Senior Controls Engineer

Job Details

Job Location
:
Concord, NC

AC Controls (a Kele Company) is in search of a Senior Controls Engineer.

AC Controls has been providing superior products and services since 1960 for process and combustion applications, offering systems integration services, combustion & process control systems, and distribution of industrial instrumentation, controls, and valves to the process and power industries in the southeast.

We are currently hiring for the role of Senior Controls Engineer.

The Senior Controls Engineer defines the overall design solution and control strategy, developing the front-end concepts, developing control system architectures, producing control panel designs, and selecting instrumentation and control valves. This role contributes to the programming, startup, and commissioning of custom control systems that meet customer specifications and applicable safety codes. This position collaborates closely with other Controls Engineers, Project Managers, Panel Shop Technicians, and Service Technicians to deliver safe, reliable, and maintainable solutions.

System design and development:

• Translate PFDs and P&IDs into control architecture, panel layouts, network topology, and I/O allocation.
• Execute custom panel design and build support, including UL508A documentation as applicable.
• Select and specify instrumentation and final control elements, including pressure and temperature transmitters, flow meters, and control valves.
• Develop gas detection, heat trace, and wireless telemetry designs using approved platforms such as Honeywell, Raychem, and Elpro.

Programming and commissioning:

• Develop PLC, safety, and logic applications for BMS and combustion control using Honeywell HC900, Honeywell Control Edge, and Allen-Bradley platforms.
• Configure SCADA and HMI applications in ICONICS, Ignition, and Red Lion Crimson.
• Create control narratives, cause-and-effect matrices, I/O lists, alarm philosophy, and interlock logic for single burner boilers, retrofit firetube and water tube units, and single burner process heat systems.
• Implement control schemes such as single point jackshaft, parallel positioning with O2 trim, and fully metered cross-limited with O2 trim.
• Execute I/O checkout, loop tuning, FAT, SAT, startup, and site commissioning. Provide operator training and handover.

Field services and support:

• Provide remote and on-site troubleshooting, tuning, warranty support, and lifecycle improvements on delivered systems.

Quality, safety, and compliance:

• Apply combustion and functional safety best practices and relevant standards in design and programming.
• Maintain version control, change management, and as-built documentation.
• Prepare customer documentation, test procedures, and training materials.

Collaboration and business support:

• Coordinate with Project Managers on schedules, risks, and scope.
• Support proposals with concepts, estimates, and technical clarifications.
• Provide technical support to Panel Shop Technicians during control panel fabrication.
• Support Field Technicians during system installation and startup with troubleshooting assistance.
• Mentor junior engineers.

• Knowledge of burner management and combustion codes and practices such as NFPA 85 and NFPA 86, and functional safety concepts aligned to ISA 84 or IEC 61511.
• Expertise in electrical design standards (e.g., NEC, UL508A) for control panels and field wiring.
• Instrument specification and sizing for pressure, temperature, flow, and final control elements in natural gas and fuel oil services.
• Experience with oxygen trim, cross-limited metering, and air-fuel ratio tuning.
• Exposure to gas detection, heat trace systems, and industrial wireless systems.
• Ability to read and produce P&IDs, electrical schematics, and network diagrams.
• Strong troubleshooting skills for field startup and service.
• Experience with version control and deployment tools for automation projects.
• Hands-on experience with at least two of the following:
  Honeywell HC900, Honeywell Control Edge, Allen-Bradley Compact Logix or Control Logix.
• Experience with ICONICS, Ignition, and Red Lion Crimson.
• Proficiency in ladder logic…