Senior Controls Engineer

AC Technical Services (a Kele Company) is a system integrator delivering integrated systems, engineered solutions, and field services to the process control industry, specializing in combustion applications. We design, program, and support Burner Management Systems (BMS), Combustion Control Systems for boilers and process heat, and related SCADA, HMI, gas detection, heat trace, and industrial wireless systems. Our typical systems include BMS and combustion control for boiler, oven, dryer, and liquid heat applications.

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.

ESSENTIAL DUTIES AND RESPONSIBILITIES

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 ControlEdge, , 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 watertube 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 install and startup with troubleshooting assistance.

· Mentor junior engineers.

KNOWLEDGE, SKILLS AND ABILITIES

· 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 ControlEdge, Allen-Bradley CompactLogix or ControlLogix.

· Experience with ICONICS, Ignition, and Red Lion Crimson.

· Proficiency in ladder logic and at least one of the following: function block or structured text.

· Demonstrated experience commissioning combustion or high-temperature process systems, including interlocks, permissives, purge, light-off, and flame supervision.

· Solid documentation habits, including revision control and test records.

· Willingness to travel for FAT, SAT, startup, training, and service as needed.

EDUCATION/TRAINING

· Two-year (2) degree in a related technical field or related work experience.

· Mechanical or Electrical Engineering degree preferred.

· Minimum seven (7) years related work experience desired.

LANGUAGE SKILLS

Ability to read, analyze, and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to write reports, business correspondence, and

procedure manuals. Ability to effectively present information and respond to questions from groups of managers, clients, customers, and the general public.

MATHEMATICAL SKILLS

Ability to work with mathematical concepts such as probability and statistical inference, and fundamentals of plane and solid geometry and trigonometry. Ability to apply concepts such as fractions, percentages, ratios, and proportions to practical situations.

REASONING ABILITY

Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists. Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.

PHYSICAL DEMANDS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Must be able to lift up to 50 pounds. Lengthy amounts of time standing, walking, bending, and using balance. Transporting of items such as a laptop computer; driving an automobile, etc.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. This is primarily an office-based position, with moderate noise. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

This job frequently operates in a professional office environment. This role routinely uses standard office equipment such as computers, phones, photocopiers, filing cabinets and fax machines. Employee is also regularly exposed to different environments while visiting warehouse or customer sites. May frequently be exposed to outside weather conditions as well as sufficient noise, either constant or intermittent, to cause marked distraction. Frequently exposed to airborne particles and moving mechanical parts. May occasionally be required to wear personal protective equipment such as a hardhat or eyewear. Employee could be exposed to hazardous materials at various job sites.