Advanced Process Control Engineer - Irving TX

Job Summary

The Advanced Process Control (APC) Engineer role is based out of the Irving, Texas office. Their primary responsibility is for the design, implementation, and maintenance of advanced process control strategies (MPC) and AI-driven models to optimize manufacturing performance, yield, and energy efficiency for a fleet of Air Separation Units (ASU). Additionally, this role maintains responsibility for PLC programming, HMI development, and troubleshooting to ensure reliable, high-level automation functionality.

Essential Functions

Lead the design, develop, implement, and maintain Model Predictive Control (MPC) and AI-based empirical models to optimize process variables and reduce variability.

Apply AI and machine learning techniques (e.g., reinforcement learning, neural networks) to process data for predictive analytics, digital twins, and autonomous control adjustments.

Lead commissioning work with operations and instrumentation engineers to commission and tune AI/APC applications on-site, ensuring seamless integration with the existing DCS.

Continuously analyze system data to identify bottlenecks, meet production targets, reduce energy consumption, and increase throughput, yield, and profitability.

PLC Coding:
Develop and troubleshoot PLC programs (Ladder Logic, Structured Text) on Control Logix or Siemens platforms to support new or existing machinery.

HMI/SCADA:
Configure and maintain HMI screens (Factory Talk View, Wonderware) to ensure effective operator interfaces.

System Integration:
Integrate APC/AI software layers with underlying PLCs to ensure seamless communication (Ethernet/IP, OPC UA).

Maintenance & Troubleshooting:
Perform on-site troubleshooting of PLC faults, field instruments, and motor drives.

Data:
Global Historian, standardize trending, KPI development & data visualization with Power BI

Documentation:
Maintain up-to-date control narratives, P&IDs, electrical schematics, and functional specifications.

Provide technical training and documentation to ensure high APC uptime and proper response to system constraints.

Utilize process simulation tools (e.g., Aspen HYSYS) to validate control models against actual plant data

Identify opportunities to modernize legacy control systems and integrate "smart" automation features into our standard operating procedures.

Follow all aspects of change management (P&IDs, EMOC, etc.)

Required for All Jobs

Performs other duties as assigned

Complies with all policies and standards

QUALIFICATIONS

Education

Bachelor's Degree in Electrical, Chemical or Mechanical Engineering Preferred

Work Experience

5+ years Proven experience in PLC/HMI programming with a deep understanding of control loop tuning is Required

5+ years Proficiency in APC platforms such as Aspen Tech (DMC), Honeywell (RMPCT), or Yokogawa (PACE) is Preferred

5+ years

Experience with air separation units, including compressors, turbo machinery and distillation columns is Preferred

Knowledge,

Skills and Abilities

Highly analytical with strong problem-solving skills and the ability to work in fast-paced, multi-project environments.

Proficiency in APC platforms such as Aspen Tech (DMC), Honeywell (RMPCT), or Yokogawa (PACE)

Deep understanding of DCS (e.g., Siemens WinCC, Simatic HMIs, Inductive Automation, Ignition, etc) and PLC (Siemens Simatic S7, Allen-Bradley, etc) systems.

Proficiency in programming such as ladder logic, structured text, Python, R, SQL or VB scripting.

Experience with industrial robotics or vision systems.

Background in continuous or batch manufacturing environments.

Strong background in control theory, data analytics & artificial intelligence

Ability to read, interpret and modify PLC wiring diagrams, Control Narratives and P&.

Advanced knowledge of all Microsoft Tools such as Word, Excel, PowerPoint, Outlook, Project and Power BI

Excellent interpersonal and communication skills.

Strong technical and analytical proficiency with the ability to multi-task effectively and thrive in a team environment.

Familiarity with ASU-specific equipment like turbo-expanders, cryogenic pumps, and adsorption pretreatment units.

Knowledge of cybersecurity standards for industrial control systems.

Licenses and Certifications

EIT Certification is Preferred

PHYSICAL DEMANDS/WORKING CONDITIONS

Working Condition:

This role will be performed primarily in an office environment, requiring extensive daily usage of a computer, and other office equipment.

Working Condition:

This role supports 24/7 operations and requires occasional night and/or weekend remote support.

Working Condition:

Field Coverage will potentially occur wherever Matheson has a facility, and during any season.

Physical Demands:
Occasionally lift and/or move objects up to 50 pounds.

Physical Demands:
Specific vision abilities required include close vision, distance vision, depth perceptions, and the ability to adjust focus.

Working Condition:

This role will be performed in office environments as well as in industrial field environments. While performing duties of this job it would…