PLC Reliability Engineer

INEOS•La Porte, TX

4d•$125,041 - $156,301•Onsite

About The Position

The PLC Engineer is a member of the I/E Reliability organization at INEOS Olefins & Polymers USA’s Battleground Manufacturing Complex (BMC) in La Porte, Texas, and reports to the IEA Unit Reliability Team Lead. The role is the reliability-side system owner for BMC’s general-purpose and safety PLC systems, including PLC-based SIS logic solvers. It provides technical accountability for platform integrity, complex troubleshooting, reliability improvement, and lifecycle management, while putting the INEOS 20 Principles into practice. The system scope includes PLC hardware, application software, I/O systems, associated computers and HMIs, communications and network interfaces in coordination with OT and cybersecurity personnel, equipment-monitoring devices integrated with PLCs, and programmable devices such as RTUs and programmable relays. For PLC-based SIS, the PLC Engineer owns platform reliability and lifecycle management; the SIS Engineer retains technical accountability for safety-function requirements and safety application logic. The position works with unit I/E engineers and technicians, Operations, the Capital Projects PLC engineering counterpart, and OT and cybersecurity specialists. It leads detailed troubleshooting of complex or recurring problems, trains and mentors unit personnel, owns the PLC lifecycle and replacement plan, executes designated lean projects, and prepares CAPEX justifications, scopes, and charters. As the reliability subject matter expert and asset-owner representative, the PLC Engineer defines requirements and acceptance criteria, challenges proposed solutions, and reviews deliverables for technical soundness, reliability, maintainability, and supportability. Capital Projects develops and executes solutions; the PLC Engineer identifies deficiencies and recommends acceptance and turnover. The role also supports unit I&E engineering and troubleshooting as needed to help maintain safe and reliable plant operations.

Requirements

Bachelor’s degree in Automation, Electrical Engineering, Chemical Engineering, Computer Engineering, or a related field; an associate degree is not sufficient.
At least 3 years of experience working with programmable logic controllers or other automation equipment, including engineering of those systems.
Hands-on experience supporting PLCs such as Rockwell, Emerson, Triconex, HIMA, GE, or Siemens.
Familiarity with networked systems and remote access of PLCs.
Experience in, and a strong desire to develop, E/I reliability capabilities in a plant operating environment.
Strong engineering background focused on automation and logic controllers.
Strong instrument, control valve, and control-system reliability and maintenance background.
Plant-level experience and understanding of P&IDs, instrument loop drawings, logic-controller terminology, and relevant industry standards, including ANSI, NFPA, ISA, IEC, and API.
Ability to lead complex PLC troubleshooting and root-cause investigations involving field devices, logic, interlocks, communications, and control-system interfaces.
Ability to develop PLC lifecycle, obsolescence, maintenance, migration, and replacement strategies addressing reliability, maintainability, supportability, and asset risk.
Ability to provide asset-owner technical assurance for PLC modifications and projects, develop technical justifications and project charters, and coordinate reviews with Capital Projects.
Ability to perform assigned unit I/E reliability engineering duties and coordinate specialist support as needed.
Experience executing lean projects and developing scopes and asset-owner requirements for turnover to Capital Projects while following site procedures and protocols.
Experience working with multiple engineering disciplines and contractors supporting PLC programming and hardware delivery and PSM initiatives.
Ability to work independently and as part of a team; strong organizational skills and ability to prioritize work and deliver quality results on time.
Strong oral and written communication skills.
Strong leadership skills, including the ability to lead and motivate individuals or teams.
Proven ability to influence and manage change.
Ability to build positive working relationships with Operations, Maintenance, Technology, and Capital Projects personnel.
Demonstrated problem-solving and troubleshooting skills.
Self-motivated, takes initiative to achieve results, and seeks opportunities for additional responsibility.

Nice To Haves

Ability to train, coach, and mentor maintenance technicians and junior-level technical staff.

Responsibilities

Lead reliability stewardship and lifecycle management of existing and newly installed PLC systems in the assigned scope.
Provide detailed troubleshooting, technical review, and reliability assurance for PLC hardware, software, and interfaces.
Provide unit I&E reliability and maintenance support as assigned, including troubleshooting, root-cause investigations, reliability improvements, and resolution of instrumentation, control valve, electrical, and control-system issues.
Lead, develop, and manage MOCs related to PLC, control system, instrumentation, and electrical modifications.
Provide technical accountability for site PLC platform reliability, including general-purpose PLCs and safety PLC hardware; coordinate with the SIS Engineer on matters affecting safety-function requirements or application logic.
Lead troubleshooting of complex, recurring, or significant PLC failures involving hardware, communications, field-system interfaces, and application logic; coordinate relevant personnel and specialists, develop corrective actions, and verify effectiveness.
Own the site PLC lifecycle by assessing system condition and recommending maintenance, upgrades, migrations, and replacements.
Maintain technical oversight of PLC hardware and software inventories, configuration records, application backups, recovery readiness, and supporting documentation.
Support, train, and mentor unit technicians in troubleshooting, reprogramming, and maintaining PLC systems.
Provide asset-owner technical review of engineering packages involving PLC hardware or software changes, including reliability, maintainability, field integration, testing, and turnover requirements.
For capital projects, define asset-owner requirements and conduct technical reviews with the Capital Projects PLC engineering counterpart, including maintenance and turnover requirements.
Own the PLC lifecycle and replacement plan; execute designated lean projects and prepare CAPEX justifications, scopes, and charters.
Identify deficiencies in proposed project solutions and provide technical recommendations for acceptance and turnover.
Stay current with technology and seek improvements to BMC general PLC systems.
Support the IEA Superintendent and I&E Team Leaders in identifying and developing training to maintain and enhance I&E personnel PLC competencies.
Contribute to applicable technical practices and training through established governance processes.