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Senior Automation & Controls Engineer

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 industries such as food, consumer products, pharmaceuticals, life sciences, aerospace, and industrial facilities. This role is responsible for delivering automation and controls solutions throughout the project lifecycle, including front-end design, detailed engineering, construction, and startup phases. Projects may involve client-directed controls work or full self-executed automation and controls EPC projects.

Key Responsibilities:

• Ensure compliance with all company and project site safety policies.

• Lead design for all automation and controls scope on assigned projects.

• Manage and mentor a team of automation and controls engineers, specialists, and designers, coordinating with multi-disciplinary project teams including project management, electrical, estimating, procurement, construction, and other engineering disciplines.

• Develop software design deliverables such as PLC and HMI programming, Batch systems, MES, servers, and virtualization, and oversee commissioning and startup activities.

• Prepare and review controls design deliverables including instrument/device lists, I/O lists, control narratives, control panel and hardware designs, device location plans, and installation details.

• Specify, design, and procure control panels and equipment, manage vendor progress, and lead Factory Acceptance Tests (FATs).

• Prepare electrical design deliverables including 480VAC and below equipment, motor power design, installation plans, and conductor schedules.

• Determine process instrumentation requirements for temperature, pressure, flow, level, analyzers, and control valves, selecting appropriate technologies for control applications.

• Review P&IDs with process engineers to define and validate project controls scope.

• Develop and verify design calculations, studies, and reports.

• Coordinate with offsite design teams, ensuring timely execution of controls deliverables.

• Conduct quality reviews of project design submittals and coordinate feedback within the department.

• Apply engineering principles, codes, and best practices to automation and controls design and execution.

• Interface with construction personnel to resolve design-related installation issues, perform field inspections, and support testing of controls systems.

• Assist project management with project budgets, estimates, and progress tracking using software tools such as ProposalWorks, Integrated Architecture Builder (IAB), SIL Solver, Bluebeam, Excel, and Visio.

• Develop client and vendor relationships, ensuring satisfaction and supporting business development opportunities.

• Lead the technical execution of onsite startup and commissioning activities.

• Develop and submit discipline change notices as needed.

• Support the hiring and resource allocation for the automation and controls team.

• Execute EPC project approaches and attend project sites as required (approx. 30% travel).

• Participate in business development initiatives, client events, and long-term project planning.

• Perform all other duties as assigned.

Qualifications:

• Bachelors degree in Electrical, Controls, Mechanical, Chemical Engineering, or related field from an ABET-accredited program, with completion of the Fundamentals of Engineering (FE) exam and 7 years of electrical engineering experience; EPC project and automation & controls experience preferred.

• Masters degree in Electrical Engineering with 6 years of experience preferred.

• Expert knowledge of standard engineering techniques, electrical equipment design, ANSI/IEEE standards, and industry best practices.

• Strong computer skills, including Microsoft Office Suite.

• Proven experience leading discipline design for large projects and delegating work effectively.

• Strong analytical, critical thinking, problem-solving, organization, and communication skills.

• Ability to perform quality reviews of detailed engineering documents and specifications.

• Must be able to travel as required and obtain a Transportation Worker Identification Card (TWIC).

• Professional Engineer (PE) license preferred.

Preferred Skills & Experience:

• Extensive knowledge of automation & controls engineering/design standards such as NFPA, ISA, IEC, IEEE, ISA/IEC 61511, ISO13849, and UL508A.

• Hands-on experience with various control and safety systems (PLC, SCADA, SIS, BMS, DCS).

• Rockwell and Siemens PLC platforms preferred; experience with GE, Modicon, Opto22, Mitsubishi, and Triconex a plus.

• SCADA experience with FactoryTalk, Wonderware, or Ignition Software is a plus.

• MES design and implementation experience (e.g., PTC ThingWorx, Ignition/Sepasoft, Parsec TrakSYS) is advantageous.

• Knowledge of machine safety risk assessment, PL design compliance to ISO13849, and process safety SIF/SIS design to ISA/IEC 61511 is preferred.

• Familiarity with PlantPAX, PackML, and simulation/design tools such as SISTEMA, CCW, IAB, BatchSIM, and PlantSIM is desired.