Automation Engineer - Site Commissioning

Automation Engineer - Site Commissioning

Company: FLSmidth Pvt Ltd

Job Location: Chennai, Tamil Nadu, India

Employment Type: Full-time

Experience Required: 5 - 12 years

About the Role

Chief Engineer, Automation Customer Services J ob 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 Execute cold commissioning : I/O loop checking Instrument calibration validation Signal verification from field to PLC/SCADA Perform hot commissioning : Equipment-wise startup (motors, drives, feeders, screens, mills) Interlock validation and permissive checks Commission FLS ECS (Expert Control System) and integrate with plant PLCs Support first material flow and ramp-up to design capacity 2.

PLC & Control Logic Execution (On-Site) Download, test, and modify PLC programs: Rockwell (Control

Logix / Compact

Logix) Siemens (S7 / TIA Portal) ABB (AC800M / 800xA) Debug real-time issues: Incorrect interlocks Sequence failures Timing issues Fine-tune control logic based on actual plant behaviour 3.

SCADA / ECS Commissioning Configure and validate SCADA systems: FLS ECS / ECS Control enter WinCC / Factory

Talk / ABB 800xA Test

Graphics and operator screens Alarm systems and priorities Trends and data logging Ensure operator usability during live operation 4.

Field Troubleshooting Diagnose and resolve

Instrument issues (level, pressure, flow, vibration) Signal noise / incorrect readings Communication failures: Modbus, Profibus, Profinet, Ethernet/IP Coordinate with: Electrical team (MCC, drives) Mechanical team (equipment readiness) Process team (operating conditions) 5. Process Stabilization & Optimization Tune control loops (PID tuning under real load) Optimize sequences for: Smooth startup/shutdown Reduced trips and false alarms Implement ECS logic improvements: Expert rules Interlock refinement 6. Integration & Communication Ensure seamless communication between: PLC SCADA ECS PLC Drives / Field devices Configure and troubleshoot: OPC communication Network architecture (industrial Ethernet) Support edge device integration (if CMS / analytics deployed) 7.

Documentation & Handover Update

As-built logic I/O lists Interlock documents Prepare commissioning reports: Test results Issue logs Modifications done Support handover to operations team with training Required Skills Core Field Skills Strong hands-on experience in: Loop checking Commissioning sequences Live troubleshooting Ability to read: P&IDs Wiring diagrams Control logic Automation Skills PLC programming & debugging: Ladder, FBD, basic Structured Text SCADA/ECS configuration and testing Strong understanding of: Interlocks Permissives Trip logic Industrial Communication Hands-on troubleshooting: Modbus TCP/IP Profibus / Profinet Ethernet/IP Basic network diagnostics Domain Knowledge (Highly Preferred) Mining / Mineral processing plants Equipment like: Crushers, mills, flotation cells, vibrating screens, thickeners ,Rotary Kilns, Filter Press, Understanding of real plant problems: Choking, overload, vibration, wear Soft Skills (Critical for Site Role) Ability to work under pressure during startup Quick decision-making in plant conditions Strong coordination with multiple teams Willingness for: Travel Shift work Shutdown work Experience 512 years in commissioning / site roles Experience in EPC / OEM commissioning preferred Typical Work Conditions On-site (plant environment) Long commissioning hours during startup Exposure to dust, noise, and industrial conditions KPIs / Success Metrics Successful startup without major delays Number of issues resolved during commissioning Time to stabilize plant operation 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 We offer all employees access to a dedicated recognition platform, empowering you to celebrate achievements, share appreciation and stay connected globally. Experience Level Executive Level .