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Senior Controls Engineer

2 months ago


Cincinnati, Ohio, United States Zepnick Solutions, Inc. Full time
About the Role

We are seeking a highly skilled Senior Controls Engineer to join our team at Zepnick Solutions, Inc. As a key member of our engineering team, you will be responsible for designing, developing, and implementing control systems for our clients.

Key Responsibilities
  • Collaborate with clients, vendors, and cross-functional internal teams to determine process control needs and solutions.
  • Support project managers and process engineers in developing estimates for controls hardware and engineering effort.
  • Lead electrical designers in specifying controls hardware components and developing electrical wiring diagrams.
  • Lead the review of electrical installation documents for technical accuracy and ensure the design meets the controls requirements.
  • Write functional descriptions that describe how control systems will operate.
  • Develop and test PLC programs based on functional descriptions.
  • During commissioning, lead electrical designers in performing onsite IO checks.
  • During commissioning, support PLC program onsite until the system is in full production, performing maintenance and operator training.
  • Perform other related duties as assigned.
Requirements
  • Proficiency in Allen-Bradley PLC programming software (RS Logix, Studio 5000).
  • Ability to develop a PLC program from scratch or customize a program based on customer-specific templates.
  • Detailed understanding of process instrumentation (flow, mass flow, temperature, pressure) and control loop concepts.
  • Proficient in batch controls, recipe management, and CIP circuits.
  • Proficient at designing, programming, and configuring variable frequency drive systems, specifically Rockwell hardware.
  • Proficiency in interpreting P&ID drawings.
  • Experience with liquid processing, including pumps, blending, filtration, heat transfer, etc.
  • Experience with utility (steam, water, air, NH3, etc.) design and impacts on process design.
  • Ability to perform in a design team environment.
  • Experience working with multi-trade-based vendors/contractors.
  • Experience in plant operations and industrial environments, understanding control system impacts to maintenance and other work processes.
  • Proficiency in Microsoft Office Suite (Outlook, Excel, Word, Project, etc.).
  • Technical writing expertise.
  • Leadership skills. Good verbal and written communication skills.
  • Attentiveness to detail, follow-up procedures, and documentation of action.
  • Proficient in time management and personal organization.
Qualifications
  • Bachelor's degree in electrical engineering.
  • 8 years of process controls experience in the pulp and paper or food and beverage industries.
  • Experience programming legal PLCs and familiarity with USDA requirements for pasteurizers.
  • Proficiency in Wonderware InTouch, Wonderware Archestra, and FactoryTalk HMI development.
  • Experience with Honeywell Experion DCS systems.
  • Experience designing controls system networks using Ethernet.
  • Experience in food and beverage manufacturing.
  • Experience in 'green field' food plant construction projects.
  • Knowledge of safety control systems.
  • Experience as a control engineering lead for large capital projects.
Work Environment
  • 60-75% standard office setting.
  • 25-40% shop and manufacturing facility.
Physical Demands
  • Sufficient mobility to work in an office setting.
  • Ability to stand or sit for prolonged periods of time.
  • Must have ability to walk long distances and possess the flexibility to maneuver in and around machinery to take measurements.
  • When on customer startups, must be able to travel long distances by car or plane and have the stamina to work extended hours (12+ hours per day) for up to 14 continuous days.