Chief Engineer, Automation Customer Services

Job Title: Automation Engineer – Site Commissioning (ECS / SCADA / PLC)

Role Overview

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

FLSmidth is the leading supplier of engineering, equipment and service solutions to customers in the mining and minerals industries – for more information please visit FLSmidth.com/careers

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