Senior Utilities / Process Control Systems Engineer

Position Summary

The Senior Utilities Operations / PCS Engineer is responsible for providing technical leadership and engineering support for facility utilities, power distribution systems, process control systems, and site infrastructure. This role serves as the technical steward for utility operations, ensuring the reliability, integrity, safety, and efficiency of critical utility systems.

The position works closely with operations, maintenance, engineering, environmental, and capital project teams to optimize utility performance, improve reliability, reduce costs, enhance safety, and support regulatory compliance. The ideal candidate combines strong electrical and mechanical engineering expertise with process control systems knowledge and project management experience.

Key Responsibilities

Utilities & Infrastructure Leadership

• Provide technical direction and recommendations related to utility systems, power distribution, and facility infrastructure.
• Serve as the process steward for utility and offsite operations, ensuring safe, reliable, and efficient performance.
• Support continuous improvement initiatives focused on safety, reliability, quality, energy efficiency, and cost reduction.
• Coordinate with operations, maintenance, and engineering teams to optimize utility performance and system reliability.

Electrical Reliability & Compliance

• Maintain the integrity and reliability of site electrical distribution systems and utility equipment.
• Ensure compliance with applicable regulatory requirements, industry standards, engineering specifications, and company policies.
• Develop and maintain electrical documentation including:
  • Single-line diagrams
  • Instrument loop drawings
  • Schematics
  • Panel schedules
  • Electrical components of P&IDs
• Monitor, inspect, test, and evaluate electrical systems to ensure safe and reliable operation.
• Qualify and support maintenance personnel performing work on high-voltage systems.

Process Control Systems (DCS/PLC)

• Provide Distributed Control System (DCS) and Programmable Logic Controller (PLC) support.
• Configure and maintain control system I/O, logic, and hardware infrastructure.
• Troubleshoot control system issues and implement corrective actions.
• Evaluate and recommend upgrades to maintain long-term system reliability and performance.
• Support Operational Technology (OT) and cybersecurity initiatives, including:
  • System audits
  • Security policy implementation
  • Incident response support
  • Cybersecurity compliance activities

Maintenance & Reliability

• Develop, review, and improve preventive and predictive maintenance programs.
• Support maintenance teams in diagnosing and resolving complex equipment failures.
• Conduct failure analyses and investigations to identify root causes and implement corrective actions.
• Ensure spare parts requirements are identified and maintained.
• Coordinate third-party inspections, testing, and preventive maintenance activities for critical equipment and infrastructure.

Safety, Environmental & Regulatory Compliance

• Participate in Process Safety Management (PSM) programs and initiatives.
• Develop and update procedures for critical equipment and instrumentation.
• Participate in Process Hazard Analyses (PHA), incident investigations, and safety observations.
• Ensure compliance with environmental, safety, security, and quality management requirements.
• Support audits, inspections, and regulatory compliance activities.

Capital Projects & Continuous Improvement

• Lead and support Capital Improvement Projects (CIP), Management of Change (MOC) activities, and capital projects.
• Assist with capital planning, project prioritization, budgeting, and execution.
• Monitor project schedules, expenditures, construction quality, and adherence to design requirements.
• Participate in contractor bid scope development and evaluation processes.
• Drive continuous improvement initiatives related to utility operations and infrastructure performance.

Energy Management

• Serve as a subject matter expert for energy management programs.
• Facilitate energy team meetings and support site-wide energy initiatives.
• Monitor utility consumption and energy performance metrics.
• Develop and maintain monthly energy reporting and performance tracking systems.
• Identify and implement opportunities for energy efficiency improvements.

Leadership & Collaboration

• Lead and participate in cross-functional problem-solving teams.
• Provide technical guidance to operations, maintenance, and engineering personnel.
• Support shutdown planning, scheduling, and execution activities.
• Participate in hiring activities and technical interviews as needed.
• Serve as backup for utility leadership during absences.

Qualifications

Education

• Bachelor's Degree in Electrical Engineering required.

Experience

• Minimum 5-10 years of engineering experience in industrial utilities, power distribution, process controls, or related manufacturing environments.
• Experience with utility systems, facility infrastructure, and energy management.
• Demonstrated experience with DCS and PLC systems.
• Experience managing capital projects from concept through implementation.
• Strong troubleshooting and root cause analysis skills.

Preferred Skills

• Knowledge of utility system design, construction, and contract administration.
• Familiarity with Process Safety Management (PSM) requirements.
• Understanding of electrical reliability and predictive maintenance programs.
• Experience with Operational Technology (OT) and industrial cybersecurity.
• Knowledge of environmental, safety, and regulatory compliance requirements.
• Strong project management, organizational, and communication skills.

Leadership & Project Management

• Leadership experience preferred.
• Project management experience required.
• Ability to lead cross-functional teams and manage multiple priorities simultaneously.

Success Measures

Performance in this role will be evaluated on:

• Utility system reliability and uptime
• Electrical system integrity and compliance
• Successful execution of capital and improvement projects
• Maintenance and engineering KPI achievement
• Safety, environmental, and regulatory compliance
• Energy efficiency improvements and cost optimization
• Budget and schedule performance

Reporting Structure

Reports to: Site Operations & Utilities Manager

Location

Orange, Texas (On-site)