Process Controls Engineer Job Houston area,Texas USA,Engineering

Job Summary

The Process Controls Engineer will provide operations, maintenance, and project team support. They will interact with various functional groups to implement new process control technology and equipment, evaluate and resolve problems with existing process control systems (using maintenance and/or third‑party consultant support as needed), ensure the control systems are properly deployed to best meet operations and maintenance requirements, participate in developing cybersecurity protocol for the controls network, and aid in managing the power distribution system.

Reports directly to the Technical Director.

Typical Duties and Responsibilities

2.1 Determine, select, and specify instrumentation and controls required to monitor, operate, and control mechanical, process, and electrical systems.
2.2 Provide input to develop P&IDs, specifically the development and optimization of control strategies.
2.3 Document and maintain control narratives (sequence of operations) and work with outside consultants for logic and HMI screen development.
2.4 Configure and maintain SCADA/HMI systems for operator interface.
2.5 During projects, assist with coordinating the development of control logic, HMI applications, and system configuration between operations and control system suppliers. Participate in factory checkout of equipment prior to delivery and witness loop checks in the field prior to final acceptance.
2.6 Prepare documentation and train operations and maintenance staff on control system operation.
2.7 Work closely with maintenance and operations to troubleshoot and resolve issues in the control system, instrumentation, PLC logic, or HMI display.
2.8 Manage and direct consultants during control‑related projects or jobs.
2.9 Maintain data historian server with the help of outside consultants as needed.
2.10 Support inventory of control system assets.
2.11 Identify patching strategies for OT systems (balancing uptime, cost, and risk).
2.12 Support system monitoring for anomalies and unauthorized access.
2.13 Identify control system vulnerabilities and remediations.
2.14 Maintain awareness of emerging threats to industrial systems.
2.15 Work with outside consultants and others as designed to develop scope and design of electrical power projects.
2.16 Other related duties as assigned.

Knowledge, Skills, and Abilities

3.1 Practical knowledge of instrumentation and controls to be able to oversee the work of a third‑party consultant in design and programming.
3.2 Ability to understand and troubleshoot ladder logic, loop diagrams, and control wiring diagrams.
3.3 Knowledge of field instrumentation including analyzers, flow meters, and control valves.
3.4 Understanding of instrument calibration principles and troubleshooting instrument failures.
3.5 Understanding signal types.
3.6 Knowledge of HMI design and usability optimization.
3.7 Knowledge of alarm management and performance tuning.
3.8 Ability to translate process requirements into control logic.
3.9 Ability to analyze trends and large datasets.
3.10 Understanding of root cause analysis and reliability improvement methods.
3.11 Strong communication skills and the ability to work with different groups including maintenance, operations, project engineering, and consultants.
3.12 Ability to assist electricians in troubleshooting electrical circuits in the field.
3.13 Other related duties as assigned.

Environmental Conditions

4.1 Work is performed indoors and outdoors with some exposure to extreme heat (100°F) and cold (32°F).
4.2 Work may involve exposure to potential noise, mechanical, electrical, explosive, fume/odor, dust/mite, chemical, toxic waste hazards with proper precautionary procedures.
4.3 Safety requirements include the ability to wear all PPE including full face respirator and supplied air.
4.4 Must be able to work in an industrial environment on‑site at GCA and customer facilities as needed.

Education, Certification, and Experience Required

5.1 Bachelor of Science in Electrical Engineering, Electronics Engineering, Instrumentation and Controls Engineering, or similar.
5.2 At least 5 years of experience in related engineering experience, including work in the field.
5.3…