Position Summary

The Senior Instrumentation & Controls (I&C) Engineer is responsible for delivering high-quality instrumentation, control and safety system engineering for modular plants, process skids and packaged systems for the oil & gas, midstream, petrochemical, power generation, hydrogen/carbon capture and other industrial markets. The role owns the I&C discipline on assigned projects from the proposal stage through basic and detailed engineering, procurement, shop fabrication, Factory Acceptance Testing (FAT) and final documentation turnover.

Unlike a purely office-based EPC role, this position combines engineering development with hands-on support to the fabrication shop. The engineer ensures that designs are technically robust, safe, constructible, maintainable and compliant with applicable codes, standards and client specifications, and serves as the I&C technical point of contact for clients, vendors and the fabrication team.

Responsibilities

Sales & Proposal Support
• Review client RFQ/ITB packages, specifications, preliminary P&IDs and datasheets to define the I&C scope of supply.
• Prepare preliminary instrument lists, I/O counts, conceptual control architecture and installation material take-offs (tubing, cable, conduit, cable tray, junction boxes).
• Obtain and evaluate budgetary quotations for instruments, control valves, analyzers and control panels; estimate I&C engineering hours and discipline cost.
• Prepare the I&C technical section of proposals, including assumptions, clarifications, deviations and exclusions.
• Attend client meetings with sales staff to support current and future projects, including technical clarification and kick-off meetings.

Engineering Development
• Philosophy of Control: define control strategy, automation levels, system architecture (PLC/DCS/SIS/BMS), alarm philosophy, redundancy, client interface signals and communication requirements.
• Control Narrative / Control Description: describe start-up, normal operation, normal shutdown and emergency shutdown sequences, control loops, permissives, interlocks and operating modes.
• Cause & Effect Diagrams: develop C&E matrices for ESD, SIS, Fire & Gas and process interlocks in coordination with Process and Safety, and verify them against HAZOP/LOPA results.
• P&IDs: develop and review instrumentation on P&IDs (ISA 5.1 tagging, control loops, safety devices, SIFs, signal lines) and manage client comments and revisions.
• Instrument List / Index: create and maintain the master instrument database, including service, range, signal type, location, hazardous area classification and procurement status.
• Instrument Data Sheets: specify pressure, temperature, level and flow transmitters, switches, thermowells (including wake frequency calculations per ASME PTC 19.3 TW), control and on/off valves, actuators, analyzers, flowmeters and gas/flame detectors.
• Control Valve Sizing Calculations: calculate Cv, noise, cavitation/flashing, outlet velocity and actuator sizing per ISA 75 / IEC 60534 using manufacturer software.
• Supporting Calculations: orifice plate sizing (ISO 5167 / AGA 3), loop load and voltage drop, instrument air consumption, and material verification for sour, cryogenic and specialty chemical services.
• Hook-up Drawings: develop process, pneumatic and electrical hook-ups with associated bills of materials.
• Installation Details: define mounting, supports, instrument protection, tubing and heat tracing, adapted to the actual skid layout.
• Cable Routing Drawings: develop instrument location plans, cable tray and conduit routing, junction box locations, cable schedules and interconnection diagrams in coordination with Electrical and 3D design.
• I/O List: define and assign signals to PLC/DCS/SIS, including third-party package signals and serial/Ethernet communications.
• Loop & Wiring Diagrams: develop or review loop diagrams, control system block diagrams and control panel/cabinet layouts.

Functional Safety (SIS)
• Participate in HAZID, HAZOP, LOPA and SIL determination workshops, providing the instrumentation perspective.
• Develop or review Safety Requirement Specifications (SRS) for Safety Instrumented Functions (SIFs).
• Perform SIL Verification / SIL Calculations (PFDavg, hardware fault tolerance, systematic capability, proof test intervals) per IEC 61511 / ISA 84, using certified reliability data (SIL certificates, FMEDA reports).
• Select voting architectures (1oo1, 1oo2, 2oo3) and SIL-certified devices; define proof test and bypass requirements.
• Apply Burner Management System (BMS) requirements per NFPA 85/86 and API 556 when included in scope.

