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 (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 plant behaviour  

3. SCADA / ECS Commissioning 

• Configure and validate SCADA systems:  

• FLS ECS / ECS Control 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)  

• 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 

• 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