Engineer Principal-Process Control

SUMMARY

Westlake Chemical Corporation Digital Office operates at the heart of the strategic direction of our enterprise. The Digital Office team drives digital transformation across the enterprise entire portfolio to achieve growth through making significant enhancements in customer experience and operational excellence.

As a member of the Digital Office, the RTO Process Control Engineer will work with Data Scientists, Data Analysts, Plants Operators, and functional subject matter experts to orchestrate a data driven enterprise and develop end-to-end analytics solutions that provide actionable insights in real-time, automating manufacturing and process control decisions.

As an RTO Process Control Engineer you will collaborate with plant operations to support the manufacturing plants safety instrumented systems, control automation strategies and OT data strategies, build process models, perform real-time optimization of process automation controls, PID loop-tuning, program distributed control systems (DCS), and advanced process control (APC) systems, work with data science teams developing AI/ML models for improving process automation control and continuous process improvements. Also, you will support the development of data platform systems, building of pipelines to transform data for data analysis and automation. You will work with a variety of infrastructures that generate and carry data such as Web, Cloud, Edge, On-Premise Servers, Open Platform Communications (OPC) to connect with control systems, SCADA, DCS, IIoT, Mobile, and Robotics in manufacturing and business processes. You will collaborate with Data Science Team to develop real-time process control using data analytics and automation applications.

The RTO Process Control Engineer provides support to the production operation teams on process control schemes, performance and best practices, and participate in reviews of management of change related to process control improvements or changes, has functional working knowledge of safety instrumented systems, control systems applications/hardware, process operation, operational goals, alarm rationalization management, process constraints, key quality specifications for feeds and products, impact on the environment, and major economic variables and how they impact site profitability and goals.

By Digital or Digitization, Westlake means a combination of technologies, tools, methods, approaches etc. that will enable Westlake to re-architect business processes and business models to achieve superior financial returns or meet the organizations strategic objectives in areas such as safety, sustainability, and business processes improvements and transformations. Digital technologies may include, and not limited to, Artificial Intelligence/Machine Learning/Data Science, Robotics, AutoBots, IoT, Big Data, Blockchain, Augmented Reality/Virtual Reality, Social Media/Collaboration, and Mobility.

DUTIES AND RESPONSIBILITIES

May include, but are not limited to, the following:

• Technical:

• Responsible for support of process control systems for Westlake petrochemical plants, including real-time optimization, process model development, loop tuning, and continuous improvements.

• Analyzes the process dynamics, develops, implement, and maintains advanced process control applications, advanced PID control, interlocks, and sequence control.

• Proactively monitoring and tuning of process control performance including base layer controller uptime, advanced process controller uptime against targets. Develops and implements improvement plans..

• Re-evaluates control approaches and performance due to changes in plant operating conditions..

• Work with data scientists and control engineers to interface advanced process controller systems to distributed control systems, programmable logic controllers, and laboratory information systems.

• Support units during turnaround events.

• Responsible for day-to-day support to production operations during plant commissioning and start-up phase followed up with the same level of support in run & maintain phase.

• Performs control system site acceptance tests and other site-based control system commissioning and start-up activities.

• Develop and implement changes following site management of change process.

• Communication:

• Provide and/or arrange training for operators and process engineers related to process automation and advanced process controller systems.

• Facilitate and encourage usage of advanced process controller systems.

• Report on usage of advanced process controller systems against targets

• Participate in distributed control systems software/hardware upgrades and alarm reviews.

• Works closely with board operators and process engineers to identify and implement improvements.

• Maintains proper documentation for the process control systems (such as control loops and tuning spreadsheet, change logs)

• Assists in process control technical assurance for management of change reviews.

• Strategy:

• Collaborates with OT/IT/Data Science to define real-time data strategy and architecture for data analytics and process automation.

• Assists in the development and implementation of technology plans (part of for example capital plans, infrastructure upgrades, reliability improvement strategies, control improvement plan) for safe, reliable, and efficient process automation, control, and optimization at plant sites.

QUALIFICATIONS

• Experience with advanced process control Applications (multivariable control, complex control loops, control logic).

• Ability to read and interpret process flowsheet diagrams, P&IDs, and control logic diagrams.

• Steady state and dynamic process modeling expertise.

• Working knowledge of software application such as AspenTech DMC3, DMCplus, Aspen Watch Performance Monitor, OSIsoft PI, PIMS, SPYRO, Honeywell APC.

• Practitioner of advanced process control and optimization related technology with hands-on experiences in chemical processes.

• Working knowledge of Industrial Automation, Electrical Engineering, Project Management, Design Engineering Practices, and industry standards.

• Demonstrated knowledge of practical process controls work experience.

• Demonstrated analytical and decision-making skills.

• Strong troubleshooting and problem-solving skills.

• Ability to cope with a variety of issues and situations.

• Able to work with diverse groups.

• Good communication skills (Oral/Written).

• Good work planning skills to handle multiple tasks with competing priorities and develop a roadmap and skillsets to support his/her discipline.

EDUCATION and EXPERIENCE

• At least 10 years of full-time work experience in a refinery, chemical, or petrochemical plant.
• BS/MS in Chemical, Electrical or Mechanical Engineering or related degree, PhD required.

PHYSICAL DEMANDS

While performing the duties of this job, the employee is regularly required to sit. The employee frequently is required to walk; use hands to touch, handle, or feel; reach with hands and arms; and talk or hear. The employee is occasionally required to stand. The employee must regularly lift and/or move up to 10 pounds, frequently lift and/or move up to 25 pounds. Any lifting in excess of 25 pounds requires assistance from another employee. Specific vision abilities required by this job include close vision, distance vision, color vision, and ability to adjust focus. The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

WORK ENVIRONMENT

The noise level in the work environment is usually moderate as normally based in an office. Some of the work may be required in the operating units which can require usage of required PPE including safety glasses, hearing protection, etc. May also result in exposure to outside elements and may require usage of stairs and elevators. Travel up to 50% including air travel or auto travel.