Chief Engineer, Automation Customer Services

The Automation Engineer (Site Commissioning) is responsible for on-site commissioning, testing, troubleshooting, and stabilization of automation systems including FLS ECS, SCADA, and PLC platforms (Rockwell, Siemens, ABB).

This role is highly hands-on and requires working in live plant environments to ensure safe startup, reliable operation, and performance optimization of process units.

Key Responsibilities

1. Site Commissioning & Startup

• Execute cold commissioning:

• I/O loop checking

• Instrument calibration validation

• Signal verification from field to PLC/SCADA

• Perform hot commissioning:

• Equipment-wise startup (motors, drives, feeders, screens, mills)

• Interlock validation and permissive checks

• Commission FLS ECS (Expert Control System) and integrate with plant PLCs

• Support first material flow and ramp-up to design capacity

2. PLC & Control Logic Execution (On-Site)

• Download, test, and modify PLC programs:

• Rockwell (ControlLogix / CompactLogix)

• Siemens (S7 / TIA Portal)

• ABB (AC800M / 800xA)

• Debug real-time issues:

• Incorrect interlocks

• Sequence failures

• Timing issues

• Fine-tune control logic based on actual plant behaviour

3. SCADA / ECS Commissioning

• Configure and validate SCADA systems:

• FLS ECS / ECS Control enter

• WinCC / FactoryTalk / ABB 800xA

• Test:

• Graphics and operator screens

• Alarm systems and priorities

• Trends and data logging

• Ensure operator usability during live operation

4. Field Troubleshooting

• Diagnose and resolve:

• Instrument issues (level, pressure, flow, vibration)

• Signal noise / incorrect readings

• Communication failures:

• Modbus, Profibus, Profinet, Ethernet/IP

• Coordinate with:

• Electrical team (MCC, drives)

• Mechanical team (equipment readiness)

• Process team (operating conditions)

5. Process Stabilization & Optimization

• Tune control loops (PID tuning under real load)

• Optimize sequences for:

• Smooth startup/shutdown

• Reduced trips and false alarms

• Implement ECS logic improvements:

• Expert rules

• Interlock refinement

6. Integration & Communication

• Ensure seamless communication between:

• PLC ↔ SCADA ↔ ECS

• PLC ↔ Drives / Field devices

• Configure and troubleshoot:

• OPC communication

• Network architecture (industrial Ethernet)

• Support edge device integration (if CMS / analytics deployed)

7. Documentation & Handover

• Update:

• As-built logic

• I/O lists

• Interlock documents

• Prepare commissioning reports:

• Test results

• Issue logs

• Modifications done

• Support handover to operations team with training

Required Skills

Core Field Skills

• Strong hands-on experience in:

• Loop checking

• Commissioning sequences

• Live troubleshooting

• Ability to read:

• P&IDs

• Wiring diagrams

• Control logic

Automation Skills

• PLC programming & debugging:

• Ladder, FBD, basic Structured Text

• SCADA/ECS configuration and testing

• Strong understanding of:

• Interlocks

• Permissives

• Trip logic

Industrial Communication

• Hands-on troubleshooting:

• Modbus TCP/IP

• Profibus / Profinet

• Ethernet/IP

• Basic network diagnostics

Domain Knowledge (Highly Preferred)

• Mining / Mineral processing plants

• Equipment like:

• Crushers, mills, flotation cells, vibrating screens, thickeners ,Rotary Kilns, Filter Press,

• Understanding of real plant problems:

• Choking, overload, vibration, wear

Soft Skills (Critical for Site Role)

• Ability to work under pressure during startup

• Quick decision-making in plant conditions

• Strong coordination with multiple teams

• Willingness for:

• Travel

• Shift work

• Shutdown work

Experience

• 5–12 years in commissioning / site roles

• Experience in EPC / OEM commissioning preferred

Typical Work Conditions

• On-site (plant environment)

• Long commissioning hours during startup

• Exposure to dust, noise, and industrial conditions

KPIs / Success Metrics

• Successful startup without major delays

• Number of issues resolved during commissioning

• Time to stabilize plant operation

• Reduction in trips and alarms / Smooth handover to operations