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Process Controls Engineer

2 months ago

East Chicago, Indiana, United States W. R. Grace & Co. Full time
Job Description

W. R. Grace & Co. is seeking a highly skilled Process Controls Engineer to join our Engineering team in Materials Technologies. This role reports to our Site Technical Manager and is located at our East Chicago plant in East Chicago, IN.

Key Responsibilities:
  • Design and Implementation: Design, test, troubleshoot, and oversee the implementation of process controls for new and existing systems.
  • Process Efficiency: Help create and implement strategies to improve process efficiency and support start-up activities.
  • Environmental, Health, and Safety: Participate in the site's environmental, health, and safety initiatives and play an integral role in achieving compliance with our EHS policy, including emergency preparedness and response.
Technical Requirements:
  • Process Controls Systems: Maintain, troubleshoot, and improve DCS (Rockwell PlantPAX) and PLC-based control systems to ensure processes operate safely while striving to optimize the plant's production, quality, and costs.
  • DCS Hardware Infrastructure: Manage DCS hardware infrastructure, backup systems, and documentation, including alarms, interlocks, and P&IDs.
  • Commissioning and Startup: Conducts and supports commissioning and startup activities, including DCS validation, PHA, PSSR, MOC, writing SOP/work instructions, and conducting DCS user training.
  • Programming and HMI Schematics: Develop, maintain, and improve programming, ladder logic, and HMI schematics for plant processes.
  • System Migration: Establish and implement long-term system migration plans to address obsolescence issues and to ensure system capabilities are in line with future controls system needs.
  • Plant Troubleshooting: Assist with plant troubleshooting during normal operations, startups, and plant emergencies, including at times, on nights and weekends.
  • Contractor Oversight: Oversee contractors who perform work on DCS systems, including software and hardware support.
  • Operator and Shift Supervisor Support: Work with plant operators and shift supervisors to improve HMI and controls.
Physical Requirements and Environment:
  • Safety Protocols: Ability to follow safety protocols and standards working in a laboratory environment with highly hazardous materials.
  • High-Hazard Environment: Ability to work in a high-hazard environment, including adverse weather conditions, elevated spaces, confined spaces, extreme temperatures, and noisy surroundings.
  • Physical Demands: Must be able to stand, walk, sit, climb, balance, stoop, kneel, crouch, crawl, and climb stairs and ladders over 100 ft.
  • Personal Protective Equipment: Must be willing to wear PPE (Personal Protective equipment) including but not limited to hard hat, protective eyewear, steel-toed boots, hearing protection, Level A suit, full face respirator.
Required Qualifications:
  • Education: BS in Chemical Engineering or related technical field.
  • Experience: 5+ years of experience in chemical manufacturing or related process industry.
  • Process Controls Systems: Fluency in process controls systems.
  • Communication Skills: Excellent communication skills - verbal and written, ability to vary style to meet needs.
  • Personal Motivation: High level of personal motivation with a drive for ownership and accountability in performance of job responsibilities.
  • Teamwork: Ability to work effectively within a team environment with excellent interpersonal skills.
Benefits:
  • Medical, Dental, Vision Insurance: Comprehensive medical, dental, and vision insurance.
  • Life Insurance and Disability: Life insurance and disability benefits.
  • Grace Wellness Program: Access to the Grace Wellness Program.
  • 401(k) Company Match: 401(k) company match - dollar to dollar up to the first 6%.
  • Paid Vacation and Holidays: Paid vacation and holidays.
  • Parental Leave: Parental leave.
  • Tuition Reimbursement: Tuition reimbursement.
  • Company Donation Match Program: Company donation match program.