Principal Engineer Advanced Process Control

Job description

Role: Principal Engineer - Advanced Process Control

Location: Houston, TX 77056

Duration: Direct Hire 

Work Authorization: US Citizen, Green Card, or Authorized to Work in US



Summary

As a Principal APC Engineer, you will lead the identification, design, implementation, and maintenance of advanced process control and optimization applications across Westlake's Performance and Essential Materials (PEM) manufacturing plants, with a focus on a variety of APC platforms, including AspenTech, Rockwell Automation, and Honeywell APC platforms.

You will partner with Data Scientists, Plant Operators, Process Engineers, and Digital Office colleagues to deploy and sustain robust APC solutions that deliver measurable improvements in safety, reliability, efficiency, product quality, and sustainability objectives.

Your expertise will directly support client's multi-year APC strategy, targeting multi-million-dollar annual benefits and harmonization of control systems across diverse technologies and sites.



Key Responsibilities

Technical Leadership

• Responsible for the entire lifecycle of an APC project, including identification, design, implementation, and maintenance of APC Applications for real-time process optimization across PEM manufacturing sites.


• Analyze process dynamics and operation challenges, and develop advanced control strategies, including multivariable control, advanced PID, sequence control, and interlocks, etc.


• Proactively monitor, troubleshoot, and tune APC and base layer PID controller performance, ensuring uptime and benefit realization targets are met.
  
  Support the implementation and maintenance of the company-wide APC KPI Dashboard system.


• Re-evaluate and adapt control strategies in response to plant operating condition changes.


• Integrate APC systems with DCS, PLCs, laboratory information systems, and plant historians (e.g., InfoPlus.21 and OSIsoft PI).
  
  Support plant operations during turnarounds, commissioning, and start-up phases; perform site acceptance testing and commissioning of control systems.


• Ensure changes follow Westlake's Management of Change (MOC) processes and maintain comprehensive documentation (PID loop tuning logs, APC design and implementation documentation, APC change logs, etc.).

Collaboration & Communication

• Provide training and coaching to operators and process engineers on APC system usage and best practices.


• Facilitate adoption and effective use of APC solutions; report usage and performance against defined KPIs. Experienced in collaborating and communicating with a variety of stakeholders of multi-disciplines, including company/plant management team, process/production team, operation team, control team, company IT/OT team, etc., during the entire lifecycle of an APC project.


• Organize and/or participate in various activities to develop Westlake's APC program, including providing training and coaching to fellow APC engineers with less experience, sharing lessons learned and best practices in company's APC network, developing & defining companywide standards or guidelines for APC project implementation and maintenance process, etc.


• Participate in DCS/PLC software and hardware upgrades, alarm rationalization, and technical assurance reviews.


• Work closely with plant operations and engineering to identify and implement process control improvements.

Strategic Initiatives

• Collaborate with OT/IT and Data Science teams to define and execute real-time data strategies and architectures for process automation and analytics.


• Contribute to the development of technology roadmaps and capital plans for process-automation, control, and optimization.


• Support standardization and harmonization of APC practices, specifications, and KPIs across client's global PEM sites.

Qualifications

Required

• Minimum 10 years of hands-on experience in identifying, designing, implementing, tuning, and sustaining AspenTech APC (DMC3/DMCplus/IQ) applications in refinery, chemical, or petrochemical plants; experiences of other APC platforms, such as Honeywell's Profit Suite/Forge APC platform, and Rockwell Automation's Pavilion8 MPC platform will also be beneficial


• Bachelor's or Master's degree in Chemical Engineering (or related field).


• Proven expertise in multivariable control and process optimization; experience in steady-state and dynamic process modeling is a plus.


• Strong working knowledge of process flowsheets, P&IDs, and control logic diagrams.
  
  Demonstrated capability on learning new processes and data analysis.


• Demonstrated ability to lead APC projects from design through commissioning and sustainment.


• Experience with plant data historians (OSIsoft PI, InfoPlus.21, etc.), PIMS, and integration with OT/IT systems.


• Excellent troubleshooting, problem-solving, and analytical skills.


• Effective oral and written communication skills; ability to work collaboratively across diverse teams and locations.


• Strong planning and organizational skills; able to manage multiple priorities and develop support roadmaps.

Preferred

• Experience with additional APC/optimization/modeling platforms (e.g., Aspen Watch, Aspen IQ, SPYRO, ProMV, etc.).


• Experience in training and mentoring plant personnel on APC and process automation topics.


• Experience in coaching APC engineers with less experience, as well as developing central APC program.


• Working knowledge of industry standards in industrial automation, and project management.

Physical Demands & Work Environment

• Office-based with frequent work in operating units requires use of PPE and potential exposure to outside elements.


• Must be able to sit, walk, use hands, talk, and hear as required by typical office and plant environments.


• Lifting up to 25 pounds may be required.


• Travel up to 50% (domestic and international) to support client PEM manufacturing plants.

About INSPYR Solutions

Technology is our focus and quality is our commitment.

As a national expert in delivering flexible technology and talent solutions, we strategically align industry and technical expertise with our clients' business objectives and cultural needs.

Our solutions are tailored to each client and include a wide variety of professional services, project, and talent solutions.

By always striving for excellence and focusing on the human aspect of our business, we work seamlessly with our talent and clients to match the right solutions to the right opportunities.

Learn more about us at (url removed).



INSPYR Solutions provides Equal Employment Opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability, or genetics.

In addition to federal law requirements, INSPYR Solutions complies with applicable state and local laws governing nondiscrimination in employment in every location in which the company has facilities.



 

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