About the role
Job Title: Automation Engineer – Site Commissioning (ECS / SCADA / PLC)
Role Overview
The Automation Engineer (Site Commissioning) is responsible foron-site commissioning, testing, troubleshooting, and stabilizationof automation systems includingFLS ECS, SCADA, and PLC platforms (Rockwell, Siemens, ABB).
This role is highly hands-on and requires working inlive plant environmentsto ensuresafe startup, reliable operation, and performance optimizationof process units.
Key Responsibilities
1. Site Commissioning & Startup
Executecold commissioning:
I/O loop checking
Instrument calibration validation
Signal verification from field to PLC/SCADA
Performhot commissioning:
Equipment-wise startup (motors, drives, feeders, screens, mills)
Interlock validation and permissive checks
CommissionFLS ECS (Expert Control System)and integrate with plant PLCs
Supportfirst material flowand ramp-up to design capacity
2. PLC & Control Logic Execution (On-Site)
Download, test, and modify PLC programs:
Rockwell (ControlLogix / CompactLogix)
Siemens (S7 / TIA Portal)
ABB (AC800M / 800xA)
Debug real-time issues:
Incorrect interlocks
Sequence failures
Timing issues
Fine-tune control logic based on actual plantbehaviour
3. SCADA / ECS Commissioning
Configure and validate SCADA systems:
FLS ECS / ECSControl enter
WinCC / FactoryTalk / 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)
Supportedge 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
Supporthandover to operations teamwith 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
5–12 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
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