oversee electrical design deliverables (480VAC and below equipment, motor power design, installation plans, conductor schedules).
Select appropriate instrumentation (temperature, pressure, flow, level, analyzers, valves).
Review P&IDs with process engineers to define controls scope.
Develop and manage design verification, calculations, reports, and project studies.
Coordinate deliverables with offsite design offices.
Perform and lead quality reviews of design submittals.
Support project estimates using tools such as ProposalWorks, IAB, SIL Solver, Bluebeam, Excel, and Visio.
Assist project managers with budget and progress tracking.
Build strong client and vendor relationships, ensuring satisfaction and repeat business.
Provide technical direction and allocate team resources effectively.
Coordinate with field personnel to resolve installation/design issues and support inspections/testing.
Lead on-site start-up and commissioning activities.
Support change management through discipline change notices.
Travel to job sites (approx. 30%) for surveys, installations, and start-ups.
Partner with business development to pursue new opportunities and client engagements.
Develop business strategies and proposals for future projects.
Support recruitment, interviewing, and onboarding of new team members.
Align workload with Automation and Controls Department leadership.
Comply with all company policies and standards.
Qualifications
Bachelors degree in Controls, Electrical, Mechanical, or Chemical Engineering (ABET accredited) plus 7+ years of electrical engineering experience, or
Masters degree in Electrical Engineering plus 6+ years of experience.
EPC project experience and Automation & Controls background preferred.
FE exam completion required; PE License preferred.
Strong knowledge of electrical equipment design (ANSI/IEEE standards).
Skilled with Microsoft Office Suite and design tools.
Experience leading discipline design on large projects, delegating tasks, and resolving technical issues.
Strong communication, critical thinking, and problem-solving skills.
Ability to perform quality reviews of engineering documents.
Must be able to obtain a Transportation Worker Identification Card (TWIC).
Ability to travel as required.
Preferred Experience
Expertise in automation/control systems (PLC, SCADA, SIS, BMS, DCS).
Rockwell and Siemens PLC platforms; additional experience with GE, Modicon, Opto22, Mitsubishi, Triconex a plus.
SCADA with FactoryTalk, Wonderware, Ignition Software.
MES design/implementation (ThingWorx, Ignition/Sepasoft, TrakSYS).
Machine safety compliance (ISO13849) and process safety design (ISA/IEC 61511).
Experience with PlantPAX, PackML, SISTEMA, CCW, IAB, BatchSIM, PlantSIM.
Familiarity with design standards (NFPA, ISA, IEC, IEEE, UL508A).
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