Role: Automation Engineer
Job DescriptionThe Senior Controls Engineer is responsible for troubleshooting, diagnosing, modifying, and optimizing industrial automation and process control systems in complex operational environments. This role focuses heavily on reverse engineering existing PLC systems, diagnosing poorly documented automation infrastructure, and supporting process optimization through controls improvements and commissioning activities.
The position requires strong hands-on experience with PLC programming, electrical troubleshooting, process controls, valve sequencing, and industrial automation systems. The ideal candidate is highly self-sufficient, capable of working autonomously, and comfortable operating in dynamic field environments where troubleshooting and problem-solving are critical.
This role supports ongoing operational reliability, system remediation, equipment commissioning, and process optimization initiatives across industrial process systems.
ResponsibilitiesPLC Troubleshooting & Reverse Engineering- Connect to, assess, and troubleshoot existing PLC systems and automation infrastructure.
- Upload, review, and reverse engineer poorly documented or legacy PLC code.
- Diagnose automation failures, communication issues, and process control problems.
- Modify and optimize PLC logic to improve operational reliability and process performance.
- Support troubleshooting and debugging of control loops, I/O systems, and sequencing logic.
Electrical & Hardware Diagnostics- Troubleshoot electrical systems, control panels, and instrumentation using standard diagnostic tools.
- Trace and verify physical wiring, I/O points, and communication pathways.
- Read, interpret, and update electrical schematics and control drawings.
- Identify and resolve issues related to valves, sensors, actuators, and field devices.
- Support hardware replacement, integration, and commissioning activities.
Process Control & Optimization- Support process optimization through tuning and adjustment of sequencing logic and timing cycles.
- Troubleshoot and optimize valve sequencing and fluid process control systems.
- Assist with commissioning and startup of process equipment and control systems.
- Provide support for gas processing, pressure-based systems, and automated process operations.
- Collaborate with operations personnel to improve system efficiency and reliability.
Project Support & Commissioning- Conduct onsite system assessments and operational reviews.
- Assist with installation, testing, and commissioning of new automation components and field devices.
- Support process modifications and operational improvements.
- Provide technical recommendations for system upgrades and process improvements.
- Participate in troubleshooting, maintenance planning, and operational support activities.
Communication & Collaboration- Work closely with operations, maintenance, and project teams to resolve automation and controls issues.
- Provide clear technical communication regarding system status, troubleshooting findings, and corrective actions.
- Maintain accurate documentation of system changes, troubleshooting activities, and process improvements.
- Support training and knowledge sharing with operations and maintenance personnel as needed.
Skills- PLC programming and troubleshooting
- Reverse engineering legacy PLC systems
- Industrial automation systems
- Electrical troubleshooting and diagnostics
- Process control systems
- Valve sequencing and timing logic
- I/O mapping and signal tracing
- HMI and SCADA systems
- Pneumatic and hydraulic controls
- Electrical schematics and wiring diagrams
- Multimeter and diagnostic tool usage
- Commissioning and startup support
- Process optimization
- Fluid and gas process systems
- Problem-solving and root cause analysis
- Independent work and time management
- Technical communication and collaboration
Qualifications- Minimum 5+ years of experience in industrial automation, controls engineering, or process control environments.
- Strong experience troubleshooting and programming PLC platforms such as Allen-Bradley/Rockwell and/or AutomationDirect.
- Proven ability to troubleshoot and reverse engineer poorly documented automation systems.
- Strong electrical troubleshooting skills including reading schematics and tracing wiring.
- Experience with process control systems, valve sequencing, and automated industrial operations.
- Experience with gas processing, chemical processing, or industrial plant operations preferred.
- Familiarity with HMI and SCADA systems preferred.
- Experience supporting commissioning, startup, and operational troubleshooting activities.
- Ability to work independently in a self-managed and field-oriented environment.
- Strong communication, analytical, and organizational skills.
- Willingness to travel onsite as required for troubleshooting, commissioning, and operational support activities.
Job DetailsPay: $100,000/per year
Schedule: Monday-Friday, 9-5, Hybrid option available
Location: Dodge City, KS
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