Chief Engineer, Automation Customer Services
Job Title: Automation Engineer – Site Commissioning (ECS / SCADA / PLC)
Role Overview
The Automation Engineer (Site Commissioning) is responsible for on-site commissioning, testing, troubleshooting, and stabilization of automation systems including FLS ECS, SCADA, and PLC platforms (Rockwell, Siemens, ABB).
This role is highly hands-on and requires working in live plant environments to ensure safe startup, reliable operation, and performance optimization of process units.
Key Responsibilities
1. Site Commissioning & Startup
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Execute cold commissioning
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I/O loop checking
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Instrument calibration validation
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Signal verification from field to PLC/SCADA
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Perform hot commissioning
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Equipment-wise startup (motors, drives, feeders, screens, mills)
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Interlock validation and permissive checks
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Commission FLS ECS (Expert Control System) and integrate with plant PLCs
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Support first material flow and ramp-up to design capacity
2. PLC & Control Logic Execution (On-Site)
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Download, test, and modify PLC programs
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Rockwell (ControlLogix / CompactLogix)
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Siemens (S7 / TIA Portal)
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ABB (AC800M / 800xA)
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Debug real-time issues
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Incorrect interlocks
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Sequence failures
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Timing issues
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Fine-tune control logic based on actual plant behaviour
3. SCADA / ECS Commissioning
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Configure and validate SCADA systems
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FLS ECS / ECS Control enter
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WinCC / FactoryTalk / ABB 800xA
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Test
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Graphics and operator screens
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Alarm systems and priorities
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Trends and data logging
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Ensure operator usability during live operation
4. Field Troubleshooting
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Diagnose and resolve
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Instrument issues (level, pressure, flow, vibration)
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Signal noise / incorrect readings
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Communication failures
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Modbus, Profibus, Profinet, Ethernet/IP
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Coordinate with
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Electrical team (MCC, drives)
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Mechanical team (equipment readiness)
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Process team (operating conditions)
5. Process Stabilization & Optimization
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Tune control loops (PID tuning under real load)
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Optimize sequences for
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Smooth startup/shutdown
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Reduced trips and false alarms
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Implement ECS logic improvements
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Expert rules
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Interlock refinement
6. Integration & Communication
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Ensure seamless communication between
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PLC ↔ SCADA ↔ ECS
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PLC ↔ Drives / Field devices
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Configure and troubleshoot
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OPC communication
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Network architecture (industrial Ethernet)
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Support edge device integration (if CMS / analytics deployed)
7. Documentation & Handover
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Update
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As-built logic
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I/O lists
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Interlock documents
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Prepare commissioning reports
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Test results
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Issue logs
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Modifications done
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Support handover to operations team with training
Required Skills
Core Field Skills
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Strong hands-on experience in
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Loop checking
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Commissioning sequences
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Live troubleshooting
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Ability to read
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P&IDs
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Wiring diagrams
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Control logic
Automation Skills
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PLC programming & debugging
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Ladder, FBD, basic Structured Text
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SCADA/ECS configuration and testing
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Strong understanding of
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Interlocks
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Permissives
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Trip logic
Industrial Communication
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Hands-on troubleshooting
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Modbus TCP/IP
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Profibus / Profinet
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Ethernet/IP
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Basic network diagnostics
Domain Knowledge (Highly Preferred)
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Mining / Mineral processing plants
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Equipment like
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Crushers, mills, flotation cells, vibrating screens, thickeners ,Rotary Kilns, Filter Press,
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Understanding of real plant problems
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Choking, overload, vibration, wear
Soft Skills (Critical for Site Role)
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Ability to work under pressure during startup
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Quick decision-making in plant conditions
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Strong coordination with multiple teams
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Willingness for
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Travel
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Shift work
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Shutdown work
Experience
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5–12 years in commissioning / site roles
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Experience in EPC / OEM commissioning preferred
Typical Work Conditions
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On-site (plant environment)
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Long commissioning hours during startup
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Exposure to dust, noise, and industrial conditions
KPIs / Success Metrics
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Successful startup without major delays
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Number of issues resolved during commissioning
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Time to stabilize plant operation
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Reduction in trips and alarms / Smooth handover to operations
FLSmidth is the leading supplier of engineering, equipment and service solutions to customers in the mining and minerals industries – for more information please visit FLSmidth.com/careers
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