Control Systems Engineer – Boiler Automation and SCADA

The Mid-Level Control Systems Engineer – Boiler Automation and SCADA is responsible for the development, maintenance, and troubleshooting of PLC-, HMI-, and SCADA-based automation systems used in the operation of boilers, steam systems, and auxiliary utility equipment. This role involves programming, control loop optimization, system upgrades, instrumentation integration, and ensuring regulatory compliance with NFPA 85, ASME, and OSHA standards. The engineer acts as a technical resource for plant operations and maintenance teams, contributing to safety, reliability, and energy efficiency.

Key Responsibilities:

1. System Design, Programming & Configuration

• Design, develop, and modify control logic for:

  • Combustion control systems (fuel/air ratio, flame safeguards)

  • Boiler interlock safety systems

  • Feedwater and condensate return systems

  • Steam pressure and temperature regulation

• Program PLCs (Allen-Bradley, Siemens, etc.), HMIs, and SCADA systems (Ignition, Wonderware, FactoryTalk).

2. SCADA Systems Management

• Configure SCADA tags, trends, and alarms to monitor critical boiler and utility system performance.

• Improve operator interface usability and real-time diagnostics.

• Maintain historical data logs, alarm reports, and system uptime records.

3. Control Loop Optimization

• Tune PID loops for combustion, pressure, and level control to improve boiler efficiency and responsiveness.

• Analyze control performance using trend data and recommend improvements.

4. Instrumentation Integration

• Support specification, installation, and calibration of field devices including:

  • Temperature, pressure, and flow transmitters

  • Level sensors, actuators, and control valves

  • Safety shutdown instrumentation (flame sensors, pressure switches)

5. Troubleshooting & Root Cause Analysis

• Diagnose control system faults, instrumentation failures, or logic issues that affect steam and boiler operations.

• Perform root cause analysis (RCA) on automation-related process upsets or equipment failures.

6. Compliance & Safety Integration

• Ensure boiler automation systems are in compliance with:

  • NFPA 85 – Combustion control and interlock safety

  • OSHA 1910 – Process safety, lockout/tagout, confined space

  • ASME Boiler & Pressure Vessel Code requirements for control systems

• Maintain documentation and validation of all safety interlocks and system testing procedures.

7. Cross-Functional Collaboration

• Work closely with:

  • Operations and utility staff for system tuning and troubleshooting

  • Maintenance teams for controls maintenance and device calibration

  • EH&S and compliance teams for audits, code updates, and safety reviews

Focus Areas:

• Boiler/steam system automation

• PLC/HMI/SCADA development and maintenance

• PID control tuning and performance optimization

• Alarm and event management

• Combustion control safety and compliance with NFPA/OSHA/ASME

Qualifications:

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

• 3–6 years of experience in industrial control systems, preferably with steam/boiler systems

• Proficient in PLC programming (Rockwell, Siemens, Schneider)

• Experienced with SCADA platforms (Ignition, Wonderware, FactoryTalk, etc.)

• Familiar with combustion systems, burner management, and flame safety principles

Certifications (Preferred):

• OSHA 30-Hour General Industry

• NFPA 85 Awareness or Combustion Safety Certification

• Certified Automation Professional (CAP) or similar

• Lockout/Tagout (LOTO) and Confined Space Safety certifications

Key Skills:

• PLC/HMI logic development

• Process instrumentation knowledge

• Technical troubleshooting and RCA

• Steam system operations understanding

• Clear technical communication and documentation