Location: Chennai
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
- 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
- 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
- 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
- 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)
- 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
- 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)
- 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
- 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.
Job description provided by FLSMIDTH.
View the original posting
