Chief Engineer, Automation Customer Services

The Automation Engineer (Site Commissioning) is responsible foron-site commissioning, testing, troubleshooting, and stabilizationof automation systems includingFLS ECS, SCADA, and PLC platforms (Rockwell, Siemens, ABB).

This role is highly hands-on and requires working inlive plant environmentsto ensuresafe startup, reliable operation, and performance optimizationof process units.

Key Responsibilities

1. Site Commissioning & Startup

• Executecold commissioning: 

• I/O loop checking 

• Instrument calibration validation 

• Signal verification from field to PLC/SCADA 

• Performhot commissioning: 

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

• Interlock validation and permissive checks 

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

• Supportfirst material flowand 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 plantbehaviour

3. SCADA / ECS Commissioning

• Configure and validate SCADA systems: 

• FLS ECS / ECSControl 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) 

• Supportedge 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 

• Supporthandover to operations teamwith 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