PLC Reliability Engineer

• General-purpose PLCs and safety PLCs, including PLC-based SIS logic solvers.

• General-purpose PLCs and safety PLCs, including PLC-based SIS logic solvers.
• PLC hardware, application software, and associated input/output systems.
• PLC-associated computers and human-machine interfaces (HMIs).
• PLC communications and associated network interfaces, in coordination with responsible OT and cybersecurity personnel.
• Equipment-monitoring devices integrated with PLC systems.
• Associated programmable devices, including remote terminal units (RTUs) and programmable relays.
• 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.

• Effective performance in this role is critical to the efficient operation of the manufacturing sites.

• Effective performance in this role is critical to the efficient operation of the manufacturing sites.
• Provide unit I&E reliability and maintenance support as assigned, assisting with troubleshooting, root cause investigations, equipment reliability improvements, and resolution of instrumentation, control valves, electrical, and control system issues.
• Demonstrate a strong understanding of the Management of Change (MOC) process and be capable of leading, developing, and managing MOCs related to PLC, control system, instrumentation, and electrical modifications.
• Provide technical accountability for the reliability of site PLC platforms, including general-purpose PLCs and safety PLC hardware. Coordinate with the SIS Engineer on issues 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 within the assigned scope. Coordinate unit I/E, Operations, OT, vendors, and other specialists; develop corrective actions and verify their effectiveness. Unit I/E retains routine troubleshooting and maintenance responsibility.
• Serve as the owner of the site PLC system lifecycle, assessing system condition and recommending appropriate 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 to troubleshoot, reprogram, and maintain all 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.
• Stay abreast of current technology and strive to improve BMC’s General PLC systems
• Support IEA Superintendent, I&E Team Leaders to identify and develop training to enhance and maintain I&E personnel PLC competencies

• Bachelor’s degree in Automation, Electrical Engineering, Chemical Engineering, Computer Engineering or related fields required. Associate degree is not sufficient
• Experience in, and a strong desire to develop, E/I reliability capabilities within a plant operating environment.
• A minimum of 3 years of experience working with Programmable Logic Controller or other Automation equipment including engineering of said systems.
• Hands-on experience supporting PLCs such as Rockwell, Emerson, Triconex, HIMA, GE, or Siemens.
• Familiarity with networked systems and remote access of PLCs.

• Strong engineering background, with focus 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 Industry Standards (ANSI, NFPA, ISA, IEC, API, etc.) that influence PLC functionality and configurations
• Demonstrated ability to lead complex PLC troubleshooting and root cause investigations involving field devices, logic, interlocks, communications, and control-system interfaces.
• Demonstrated ability to develop PLC lifecycle, obsolescence, maintenance, migration, and replacement strategies that address reliability, maintainability, supportability, and asset risk.
• Ability to provide asset-owner technical assurance for PLC modifications and projects, develop technical justification 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, observing site procedures and protocols.
• Experience working with multiple engineering disciplines, as well as contractors supporting delivery of PLC programming/hardware and PSM Initiatives.
• Must be a self-starter and capable of working on an individual basis and in a team environment.
• Strong organizational skills and ability to prioritize work and deliver quality results on time.
• Ability to train, coach, and mentor maintenance technicians and junior level technical staff preferred.
• Strong oral and written communication skills
• Strong leadership skills, including ability to lead and motivate individuals or teams
• Proven ability to influence and manage change.
• Demonstrated ability to build positive relationships with plant personnel supporting PLC optimization: Operations, Maintenance, Technology, and Capital Projects teams.
• Demonstrated problem solving and troubleshooting skills.
• Self-Motivated individual who takes initiative to get results and seeks opportunities for additional responsibility.