Procurement & Vendor Management
• Material Requisitions: prepare technical requisitions for instruments, valves, analyzers, control panels/PLCs, cables and installation materials.
• Technical Bid Evaluations (TBE): evaluate vendor offers, identify deviations and issue technical recommendations.
• Vendor Drawings & Datasheets Review: review and approve vendor drawings, datasheets, certificates (SIL, hazardous area, NACE materials), calculations and manuals, including third-party packages.
• Coordinate integration of third-party package instrumentation and signals (compressors, pumps, analyzers, metering systems).
• Expedite critical instrumentation deliveries that impact the fabrication schedule.

Fabrication Shop Support
• Provide technical support to the shop during installation of instruments, tubing, cable tray, conduit, junction boxes and wiring.
• Resolve Requests for Information (RFIs), clashes and installation deviations; approve and document field solutions.
• Verify installation against hook-ups, installation details and hazardous area requirements (seals, cable glands, NEMA/IP ratings).
• Coordinate with QA/QC on calibration checks, continuity and insulation tests, and tubing leak tests.
• Manage Engineering Change Notices / Management of Change (MOC) and keep redlines up to date.
• Attend production meetings and provide status reports on I&C activities.

Factory Acceptance Testing (FAT), Commissioning & Turnover
• Prepare I&C FAT procedures and protocols (point-to-point checks, loop tests, functional sequence tests and Cause & Effect testing).
• Lead or support FAT execution with clients and third-party inspectors; record and close punch list items.
• Attend vendor FATs for control panels, PLCs and analyzers as required.
• Prepare the final I&C documentation package: as-built drawings, final datasheets, certificates, calibration reports and input to the Manufacturing Data Record (MDR) and O&M manuals.
• Support SIT (Site Integration Test), installation, commissioning and start-up activities remotely or on site when required by contract.

Technical Leadership & Continuous Improvement
• Review and approve deliverables prepared by designers and junior engineers; provide technical training and mentorship.
• Develop and update internal specifications, standard datasheet templates, typical hook-ups, guidelines and best practices for the I&C discipline.
• Maintain technical documentation and lessons learned; identify improvements in cost, quality, safety and productivity.
• Manage I&C scope, man-hour budget and schedule; notify the Engineering Manager early of technical risks and impacts.
• Communicate effectively and consistently with internal and external clients.
• Comply with and promote company and shop Health, Safety & Environmental (HSE) policies.

#LI-TS1 #ZRTS

Key Deliverables

The candidate must be able to independently prepare, review and approve, at a minimum, the following deliverables: Deliverable

Main Content

Reference Standards

Philosophy of Control

Architecture, control levels, alarms, redundancy, interfaces

ISA 18.2, ISA 101, IEC 61511

Control Narrative

Sequences, loops, permissives, operating modes

ISA 5.1, ISA 88

Cause & Effect Diagram

Initiators and ESD/SIS/F&G actions

IEC 61511, API RP 14C

P&ID

Instrumentation, loops, SIFs, tagging

ISA 5.1, ISA 5.3

Instrument List / Index

Master instrument database

ISA 20 / ISA TR20.00.01

Instrument Data Sheets

Technical specification per instrument

ISA 20, API RP 551, ASME PTC 19.3 TW

Control Valve Sizing

Cv, noise, cavitation, actuator

ISA 75.01 / IEC 60534, API 553

Hook-up Drawings

Process, pneumatic and electrical connections

API RP 551, ASME B31.3

Installation Details

Mounting, supports, tubing, protection

API RP 551, client specifications

Cable Routing Drawings

Tray, conduit, junction boxes, cable schedule

NFPA 70 (NEC) Art. 500/505, API RP 552

I/O List

Signal assignment to PLC/DCS/SIS

Project / client specifications

SIL Verification

PFDavg, HFT, proof test intervals, SRS

IEC 61511 / ISA 84, IEC 61508

Material Requisition / TBE

Technical requirements, bid evaluation

Project specifications

Vendor Document Review

Vendor drawings, datasheets and certificates

Project specifications

FAT Procedure / Report

Protocols, loop and C&E tests, punch list

IEC 62381

Sales Proposal (I&C)

Scope, estimate, clarifications and exclusions

Client RFQ

Location: USA:TX:Katy

DXP offers a comprehensive benefits package for full-time regular employees, normally working a minimum of 30 hours per week, including: medical, dental, vision, flexible spending account, paid holidays, life and disability insurance, and additional supplemental benefits. All employees are eligible to participate in the 401(k) plan.

Salary is commensurate with experience.