The Senior Control Systems Engineer – Boiler Automation and SCADA leads the design, integration, maintenance, and optimization of advanced control systems for boilers, steam generation, pressure vessels, and auxiliary utility systems. This role oversees PLC/DCS logic development, SCADA system configuration, alarm management, and regulatory compliance with NFPA 85, OSHA 1910, and ASME Boiler & Pressure Vessel Code. The engineer collaborates cross-functionally to drive reliability, energy efficiency, and safety in steam and utility operations across plant sites.
Architect and implement control strategies for:
Combustion control systems
Burner management systems (BMS)
Feedwater regulation
Steam pressure and thermal load balancing
Design and modify advanced control logic in PLC/DCS platforms (e.g., Rockwell/Allen-Bradley, Siemens, Emerson DeltaV).
Oversee SCADA system architecture (e.g., Ignition, Wonderware, FactoryTalk) for real-time boiler and steam system monitoring.
Develop and optimize HMI interfaces for usability, visibility, and alarm prioritization.
Lead historian and trending system setup for diagnostics and regulatory data retention.
Conduct control loop performance analysis and PID tuning for efficiency, responsiveness, and emissions control.
Apply analytics to reduce unplanned shutdowns, enhance steam demand control, and minimize energy waste.
Introduce digital tools (dashboards, predictive alerts, IIoT integration) to enhance reliability.
Ensure automation systems meet regulatory and code requirements, including:
NFPA 85 (Boiler and Combustion Hazards)
OSHA 1910 (Lockout/Tagout, Process Safety)
ASME BPVC Sections I, IV, VIII
Lead system validation, functional testing, and documentation required for compliance audits and insurance inspections.
Specify and integrate instrumentation for temperature, pressure, level, and flow control in high-pressure steam systems.
Support I/O checkout, FAT/SAT, and commissioning for new boiler plants and upgrades.
Train maintenance and operations staff in system operation, fault diagnosis, and interlock testing.
Lead automation aspects of capital projects involving boiler system upgrades, fuel skids, deaerators, and steam header expansions.
Manage controls contractors, integrators, and OEMs from design through commissioning.
Develop technical specifications for procurement and support cost estimation for automation scopes.
Maintain comprehensive technical documentation:
Control logic diagrams, loop sheets, interlock matrices
Alarm & event logs, cause/effect charts
Change management records and functional design specifications
Lead knowledge transfer through training sessions, SOPs, and mentoring junior engineers.
Advanced boiler and steam automation
PLC, SCADA, DCS programming and diagnostics
PID control tuning and combustion efficiency
Regulatory compliance (NFPA, OSHA, ASME)
Burner safety and interlock systems
Utilities control strategy optimization
Bachelor’s or Master’s degree in Electrical, Controls, Instrumentation, or Mechanical Engineering
7+ years of hands-on experience in control systems engineering for utility operations or process plants
Strong experience with PLC/HMI programming, SCADA architecture, and instrument integration
In-depth knowledge of boiler operations, burner management systems, and thermal utilities
Certified Automation Professional (CAP) or equivalent
OSHA 30-Hour General Industry Certification
NFPA 85 Combustion Safety Training
ISA/IEC 61511 (SIS – Safety Instrumented Systems) knowledge or certification
First Aid, Confined Space, and Lockout/Tagout certifications
Expert-level PLC/DCS programming (Rockwell, Siemens, DeltaV, etc.)
SCADA system design, deployment, and optimization
High-level troubleshooting, alarm analysis, and system restoration
Strong leadership, vendor management, and cross-functional collaboration
Fluent in P&ID interpretation, loop checks, and combustion control diagrams