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
- 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
- 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
- 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
- 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)
- 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
- 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)
- 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
- Strong 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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