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

- Solid 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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📌 Chief Engineer, Automation Customer Services (Chennai)
🏢 Flsmidth
📍 Chennai