Controls Engineer – Turbine Systems (PLC/DCS/Mark VIe)

The Mid-Level Controls Engineer is responsible for the design, development, commissioning, and troubleshooting of control systems for gas and steam turbines and their auxiliaries. This role involves hands-on work with PLCs, DCS, and OEM-specific platforms (GE Mark VIe, Siemens T3000, Allen-Bradley, etc.), ensuring reliable operation, regulatory compliance, and high availability of turbomachinery systems.

Key Responsibilities:

1. Control System Design & Programming

• Develop and configure turbine control systems using GE Mark VIe, PLC (Siemens, Allen-Bradley), and DCS platforms.

• Design logic for sequencing, permissive checks, interlocks, start/stop routines, trip handling, and HMI interfaces.

2. Project Engineering & Documentation

• Prepare control philosophies, logic narratives, cause & effect matrices, I/O lists, and control panel layouts.

• Develop functional specifications and collaborate with mechanical and process teams for system integration.

3. Field Support & Commissioning

• Lead or support on-site commissioning and start-up of turbine control systems and auxiliary subsystems.

• Perform loop checks, I/O testing, control logic validation, and tuning of PID loops.

4. Troubleshooting & Technical Support

• Analyze turbine alarms, trip logs, and HMI data to diagnose faults or performance issues.

• Provide technical support during maintenance shutdowns, outages, and emergency callouts.

5. System Integration

• Interface turbine controls with plant DCS, SCADA, or BOP systems.

• Ensure compatibility with other packages such as vibration monitoring (Bently Nevada), compressor antisurge, and Lube Oil systems.

6. Upgrades & Modifications

• Implement control system upgrades, patching, and logic revisions to improve reliability or efficiency.

• Manage retrofits or migrations from legacy systems to modern platforms (e.g., Mark V to Mark VIe).

7. Compliance & Safety

• Ensure all systems meet IEC, ISA, NFPA, and plant safety standards.

• Support SIL assessments, HAZOP reviews, and control logic validation processes.

Key Focus Areas:

• Control Platforms:

  • GE Mark VIe / ToolboxST

  • Siemens T3000 / S7 / TIA Portal

  • Allen-Bradley (RSLogix/Studio 5000)

  • Emerson DeltaV (if applicable)

• Turbomachinery Focus:

  • Gas turbines (GE Frame, Siemens SGT, Solar, etc.)

  • Steam turbines (industrial & utility scale)

  • Turbo-compressors, generators, expanders

• Auxiliary Systems:

  • Fuel gas systems, lube oil skids, seal gas, cooling systems

  • Bently Nevada vibration & condition monitoring systems

• Field Interfaces & Tools:

  • SCADA/HMI (GE Cimplicity, WinCC, InTouch)

  • Instrumentation calibration and loop tuning

  • I/O and network troubleshooting, fiber & ethernet diagnostics

• Standards & Protocols:

  • IEC 61131, ISA S88, SAMA, API 670, API 612/616

  • Modbus, Profibus, OPC, Ethernet/IP communication

Qualifications & Skills:

• Education: Bachelor’s Degree in Electrical, Electronics, Instrumentation, or Control Engineering

• Experience: 3–7 years in control systems engineering for turbines or heavy rotating equipment

• Certifications (Preferred):

  • OEM Training (GE Mark VIe, Siemens PCS 7, Rockwell)

  • Instrumentation & Safety (ISA, TÜV Functional Safety)

• Technical Strengths:

  • Solid understanding of turbine control logic and trip handling

  • Proficient in control logic development, HMI configuration, loop tuning

  • Troubleshooting of PLC/DCS systems in high-stakes environments

• Soft Skills:

  • Strong analytical thinking, documentation skills, and communication with multidisciplinary teams

  • Willingness to travel for field support, shutdowns, and commissioning