Company:
INEOS Olefins & Polymers USA

PLC Engineer

Grade

33-35, DOQ $125,041-$156,301

Location

Battleground Manufacturing Complex

1230 Battleground Rd., La Porte, TX

Organizational context and job purpose

The O&P USA business includes the product lines Ethylene, propylene, butadiene, polypropylene and High density polyethylene. Manufacturing sites include Chocolate Bayou Works (Alvin, TX), Battleground Manufacturing Complex (LA Porte, TX), and Carson, (Carson, CA), with a division office in League City, TX.

INEOS Olefins and Polymers USA includes the Battleground Manufacturing Complex (BMC) Polyethylene and Polypropylene units in La Porte, TX, the Chocolate Bayou Plant (CBW) south of Alvin, TX, which manufactures Olefins and Polypropylene, the Carson, Ca. Polypropylene manufacturing plant and the Hobbs, NM gas plant.

The PLC Engineer (Programmable Logic Controller) is a member of the I/E Reliability organization at BMC and reports to the IEA Unit Reliability Team Lead. The position serves as the reliability-side system owner for all BMC PLC systems, including general-purpose and safety PLCs, providing technical accountability for system integrity, complex troubleshooting, reliability improvement, and lifecycle management. The position is accountable for understanding and putting into practice the INEOS 20 Principles.

The position’s system scope includes:

General-purpose PLCs and safety PLCs, including PLC-based SIS logic solvers.
PLC hardware, application software, and associated input/output systems.
PLC-associated computers and human-machine interfaces (HMIs).
PLC communications and associated network interfaces, in coordination with responsible OT and cybersecurity personnel.
Equipment-monitoring devices integrated with PLC systems.
Associated programmable devices, including remote terminal units (RTUs) and programmable relays.
PLC-based SIS: The PLC Engineer owns platform reliability and lifecycle management; the SIS Engineer retains technical accountability for safety-function requirements and safety application logic.

This position works closely with unit I/E engineers and technicians, Operations, the Capital Projects PLC engineering counterpart, and the responsible OT and cybersecurity specialists. The PLC Engineer provides specialist support, leads detailed troubleshooting of complex or recurring system issues, and trains and mentors unit I/E personnel.

The position owns the PLC lifecycle and replacement plan, executes designated lean projects, and prepares CAPEX justifications, scopes, and charters. As Reliability’s PLC subject matter expert and asset-owner representative, the position defines requirements and acceptance criteria, challenges solutions, and reviews deliverables for technical soundness, reliability, maintainability, and supportability. Capital Projects develops and executes the defined solutions; the PLC Engineer identifies deficiencies and provides the technical recommendation for acceptance and turnover.

The PLC Engineer provides support for unit I&E engineering activities and troubleshooting efforts as needed or as assigned, assisting operating units in resolving critical instrumentation, electrical, and control system issues to support safe and reliable plant operations.

Responsibilities AND Accountabilities

The PLC Engineer leads reliability stewardship and lifecycle management of existing and newly installed PLC systems within the assigned scope. The position provides detailed troubleshooting, technical review, and reliability assurance for system hardware, software, and interfaces. For capital projects, the position provides asset-owner requirements and technical review in coordination with the Capital Projects PLC engineering counterpart, including reliability, maintainability, testing, turnover documentation, and maintenance requirements. The position contributes to applicable technical practices and training through established governance processes.

Further responsibilities & Accountabilities

Effective performance in this role is critical to the efficient operation of the manufacturing sites.
Provide unit I&E reliability and maintenance support as assigned, assisting with troubleshooting, root cause investigations, equipment reliability improvements, and resolution of instrumentation, control valves, electrical, and control system issues.
Demonstrate a strong understanding of the Management of Change (MOC) process and be capable of leading, developing, and managing MOCs related to PLC, control system, instrumentation, and electrical modifications.
Provide technical accountability for the reliability of site PLC platforms, including general-purpose PLCs and safety PLC hardware. Coordinate with the SIS Engineer on issues affecting safety-function requirements or application logic.
Lead detailed troubleshooting of complex, recurring, or significant PLC failures involving hardware, communications, field-system interfaces, and application logic within the assigned scope. Coordinate unit I/E, Operations, OT, vendors, and other specialists; develop corrective actions and verify their effectiveness. Unit I/E retains routine troubleshooting and maintenance responsibility.
Serve as the owner of the site PLC system lifecycle, assessing system condition and recommending appropriate maintenance, upgrade, migration, and replacement strategies.
Maintain technical oversight of PLC hardware and software inventories, configuration records, application backups, recovery readiness, and supporting documentation.
Support, train, and mentor unit technicians to troubleshoot, reprogram, and maintain all PLC systems
Provide asset-owner technical review of engineering packages involving PLC hardware or software changes, including reliability, maintainability, field integration, testing, and turnover requirements.
Stay abreast of current technology and strive to improve BMC’s General PLC systems
Support IEA Superintendent, I&E Team Leaders to identify and develop training to enhance and maintain I&E personnel PLC competencies

skills & Competencies and experience

Education and Experience:

Bachelor’s degree in Automation, Electrical Engineering, Chemical Engineering, Computer Engineering or related fields required. Associate degree is not sufficient
Experience in, and a strong desire to develop, E/I reliability capabilities within a plant operating environment.
A minimum of 3 years of experience working with Programmable Logic Controller or other Automation equipment including engineering of said systems.
Hands-on experience supporting PLCs such as Rockwell, Emerson, Triconex, HIMA, GE, or Siemens.
Familiarity with networked systems and remote access of PLCs.

Skills and Competencies:

Strong engineering background, with focus on automation and logic controllers
Strong instrument, control valve and control system reliability and maintenance background
Plant level experience and understanding of P&IDs, instrument loop drawings, logic controller terminology, and Industry Standards (ANSI, NFPA, ISA, IEC, API, etc.) that influence PLC functionality and configurations
Demonstrated ability to lead complex PLC troubleshooting and root cause investigations involving field devices, logic, interlocks, communications, and control-system interfaces.
Demonstrated ability to develop PLC lifecycle, obsolescence, maintenance, migration, and replacement strategies that address reliability, maintainability, supportability, and asset risk.
Ability to provide asset-owner technical assurance for PLC modifications and projects, develop technical justification and project charters, and coordinate technical reviews with Capital Projects.
Ability to perform assigned unit I/E reliability engineering duties and coordinate specialist support as needed.
Experience executing lean projects and developing scope and asset-owner requirements for turnover to Capital Projects, observing site procedures and protocols.
Experience working with multiple engineering disciplines, as well as contractors supporting delivery of PLC programming/hardware and PSM Initiatives.
Must be a self-starter and capable of working on an individual basis and in a team environment.
Strong organizational skills and ability to prioritize work and deliver quality results on time.
Ability to train, coach, and mentor maintenance technicians and junior level technical staff preferred.
Strong oral and written communication skills
Strong leadership skills, including ability to lead and motivate individuals or teams
Proven ability to influence and manage change.
Demonstrated ability to build positive relationships with plant personnel supporting PLC optimization: Operations, Maintenance, Technology, and Capital Projects teams.
Demonstrated problem solving and troubleshooting skills.
Self-Motivated individual who takes initiative to get results and seeks opportunities for additional responsibility.

Interested internal candidates should submit their resume and/or profile + last 2 performance appraisals to the Hiring Manager (Supervisor) and HR Contact via e-mail. Department Manager approval is required prior to applying for position.

Ineos Americas Llc

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