PLC Reliability Engineer

INEOS•La Porte, TX

2d•Onsite

About The Position

The PLC Reliability Engineer is a member of the I/E Reliability organization at INEOS Olefins & Polymers USA’s Battleground Manufacturing Complex (BMC) in La Porte, Texas. The position reports to the IEA Unit Reliability Team Lead and serves as the reliability-side system owner for BMC programmable logic controller systems, including general-purpose and safety PLCs. The role provides technical accountability for system integrity, complex troubleshooting, reliability improvement, and lifecycle management. The system scope includes PLC hardware, application software and I/O systems; PLC-associated computers and HMIs; communications and network interfaces in coordination with OT and cybersecurity personnel; equipment-monitoring devices integrated with PLC systems; and associated programmable devices such as RTUs and programmable relays. For PLC-based SIS, the role owns platform reliability and lifecycle management, while the SIS Engineer retains technical accountability for safety-function requirements and safety application logic. The PLC Engineer works closely with unit I/E engineers and technicians, Operations, Capital Projects’ PLC engineering counterpart, and OT and cybersecurity specialists. The role provides specialist support, leads detailed troubleshooting of complex or recurring issues, and trains and mentors unit I/E personnel. It 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 position defines requirements and acceptance criteria, reviews deliverables for technical soundness, reliability, maintainability, and supportability, and recommends acceptance and turnover. Capital Projects develops and executes defined solutions. The position also supports unit I&E engineering and troubleshooting as needed or assigned, helping resolve critical instrumentation, electrical, and control system issues in support of safe and reliable plant operations. The role is expected to understand and put into practice the INEOS 20 Principles.

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 PLC platforms 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 instrumentation, control valve, control system reliability, and maintenance background.
Plant-level experience and understanding of P&IDs, instrument loop drawings, logic controller terminology, and industry standards such as ANSI, NFPA, ISA, IEC, and API that influence PLC functionality and configurations.
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 technical 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 scope 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 and build positive relationships with plant personnel in Operations, Maintenance, Technology, and Capital Projects.
Demonstrated problem-solving and troubleshooting skills; self-motivated and takes initiative to achieve results and seek 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 within the assigned scope.
Provide technical accountability for the reliability of site PLC platforms, including general-purpose PLCs and safety PLC hardware, and coordinate with the SIS Engineer on matters affecting safety-function requirements or application logic.
Lead detailed 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 their effectiveness.
Provide assigned unit I&E reliability and maintenance support, including troubleshooting, root-cause investigations, equipment reliability improvements, and resolution of instrumentation, control valve, electrical, and control system issues.
Lead, develop, and manage Management of Change processes related to PLC, control system, instrumentation, and electrical modifications.
Own the site PLC system lifecycle by assessing system condition and recommending maintenance, upgrade, migration, and replacement strategies.
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, turnover documentation, and maintenance requirements.
Coordinate with the Capital Projects PLC engineering counterpart to establish asset-owner requirements and review project deliverables; identify deficiencies and provide technical recommendations for acceptance and turnover.
Execute designated lean projects and prepare CAPEX justifications, project scopes, and charters.
Contribute to applicable technical practices and training through established governance processes.
Stay abreast of current technology and work to improve BMC general PLC systems.
Support the IEA Superintendent and I&E Team Leaders in identifying and developing training to maintain and improve I&E personnel PLC competencies.