Job Purpose:
The I&C Site Commissioning Engineer will be responsible for overseeing the on-site implementation and performance of control systems, ensuring that installation and functionality aligns with the engineering design. The core of the role involves leading the Commissioning phase, performing loop checks, and troubleshooting communication networks and automation software to ensure a seamless handover to operations.
Key Responsibilities
- On-Site Design Validation: Review and interpret engineering documentation (P&IDs, Loop Drawings, Wiring Diagrams). Verify that physical installation aligns with the design and manage field modifications (Redlines).
- Commissioning management: Lead the I&C commissioning phase, from cold loop checks to hot commissioning and system handover. Coordinate with the engineering office to ensure functional logic matches process requirements.
- Signal & Loop Diagnostics: Perform end-to-end verification of control loops. Identify and resolve issues related to signal integrity, electrical noise, or incorrect wiring.
- Motorized Actuator Setup: Execute the commissioning of motorized valves and actuators (e.g., Rotork, Bernard, Auma). Responsible for setting mechanical end-limits, configuring torque switches, and verifying both hardwired and bus-based feedback to the PLC.
- System Integration: Download PLC/HMI projects provided by the engineering office, configure hardware parameters, and establish communication between different platform nodes.
- Fault Detection & Troubleshooting: Act as the primary point of contact for technical discrepancies on-site, providing local solutions or technical reports to the home office.
Technical Requirements
- Instrumentation & Field Sensors:
- Expertise in 4-20mA analog signals and discrete I/O diagnostics.
- Advanced use of HART protocol for instrument configuration, calibration, and range adjustment (using Emerson 475/AMS or similar).
- Proficiency with diagnostic tools: Multimeters, signal calibrators, and loop simulators.
- Motorized Actuators: Practical knowledge in commissioning motorized valves (setting limits, torque, and feedback) and their integration with the PLC.
- Industrial Communications and Electrical Panels interface:
- Solid understanding and hands-on experience with Modbus TCP and Modbus RTU.
- Ability to troubleshoot physical layers (RS-485, Ethernet) and use PC-based software (e.g., Modbus Poll) to simulate or sniff traffic.
- Electrical Cabinets & Interlocks: Ability to interpret electrical schematics to verify hardwired interlocks, relay logic, and cabinet-to-field wiring integrity.
- Control Platforms (Diagnostics Level):
- Siemens: Proficiency in TIA Portal: Must be able to go online, check hardware diagnostics, force I/O, and monitor logic. Ability to perform hardware configuration, firmware updates, and program downloads.
- Rockwell Automation: Proficiency in Studio 5000: Must be able to go online, check hardware diagnostics, force I/O, and monitor logic. Capable of managing firmware, communication paths (RSLinx), and code monitoring.
- HMI/SCADA: Ability to configure IP addresses, communication drivers, and verify data mapping on HMI screens (WinCC, FactoryTalk View).
