Chief Engineer, Automation Customer Services

J ob 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.

• 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

• 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

• 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

• 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)

• 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

• 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)

• 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

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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