DeltaV Application Programmer

We are seeking an experienced DeltaV Application Programmer to design, configure, program, and maintain Emerson DeltaV Distributed Control System (DCS) applications within our clients GMP-regulated pharmaceutical manufacturing facility. The ideal candidate combines strong DeltaV batch/continuous software configuration skills with hands-on knowledge of DeltaV hardware architecture and industrial networking and is comfortable working within a validated (CSV), GMP-compliant environment where documentation, change control, and data integrity are critical. This role supports process automation for API, drug product, biologics, and/or fill-finish operations, ensuring systems remain compliant, reliable, and audit-ready

Key Responsibilities

•     Design, develop, test, and deploy DeltaV control strategies, including continuous control modules, phase logic, S88-based batch recipes, and sequential function charts (SFCs), for GMP manufacturing processes.

•     Configure and maintain DeltaV Operator Interface (Control Studio, Process History View, and Dynamo graphics/HMI displays) to support safe, compliant, and efficient plant operations.

•     Build and maintain DeltaV database configurations, including module templates, alarms, historian tags, and I/O assignments, in accordance with site data integrity standards (ALCOA+).

•     Configure and troubleshoot DeltaV hardware including MD/SD/SQ series controllers, CHARMI/O cards and terminals, workstations, and redundant controller pairs installed in classified and non-classified manufacturing areas.

•     Support and maintain DeltaV network architecture, including the Control Network(fiber/copper), Application Station connectivity, redundant network switches, and integration with plant-wide Ethernet/IT and MES/ERP networks.

•     Perform system health checks, diagnostics, and troubleshooting of hardware faults, network communication failures, and controller/I-O card issues, minimizing unplanned downtime in production areas.

•     Execute DeltaV software and firmware upgrades, patches, and system backups under formal change control, in coordination with IT/OT cybersecurity and Quality/Validation requirements.

•     Develop and maintain functional specifications, control narratives, I/O lists, and system documentation to support GMP documentation requirements (URS, FS, DS, traceability matrices).

•     Author and execute IQ/OQ/PQ protocols and support Computer System Validation (CSV)activities for new or modified DeltaV applications, per site validation policies and 21 CFR Part 11 / Annex 11 requirements.

•     Support Electronic Batch Record (EBR) configuration and integration between DeltaV and MES/Historian systems (e.g., Syncade, PAS-X, DeltaV Batch Historian).

•     Participate in Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT),commissioning, and startup activities for new or modified control systems, including automation for new drug product/API introductions.

•     Collaborate with process engineering, QA, validation, and automation teams to implement new control strategies and modifications via Management of Change (MOC) and deviation/CAPA processes.

•     Provide troubleshooting support and root cause analysis for control system malfunctions, including investigation support for deviations impacting batch disposition, and on-call/after-hours support as needed.

•     Maintain system configurations in accordance with data integrity, audit trail, and electronic signature requirements; support internal audits and regulatory inspections (FDA, EMA, etc.) as a system SME.

•     Ensure compliance with cybersecurity standards (e.g., IEC 62443) for DCS network and workstation configurations within a validated environment.

•     Bachelor's degree in Electrical Engineering, Instrumentation & Control, Chemical Engineering, Computer Engineering, or related field, or equivalent hands-on experience.

•     10+years of hands-on experience programming and configuring Emerson DeltaV DCSsystems, preferably within a GMP-regulated pharmaceutical, biotech, or lifesciences manufacturing environment.

•     Strong working knowledge of DeltaV software tools: Control Studio, Recipe Studio, Diagnostics, Explorer, and Batch Historian, including S88-based batch/phaselogic development.

•     Solid understanding of DeltaV hardware components: controllers (MD, SD, SZ, SQseries), CHARM I/O, Smart Switches, Application/Professional Plus Stations, and redundant power supplies.

•     Practical knowledge of DeltaV networking architecture, including Control Network topology, VLAN segmentation, redundant network design, and integration points with plant IT/MES networks.

•     Familiarity with industrial communication protocols (e.g., Modbus, HART, Foundation Fieldbus, Profibus, OPC/OPC-UA).

•     Working knowledge of GMP requirements, 21 CFR Part 11 (electronic records/signatures),and Computer System Validation (CSV) practices, including IQ/OQ/PQ documentation.

•     Understanding of P&IDs, control narratives, cause & effect diagrams, and instrumentation loop drawings.

•     Experience working within a formal change control (MOC) and quality management system(QMS) environment.

•     Strong analytical and troubleshooting skills for diagnosing hardware, software, and network-level issues without compromising product quality or batch integrity.

•     Excellent written and verbal communication skills for authoring GMP documentation and collaborating cross-functionally with Quality, Validation, and Manufacturing teams.

•     Experience in DeltaV integration with MES platforms (e.g., Werum PAS-X, Syncade, POMSnet)for Electronic Batch Records.

•     Experience with virtualized DeltaV environments and DeltaV system redundancy design.

•     Familiarity with cybersecurity hardening practices for DCS environments (patching, whitelisting, network segmentation) within a validated 21 CFR Part 11 system.

•     Experience supporting FDA/EMA regulatory inspections or internal quality audits as an automation system SME.

•     Working knowledge of AMS Device Manager or other asset management software.

•     Familiarity with GAMP 5 risk-based approach to CSV.

Skills

Deltav, Configuring Databases, Technical Drawing, Network Implementation, Emerson DeltaV, Development, GMP Environment, Industrial control systems, machinery downtime, FDA GMP, Embedded Controllers, Requirements Documentation, Communication Protocols, Networking, Hands-On Experience, Updating of firmware, Plant Operations