Electrical Controls Engineer

Description

• POSITION SUMMARY
• Design complex industrial control systems for plasma welders, plasma melters, induction vacuum casters, electron beam melters, and vacuum arc re-melters, as well as associated material handling equipment.
• Create electrical schematics, program PLCs and HMIs as well as installation, testing, and troubleshooting of industrial control systems.
• Lead teams of designer/drafters on multiple projects simultaneously.
• Provide training on the use of large capital equipment projects mainly in the specialty metals industry. This may require extensive domestic or international travel.

• Responsible for designing and/or approving, in detail, all final control system designs, design changes, specifications, and drawing releases while ensuring their compliance with engineering principles, company standards, customer contract requirements, and related specifications.
• Develop PLC code and HMI screens/code for complex industrial control systems.
• Direct and perform equipment commissioning, startup, and testing activities both at the factory and at the end user’s installation site. Equipment commissioning ensures conformance to project specifications and requires familiarity with all aspects of machine performance including mechanical, electrical and process performance characteristics.
• Conduct internal and external design reviews to project requirements and incorporate input from customers, vendors, engineering colleagues, designers, and operations personnel.
• Generate test procedures, equipment and software design specifications, field reports, operating/maintenance manuals, reports, proposals, and other documentation that may be distributed to customers or internal.
• Provides updates on the status of project milestones and adjusts schedules accordingly.

• Knowledge of three-phase power systems and motor controls.
• Design PLC control systems architectures and networks, I/O module selections.
• Knowledge of and experience with P&IDs, hydraulics and vacuum systems, and electrical standards (including CE and UL marking).
• Must be able to specify and size motors, drives, circuit protective devices, wire, and power supplies.
• Familiar with process control instrumentation such as vacuum/pressure, temperature, and flow.
• Proficient with PLC programming in Ladder Logic, Function Block and Structured Text language techniques as well as program and tune PI and PID closed loop controls.
• Familiar with common industrial networks and protocols such as Ether Net/IP, CIP, and IO Link.
• Adhere to the codes and principles of NFPA 79, UL508A and the NEC.
• Familiar with Wonderware (InTouch or System Platform) HMI software.
• Ability to interpret and produce NFPA format electrical drawings (Solidworks Electrical or AutoCAD Electrical experience a plus).
• A highly organized approach to system design, programming, and documentation.
• Ability to develop project plans, maintain project schedules, and adhere to budgets.
• Working knowledge of Vacuum Metallurgy, Plasma Welders & Melters, Electron Beam Melters, and Vacuum Arc Re-melters preferred.
• Familiar using Visual Studio (VB6) and the .Net platform with C# or VB programming languages a plus.
• Familiar with standard meters and test equipment.
• Familiar with PC hardware, software installation, and the ability to troubleshoot software and hardware issues.

• Bachelor’s degree in electrical engineering, electrical engineering technologies, mechatronics engineering, or related degree.
• Minimum of 3 years’ experience working as an Electrical Engineer, Controls Engineer, Project Engineer, or similar, preferably designing industrial control systems for high temperature furnaces, heavy material handling equipment, or other capital equipment.
• Minimum of 2 years’ experience programming with RSLogix 5000, Studio 5000 programming software or similar (Siemens S7 a plus).
• Minimum of 1 year experience programming with Wonderware, Ignition HMI or similar.
• Extensive experience developing, verifying, and validating complex control system and Safety interlocks.
• Experience with Solidworks Electrical, AutoCAD Electrical, or similar.
• Experience with VFD and…