Senior Rockwell / Allen-Bradley PLC & HMI Programmer

The Senior Rockwell/Allen-Bradley PLC & HMI Programmer is responsible for the design, programming, commissioning, and lifecycle support of industrial control systems utilizing Rockwell Automation hardware and software platforms. This role will lead automation efforts for complex process systems—such as gas handling, thermal systems, chemical processing, and high-reliability nuclear equipment—ensuring safe, robust, and maintainable control architectures.

The ideal candidate is deeply experienced with ControlLogix, CompactLogix (5069/5094), GuardLogix, and FactoryTalk View ME/SE, and can take a system from P&IDs to a fully commissioned automation solution.

Key Responsibilities

PLC Programming & Architecture

• Develop, test, and deploy PLC logic in Studio 5000 Logix Designer, including:
  
  • Structured Text, Ladder Logic, Function Block, and SFCs.
    
  • Safety logic in GuardLogix (SIL-rated systems) aligned with IEC 62061 / IEC 61511 / ISA-84 preferred.
    
  • High-reliability analog and digital I/O processing.
    
  • Integration of CompactLogix 5069-series and 5094-series distributed I/O over EtherNet/IP.
• Architect control strategies for continuous and batch processes, motion systems, and interlock logic.
  
• Manage CIP connections, task scheduling, buffer sizing, UDT/ADD-ON instruction development, and diagnostics.

HMI & SCADA Development

• Develop operator interfaces in:
  
  • FactoryTalk View SE / ME
    
  • FactoryTalk Linx / Studio / ViewPoint
    
• Implement high-reliability graphics, alarming, historian integration, and navigation.
  
• Ensure HMI standards for clarity, usability, ISA-101 compliance, and system maintainability.

Network & Communications

• Design and configure EtherNet/IP networks.
  

• Integrate OPC-UA/DA servers, Modbus TCP gateways, and third-party instrumentation.
  

• Troubleshoot network latency, connection limits, and performance issues

Instrumentation & Controls Integration

• Integrate field instrumentation including flow, pressure, temperature, level, and analyzer signals (4–20 mA, HART, RTDs, high-temp transmitters, SIL-rated devices).
  
• Support loop checkout, I/O calibration, FAT, SAT, and commissioning activities.
  
• Read and interpret P&IDs, electrical schematics, Loop Sheets, and cause-and-effect matrices.

Project Execution & Leadership

• Lead automation design from requirements through commissioning.
  
• Work cross-functionally with mechanical, electrical, process, and safety teams.
  
• Prepare functional specifications, control narratives, and test documentation.
  
• Provide mentorship to junior engineers and technicians.
  
• Manage scope, schedule, and deliverables for automation segments of the project.

Troubleshooting & Support

• Diagnose complex PLC/HMI issues, network faults, and field wiring problems.
  
• Support root cause failure analysis (RCFA).
  
• Implement system improvements for reliability, cybersecurity, and performance.

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Computer Engineering, Mechatronics, or related field (or equivalent experience).
  
• 8+ years of hands-on experience programming Rockwell PLCs and FactoryTalk HMI systems.
  
• Deep proficiency with:
  
  • Studio 5000 (v30+)
    
  • ControlLogix / CompactLogix (5069-L3xx, L8x preferred)
    
  • GuardLogix safety controllers
    
  • 5069 & 5094 I/O platforms
    
  • FactoryTalk View SE/ME
    
  • FactoryTalk Linx, FactoryTalk Studio
    
• Strong understanding of industrial networking (EtherNet/IP, Stratix configuration).
  
• Experience integrating VFDs, servo drives, intelligent MCCs, remote I/O, and industrial sensors.

Preferred Experience

• Experience in one or more of the following industrial sectors:
  
  • Gas systems (hydrogen, helium, natural gas, industrial gases)
    
  • Chemical processing
    
  • Power generation (including nuclear research/test facilities)
    
  • Thermal and high-temperature systems
    
• Knowledge of IEC 61511 / ISA-84, SIL verification, and Safety Instrumented Functions.
  
• Experience with historians: FT Historian, PI, Canary Labs, Ignition.
  
• Experience with virtualization (VMWare, Hyper-V), Rockwell Patch Manager, version control (FactoryTalk AssetCentre or Git-based workflows).
  
• Cybersecurity standards (ISA/IEC 62443).