Senior Controls Engineer

KELE INC • Concord, NC

3d

About The Position

The Senior Controls Engineer defines control-system design solutions and strategies, develops front-end concepts and system architectures, designs control panels, and selects instrumentation and control valves. The role contributes to programming, startup, and commissioning of custom control systems that meet customer specifications and applicable safety codes. It collaborates with Controls Engineers, Project Managers, Panel Shop Technicians, and Service Technicians to deliver safe, reliable, and maintainable solutions.

The engineer develops PLC, safety, and logic applications for building management systems (BMS) and combustion control; configures SCADA and HMI applications; and produces control narratives, cause-and-effect matrices, I/O lists, alarm philosophy, and interlock logic for boilers and process heat systems. The position also performs testing, commissioning, training, troubleshooting, warranty support, and lifecycle improvements. It supports project planning, proposals, panel fabrication, installation, and startup, and mentors junior engineers.

Requirements

• Two-year degree in a related technical field or related work experience.
• Minimum seven years of related work experience desired.
• Knowledge of burner management and combustion codes and practices, such as NFPA 85 and NFPA 86, and functional safety concepts aligned to ISA 84 or IEC 61511.
• Expertise in electrical design standards such as NEC and UL508A for control panels and field wiring.
• Ability to specify and size instrumentation for pressure, temperature, flow, and final control elements in natural gas and fuel oil services.
• Experience with oxygen trim, cross-limited metering, and air-fuel ratio tuning.
• Ability to read and produce P&IDs, electrical schematics, and network diagrams.
• Strong troubleshooting skills for field startup and service.
• Experience with version control and deployment tools for automation projects.
• Hands-on experience with at least two of Honeywell HC900, Honeywell Control Edge, Allen-Bradley CompactLogix, or ControlLogix.
• Experience with ICONICS, Ignition, and Red Lion Crimson.
• Proficiency in ladder logic and at least one of function block or structured text.
• Demonstrated experience commissioning combustion or high-temperature process systems, including interlocks, permissives, purge, light-off, and flame supervision.
• Solid documentation habits, including revision control and test records.
• Willingness to travel for FAT, SAT, startup, training, and service as needed.

Nice To Haves

• Mechanical or Electrical Engineering degree preferred.
• Exposure to gas detection, heat trace systems, and industrial wireless systems.

Responsibilities

• Translate PFDs and P&IDs into control architectures, panel layouts, network topologies, and I/O allocations.
• Design custom control panels and support panel builds, including UL508A documentation when applicable.
• Select and specify instrumentation and final control elements, including pressure and temperature transmitters, flow meters, and control valves.
• Develop gas detection, heat trace, and wireless telemetry designs using approved platforms such as Honeywell, Raychem, and Elpro.
• Develop PLC, safety, and logic applications for BMS and combustion control using Honeywell HC900, Honeywell Control Edge, and Allen-Bradley platforms.
• Configure SCADA and HMI applications in ICONICS, Ignition, and Red Lion Crimson.
• Create control narratives, cause-and-effect matrices, I/O lists, alarm philosophy, and interlock logic for boiler and process heat systems.
• Implement combustion control schemes, including single point jackshaft, parallel positioning with O2 trim, and fully metered cross-limited control with O2 trim.
• Execute I/O checkout, loop tuning, FAT, SAT, startup, and site commissioning; provide operator training and handover.
• Provide remote and on-site troubleshooting, tuning, warranty support, and lifecycle improvements.
• Apply combustion and functional safety best practices and relevant standards in design and programming.
• Maintain version control, change management, and as-built documentation; prepare customer documentation, test procedures, and training materials.
• Coordinate schedules, risks, and scope with Project Managers and support proposals with concepts, estimates, and technical clarifications.
• Provide technical support to Panel Shop Technicians during fabrication and Field Technicians during installation and startup.
• Mentor junior engineers.

Benefits

• Medical, vision, and dental insurance
• HSA and FSA for medical and dependent care
• 401(k) with employer match up to 4% and immediate vesting
• Employer-paid short- and long-term disability coverage
• Employer-paid basic life and AD&D insurance; supplemental life insurance available for employees and dependents
• Paid time off and paid holidays
• Tuition reimbursement
• Paid maternity leave

What This Job Offers

• Job Type: Full-time
• Career Level: Senior
• Education Level: Associate degree