Senior Control Systems Engineer - DCS Programming & Plant Modifications

Are you a highly skilled Senior Control Systems Engineer with advanced Foxboro DCS programming expertise and proven experience implementing control system modifications within a continuous process manufacturing environment?

Our client, a leading manufacturing organisation, is seeking an experienced, technically strong and hands-on Senior Control Systems Engineer to join their team.

This is a specialist engineering position requiring an individual who can independently program, modify, troubleshoot, optimise and commission Distributed Control Systems (DCS) to support plant modifications, process improvements and operational reliability.

This is not a purely project management or maintenance coordination role. We require a technically proficient engineer who is actively involved in DCS programming and control system modifications.

• Independently develop, program, implement and commission DCS modifications to accommodate plant and process changes.

• Perform advanced programming, configuration and troubleshooting on Foxboro DCS platforms.

• Modify existing control logic, control strategies, sequences and process automation systems.

• Design and implement process control improvements to optimise plant reliability, efficiency, safety and throughput.

• Provide specialist technical support to production, process and engineering teams.

• Configure and optimise PID control loops and associated process control functionality.

• Diagnose and resolve complex DCS software, hardware, networking and communication faults.

• Support plant upgrades, process modifications, expansions and automation projects from design through to commissioning.

• Maintain the integrity, reliability and security of existing control systems.

• Manage system backups, software changes, disaster recovery procedures and technical documentation.

• Support integration between DCS, PLC, SCADA and associated industrial communication networks.

• Provide technical assistance during plant breakdowns, shutdowns and commissioning activities.

• Ensure all modifications comply with engineering standards, change management procedures and operational safety requirements.

• BSc or BTech in Electrical Engineering (Light Current), Process Control or Computer Systems Engineering.

• Minimum 10 years' Control Systems Engineering or Software Engineering experience within a production or manufacturing environment.

• Extensive hands-on experience in DCS programming, particularly Foxboro.

• Proven ability to independently execute plant control system modifications, including programming, testing and commissioning.

• Experience working within continuous process manufacturing or complex industrial production environments.

• Strong knowledge of control system architecture, industrial networking, PLC/SCADA integration and communication protocols.

• Advanced understanding of structured text programming, PID loop configuration and tuning, Profibus and Modbus.

• Experience with control system hardware, including controllers, I/O modules, servers and network infrastructure.

• Knowledge of control system cybersecurity, backup procedures and change management.

Critical DCS Experience Requirements

Candidates must demonstrate strong practical programming and modification experience across the following systems:

• Foxboro DCS – 70%: Essential and the primary focus of this position. Advanced hands-on programming, configuration, troubleshooting and modification experience on both legacy and modern Foxboro systems.

• Emerson DeltaV DCS – 20%: Experience in programming, configuration, system modifications and optimisation.

• Honeywell DCS – 10%: Working knowledge and practical experience in programming, maintenance and modifications.

Advanced Foxboro DCS programming experience is non-negotiable.

Important

Applicants must have substantial, demonstrable hands-on Foxboro DCS programming experience. Experience limited to DCS operation, monitoring, basic maintenance or contractor supervision will not meet the technical requirements of this position. The successful candidate must be willing to provide after-hours technical support and standby assistance when operationally required.

If you are a technically accomplished Senior Control Systems Engineer who enjoys hands-on programming, solving complex automation challenges and implementing meaningful plant improvements, we would welcome your application.