Senior Automation and Controls Engineer

VVater • Austin, TX

1d • Onsite

About The Position

The Senior Automation and Controls Engineer owns the physical treatment module as it becomes a controllable, manufacturable, field-ready product. The role turns a proven process into a packaged system by designing its layout, piping, structure, instrumentation, and control logic; validating it in a digital twin; and supporting build and field commissioning. The engineer connects the physical package to sensors and controllers, validates the digital twin against real operating data to a defined tolerance, and incorporates field lessons into the design. The role collaborates with mechanical, electrical, process, and manufacturing teams. This is an onsite position based in Austin, Texas; remote and hybrid work are not available. VVater describes a fast-paced environment focused on accelerating the development and adoption of water-industry technologies.

The position also includes support and maintenance of DMS applications and development of operating documentation and reusable packaging and controls standards. The engineer conducts feasibility studies and cost analyses, performs root-cause analysis, supports suppliers and vendors, creates test environments, and mentors junior engineers and designers. Applicants are required to complete assessment tests as part of the recruitment process for their application to progress.

Requirements

• Bachelor’s or master’s degree in Instrumentation, Controls, or Mechanical Engineering, or a closely related field with equivalent depth.
• At least 5 years of equipment or package-system design experience.
• Working knowledge of PLC/SCADA/HMI and integration of instrumentation and basic control logic.
• Demonstrated digital-twin or model-calibration experience, including building a model, validating it against test or field data, and using it to guide design or operating decisions.
• CFD proficiency using STAR-CCM+, Simcenter, or an equivalent tool.
• Strong knowledge of Rockwell, Control Logix, Iconics, Siemens, Delta-V, Allen Bradley, WonderWare Intouch, Zenon, and other related systems.
• DFM/DFA experience taking hardware from prototype to production.
• Field commissioning experience, including FAT/SAT.
• Programming skills in Python, MATLAB, or similar for data processing and model-to-data integration.
• Hands-on fluency with modern AI tools such as Claude or equivalents.
• Exceptional written and verbal communication, including the ability to explain designs and model reliability to engineers, operators, and customers.
• Comfort with ambiguity and sound judgment to determine what to design, model, and test next without waiting for direction.
• Willingness to work onsite in Austin, Texas; remote and hybrid work are unavailable.
• Completion of required assessment tests as part of the recruitment process.

Nice To Haves

• Python programming is preferred.

Responsibilities

• Design and package treatment modules, including general arrangement and layout, piping, structural components, skids or trailers, and mechanical, hydraulic, and utility packages.
• Develop fabrication-ready packages, including piping and instrumentation drawings, structural details, bills of material, and assembly documentation.
• Apply design for manufacturing and assembly (DFM/DFA) and tolerance analysis to support consistent builds and scaling from prototype to production.
• Select and integrate instrumentation such as flow, pressure, level, conductivity, and pH/ORP sensors, along with sensors required for safe, observable unit operation.
• Develop and commission basic control logic and interlocks across PLC/SCADA/HMI systems; define I/O lists, control narratives, alarms, and safety logic.
• Define operating envelopes and automated responses, including safe-state and shutdown behavior.
• Partner with the electrical team on power delivery, panel layout, and field wiring.
• Build and maintain the engineering digital twin of each module and validate it against bench, pilot, and field data to a defined tolerance.
• Develop 3D CFD models of reactors and process units to guide hydraulic and thermal design.
• Use simulation to size and de-risk packages before construction, and quantify model reliability.
• Couple the digital twin to live instrumentation where useful to keep the model and as-built system synchronized.
• Support bill-of-material creation, builds, and shop assembly; resolve fit, fabrication, and integration issues on the floor.
• Lead or support Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and field commissioning.
• Troubleshoot mechanical, hydraulic, and control issues on deployed modules and incorporate field lessons into the design and digital twin.
• Support and maintain DMS applications, including SCADA, FISR, Self-Healing, Load Var Management, Powerflow, VMS, FMS, and database updates to keep the DMS aligned with field conditions.
• Develop and maintain SOPs, operating envelopes, commissioning checklists, and manuals for owned modules.
• Conduct feasibility studies and cost analyses for automation projects.
• Perform root-cause analysis to identify and address system failures or malfunctions.
• Collaborate with mechanical engineers on physical installation and process engineers on performance intent.
• Set packaging and controls standards and create reusable templates.
• Mentor junior engineers and designers in controls integration, packaging, and commissioning practices.
• Collaborate with suppliers and vendors to source equipment and components.
• Create test environments and provide necessary research and support.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior