Controls Engineer II

Overview

The Senior Controls Engineer is the refinery’s technical authority for automation, instrumentation, industrial networking, and process control systems. This role ensures reliable, secure, and sustainable control infrastructure that supports production, quality, safety, environmental compliance, and operational excellence. 

The position partners with Corporate Controls Engineering, leads controls lifecycle and modernization strategies, and advances the site from reactive maintenance toward preventive, condition-based, and predictive practices.

Detailed Roles and Responsibilities

Technical Leadership and Governance 

• Serve as the site technical authority for controls, instrumentation, industrial networks, and process automation. 

• Lead system implementations, upgrades, and modifications in accordance with company, ISA, functional safety, cybersecurity, and hazardous-area requirements. 

• Direct and mentor engineers, technicians, contractors, and cross-functional teams while promoting standardization and knowledge sharing across ASR. 

• Establish and govern programming, alarm management, architecture, documentation, testing, validation, and cybersecurity standards. 

Asset Lifecycle, Reliability, and Spare Parts 

• Develop and execute a multi-year controls and automation roadmap aligned with operational, maintenance, and capital priorities. 

• Manage the lifecycle of PLCs, HMIs, historians, servers, operating systems, networks, instrumentation, and automation hardware. 

• Identify obsolescence and criticality risks; develop modernization, replacement, stocking, replenishment, and vendor-supported spare-parts strategies. 

• Maintain automation asset inventories and optimize costs while reducing exposure to obsolete or long-lead equipment. 

Predictive Maintenance and Continuous Improvement 

• Lead preventive, predictive, and condition-based programs using PLC/VFD diagnostics, event logs, fault histories, network monitoring, historians, and asset management tools. 

• Use plant data and analytics to identify degradation, improve reliability, and develop asset-health KPIs and dashboards. 

• Lead root-cause investigations for controls and instrumentation failures and implement sustainable corrective actions. 

• Partner with IT, OT, Maintenance, Procurement, and Corporate Controls Engineering to improve system performance, cybersecurity, data access, and asset visibility. 

Management of Change and Project Execution 

• Own the controls Management of Change process and ensure modifications meet testing, validation, documentation, cybersecurity, and process-safety requirements. 

• Provide controls and instrumentation expertise for capital projects, modernization work, commissioning, and major maintenance activities. 

• Troubleshoot and optimize refinery, packaging, and auxiliary control systems; lead recovery after failures and prevent recurrence. 

• Anticipate technical risks, provide on-call coverage, and support other engineers as needed.

Education and/or Experience

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related engineering discipline from an accredited college or university is required. 

WORK EXPERIENCES

• 10+ years of controls, automation, instrumentation, or process-control experience in refining, manufacturing, food or chemical processing, power generation, or a related industrial environment. 

• Demonstrated success leading controls lifecycle, predictive maintenance, standards, modernization, and Management of Change programs. 

• Experience upgrading industrial control systems, instrumentation, networks, and automation infrastructure. 

• Experience leading capital projects from concept through startup and commissioning, including technical teams, contractors, consultants, and cross-functional partners. 

• Experience with spare-parts strategy, inventory optimization, asset management systems, or vendor-managed inventory is preferred. 

Technical and Leadership Capabilities 

• Advanced knowledge of Allen-Bradley ControlLogix, CompactLogix, PLC5, SLC500, VFDs, soft starters, servo systems, and MCCs. 

• Advanced knowledge of Wonderware System Platform, InTouch, Historian, ArchestrA, and related platforms. 

• Working knowledge of industrial networks, managed switches, communication protocols, Windows Server, virtualization, and industrial cybersecurity. 

• Strong knowledge of process instrumentation, including control valves, transmitters, analyzers, and measurement devices. 

• Strong analytical, troubleshooting, project management, planning, budgeting, communication, and stakeholder-influencing skills. 

• Ability to mentor technical teams, balance immediate operational needs with long-term strategy, and execute technology roadmaps aligned with business objectives. 

Essential Capabilities / Competencies

• Analytical Thinking & Decision Making – Identifies and understands trends and/or issues; connects data points through analysis to arrive at a logical conclusion.
• Business & Financial Acumen – Demonstrates knowledge and understanding of the financial, accounting, marketing and operational functions of our organization; interpreting and applying understanding of key financial indicators to make better corporate decisions.
• Effective Communication – Expresses ideas and information in a clear and concise manner by tailoring one's message to fit the interests and needs of the audience.
• Customer Orientation – Keeps internal and/or external customer(s) in mind at all times.  Strives to proactively address customer concerns and needs.  Assists business partners and customers to achieve their work goals via application of their own skills and knowledge; strives to provide consistent customer satisfaction.
• Establishes Trust – Gaining the confidence and faith of others by actions and words that promote being honest, forthcoming, integrious and vulnerable.
• Problem-Solving – Anticipates, evaluates, diagnoses, and resolves problems in a systematic and fact-based manner.
• Results Orientation & Accountability – Takes accountability, identifies, executes and drives actions to consistently achieve desired results.
• Teamwork & Collaboration – Creates a climate that fosters commitment to a common vision and shared values that promote cooperation and working together through trust and support of others.
• Adaptability/Flexibility – Maintaining effectiveness in varying environments and with different tasks, responsibilities and people.
• Continuous Improvement – Establishes methods and utilizes specialized techniques to monitor and improve performance of systems and processes.
• Self-Development – Seeks feedback on one’s strengths and weaknesses and initiates activities to increase or enhance their knowledge, skills, and proficiency in order to perform more effectively or enhance their career. 

Location of Role

• Baltimore, Maryland

REWARD PACKAGE    

The expected pay range for this position is $93,000 - $172,500 and will depend on the candidate’s qualifications and prior experience.

• Full benefits package including medical, dental, vision, life insurance, 401K and other benefits