Sr Process Control Engineer Jobs in Madison, WI (NOW HIRING)

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Full Time Professional Deer Island, OR, US

13 days ago Requisition ID: 1008

The Process Optimization & Controls Engineer is responsible for improving manufacturing and production performance through advanced process control, automation, and data‑driven optimization. This role combines control systems engineering with continuous improvement, focusing on enhancing safety, quality, throughput, reliability, and cost efficiency across operations.

This role focuses on alarm management, controller performance, and control loop optimization to improve process stability and reduce operator workload. The position works closely with Operations, Process Engineering, Maintenance, and Reliability and contributes to operating discipline, process safety, and continuous improvement initiatives.

• Strong grounding in HSE, PSM principles, and alarm management practices
• Hands‑on experience with PLC/DCS platforms (Rockwell, Siemens, Emerson, Honeywell, Yokogawa, etc.)
• Strong understanding of PID control, control loop tuning, and process dynamics
• Experience interpreting P&IDs, control schematics, and electrical diagrams
• Knowledge of safety systems (SIS, SIL)
• Ability to analyze DCS and historian data to drive data‑based improvements
• Working knowledge of ammonia manufacturing and continuous chemical processes
• Strong collaboration skills across operations, maintenance, and engineering teams
• Strong written and verbal communication skills with the ability to explain technical concepts to non‑technical stakeholders
• Positive attitude, strong work ethic, and commitment to company values
• Strong analytical, troubleshooting, and communication skills

Bachelor’s degree in chemical engineering, electrical engineering, controls engineering or equivalent

Minimum of 3-5 years of process engineering experience at an Ammonia Manufacturing Plant or Chemical Plant

Ammonia Manufacturing, Oil & Gas, Chemical

OSHA, PSM, NFPA, EPA, IEC, IEEE, NEC, API

• Analyze production processes to identify efficiency, yield, and capacity improvement opportunities
• Optimize control strategies, PID loops, and automation logic to stabilize and improve process performance
• Use process data, historians, and statistical tools to diagnose variability and root causes
• Lead or support continuous improvement initiatives (Lean, Six Sigma, OEE improvement)
• Develop and maintain control narratives, functional specifications, and logic diagrams
• Specify, install, and troubleshoot process instrumentation and control hardware
• Support startup, commissioning, and validation of new or modified control systems
• Monitor controller and loop performance using DCS and historian data to identify and implement control improvements
• Partner with operators, process engineers, and maintenance to develop and deploy improved control strategies
• Provide control room oversight during implementation of controller optimization, loop tuning, and control logic changes
• Provide instrumentation and controls engineering support including completion of instrument specification sheets

• Provide day‑to‑day technical support for control systems and process upsets
• Collaborate with operations and maintenance to resolve control, instrumentation, and automation issues
• Implement alarm management and control system reliability improvements
• Maintain system documentation, backups, and configuration control
• Own and maintain the plant Alarm Management Program in accordance with site standards and best practices
• Maintain and continuously improve the alarm management database to reduce nuisance alarms and improve operator effectiveness

• Participate in projects from concept through commissioning by providing DCS and controls support for capital and non‑capital projects
• Work with cross‑functional teams including process engineering, IT, quality, safety, and vendors
• Ensure control system designs meet operational, safety, and cybersecurity requirements

• Support process safety activities including PHA, MOC, and safety interlocks
• Ensure control systems comply with applicable regulatory and company standards

Support regulated environments (e.g., FDA, EPA) where applicable.