Control Systems Engineer – Boiler Automation and SCADA

The Junior Control Systems Engineer – Boiler Automation and SCADA supports the design, implementation, and troubleshooting of automation and control systems for boiler and steam generation equipment. This entry-level role involves programming support, PLC/HMI configuration, data logging, and assisting in the operation of SCADA systems used to monitor boilers, burners, feedwater systems, fuel handling, and combustion controls. The position is ideal for candidates interested in process automation, control logic, and industrial safety systems.

Key Responsibilities:

1. Support for Boiler Control Systems

• Assist in maintaining and troubleshooting PLC- and DCS-based boiler control systems.

• Monitor and tune control loops related to:

  • Combustion air/fuel ratio

  • Steam pressure regulation

  • Feedwater level control

  • Burner management systems (BMS)

2. SCADA and HMI Support

• Support day-to-day operation and configuration of SCADA systems used to monitor boiler room KPIs (e.g., temperature, pressure, alarms).

• Help update HMI screens for better usability and visualization.

• Assist in alarm management and event logging.

3. Instrumentation and I/O Testing

• Perform loop checks and signal verification for:

  • Pressure transmitters

  • Level sensors

  • Safety interlocks and flame sensors

• Assist maintenance during calibration and validation of control system inputs and outputs.

4. Data Collection and Reporting

• Extract control system data and generate trend charts or reports for boiler performance and energy usage.

• Monitor alarms, downtime events, and logging of boiler efficiency metrics.

5. Project and Startup Support

• Support senior engineers in commissioning new boiler systems, fuel skids, or upgraded control panels.

• Participate in FAT (Factory Acceptance Tests) and SAT (Site Acceptance Tests) with vendors.

6. Documentation and Compliance

• Maintain and update control logic documentation (ladder logic, function block diagrams).

• Assist in ensuring systems meet NFPA 85 (Boiler and Combustion Systems), ASME, and OSHA requirements related to control systems and safety.

Focus Areas:

• Control systems logic for boiler automation

• SCADA system support and troubleshooting

• Data logging, trend analysis, and alarm diagnostics

• Support of BMS, PLCs, and instrumentation loop integrity

• Boiler safety and regulatory compliance integration

Qualifications:

• Bachelor’s degree in Electrical Engineering, Instrumentation, Controls Engineering, or Mechatronics

• 0–2 years of experience (internships acceptable) in industrial automation or utilities control systems

• Familiarity with PLCs (Allen-Bradley, Siemens, Schneider, etc.) and HMI/SCADA platforms (Wonderware, Ignition, Rockwell FactoryTalk)

• Basic understanding of boiler operations and process control principles is a plus

Certifications (Preferred/Optional):

• OSHA 10-Hour General Industry Certification

• Basic SCADA/PLC programming course (Siemens, Rockwell, or equivalent)

• NFPA 85 awareness or combustion safety fundamentals certification (optional)

Key Skills:

• Strong analytical and troubleshooting ability

• Basic ladder logic programming and SCADA navigation skills

• Eager to learn industrial safety and control logic design

• Good documentation, communication, and teamwork skills

• Ability to interpret P&IDs, wiring diagrams, and loop sheets

Tools and Platforms Exposure:

• PLC Software (RSLogix, TIA Portal, etc.)

• SCADA platforms (Wonderware, Ignition, FactoryTalk View)

• AutoCAD, Microsoft Excel, and alarm/event reporting systems

• Control panels, sensors, actuators, and industrial networks (Ethernet/IP, Modbus)