Systems Engineer - HROC

Location: Cairo

Time Type: Full time

Job Description

Reporting to: Functional Engineering Lead – HROC

Job Purpose:

In this role, you will be responsible for providing technical support and expertise to multiple cement plants within a designated region. You will collaborate effectively across departments to achieve shared goals.

Based in a central location remote to the plants, you will collaborate closely with plant teams & train, coach them to optimize process performance, troubleshoot issues, and drive continuous improvement initiatives across the region. Occasional travel to the plant sites supported will be required.

Roles and Responsibilities:

• Control System Support: Provide technical support for the operation, maintenance, and troubleshooting of control systems at multiple cement plant sites. Collaborate with plant teams and process engineers to identify and resolve control system issues, ensuring minimal disruption to plant operations. Ensure compliance with safety and regulatory standards.
• Hands on Control Systems Engineering experience depending on the site supported: Siemens PCS7, WinCC, CEMAT, ACSYS, ABB 800xA, FLS ECS ControlCenter & PLC Engineering: S7-200/300/400/1200/1500, LOGO, ET200, Safety PLCs, Schneider Control Expert, ABB AC800M & SCADA Systems: Panorama, WinCC Professional, WinCC Unified, 800xA, ECS.
• System Optimization: Collaborate with plant teams and process engineers to analyze control system performance data, identify opportunities for optimization, and implement improvement strategies. Optimize control algorithms, tuning parameters, and control loops to enhance process stability, efficiency, and product quality.
• Expert System Application Maintenance and Optimization: Work in coordination with plant teams and process engineers to maintain and optimize expert system applications in crushing, milling, pyro-processing, environmental compliance, and quality control applications to drive high utilization and value.
• Expert Systems: FLS Process Expert, G2 Expert System, Kiln Expert, Mill Expert, PID, Fuzzy Logic, MPC.
• Industrial Communications: OPC DA/UA, Kepware, Profibus, Modbus, HART, MQTT.
• Data Acquisition/Historian Support: Provide technical support for the maintenance and troubleshooting of the company’s data historian. Add tags and configure connections to new systems, build customer reports, manage user accounts, and assist process engineers with development of trends and other historian tools.
• Reporting & Data Systems: PxTrend, HProduce, LIMS, SQL, Power BI, PI, AVEVA Historian.
• System Upgrades and Integration: Support control system upgrades, migrations, and integration projects. Collaborate with cross-functional teams, including project managers, IT, process engineers, and vendors, to plan and execute system upgrades, implement new functionalities, and ensure seamless integration with existing plant systems.
• Maintenance and Documentation: Develop and implement preventive maintenance plans for control systems, including routine inspections, calibrations, and software updates. Maintain accurate and up-to-date documentation of control system configurations, interlock diagrams, network diagrams, business continuity plans and standard operating procedures. Ensure compliance with change management processes. Instrumentation: Gas analyzers, QCX, Cross Belt Analyzers, Pfister, Schenck, Smart instrumentation.
• Drives & Electrical Systems: SINAMICS, ABB ACS800/880/1000/6000, Perfect Harmony, SIPROTEC.
• Engineering Governance: EPLAN, COMOS, AutoCAD, FAT, SAT, Commissioning.
• Training and Knowledge Transfer: Provide training and technical guidance to operators and process engineers on control system operation, troubleshooting techniques, and best practices. Foster a culture of knowledge sharing and continuous learning by conducting workshops, developing training materials, and sharing expertise with the plant teams.
• Cybersecurity: Collaborate with IT teams and cybersecurity experts to implement robust security measures and protocols to protect process network systems from cyber threats. Monitor and assess system vulnerabilities, recommend, and implement security enhancements, and ensure compliance with cybersecurity standards.
• OT Infrastructure & Cybersecurity: VMware, AD, Scalance, Hirschmann, Cisco, Fortinet, IEC62443, NIST, Defender for IoT, Clarity.
• Digitalization: AI, ML, Industrial Edge, Digital Twin, Azure Analytics.
• Provide basic support for Windows systems, PCs, peripherals, and Microsoft 365
• Troubleshoot user issues related to system, application, and connectivity
• Support collaboration and AV equipment (conferencing systems, headsets, displays)
• Deliver remote support and escalate issues through IT processes

Job Qualifications, Requirements & Experience:

Education

• Bachelor's degree in electrical, Automation Engineering, Control Systems Engineering, or related fields.
• 10-12 years Expectational subject & site experience in control systems engineering in the cement industry.
• Proven experience supporting multiple plants remotely.
• Extensive experience with commissioning, startup, modernization, and optimization projects.
• Strong knowledge of control system principles, distributed control systems (DCS), programmable logic controllers (PLC), human-machine interfaces (HMI), and process automation.
• Proficiency in programming languages such as ladder logic, structured text, or function block. Working knowledge of multiple control systems is preferred.
• Strong hands-on experience with (Siemens PCS 7, CEMAT, TIA Portal, ABB 800xA, FLS ECS Control Center & ACSYS, Panorama SCADA, FLS Process Expert, G2 Expert System, CFC, SFC, STL & SCL Programming, PLC Platforms (Siemens S7-200/300/400/1200/1500, Siemens Safety PLCs, Schneider Control Expert (Unity Pro), ABB AC800M)
• Experience with control system hardware, networking, and communication protocols.
• Experience configuring and maintaining VMware virtual environments.
• Experience with OPC DA servers, OPC UA, Profinet , Profibus, Modbus, HART, MQTT clients and tunnellers.
• Familiarity with cybersecurity principles and practices for control systems.
• Infrastructure & Cybersecurity: Experience with (VMware, Windows Server, Active Directory, Firewalls, OT Networking, IEC62443, OT Asset Management, Cybersecurity Governance, Scalance, Hirschmann, Cisco.
• Familiarity with digitalization, artificial intelligence, data historians, and expert systems, advanced Process Control (APC), Model Predictive Control (MPC), Fuzzy Logic & PID Control, Process Expert & G2 Expert Systems, AI, Machine Learning, Predictive Maintenance, Digital Twins, Power BI, SQL Server.
• Familiarity with power metering, instrumentation, gas analyzers, control devices, motor control centers, switchgear and control panel design and engineering. Experience using EPLAN, COMOS, and AutoCAD. Electrical and ETAP. Support Siemens SINAMICS, ABB ACS800/880, ABB ACS2000 and Perfect Harmony, Support SIPROTEC relays, ABB REF 620,615 protection relays, SICAM and load shedding systems.
• Good knowledge of Windows environments and end-user computing
• Basic troubleshooting skills for PCs, peripherals, and applications
• Understanding of networking fundamentals (connectivity, Cisco switching)
• Experience with PxTrend, SQL, Historians, Power BI and AI solutions.
• Ability to resolve common access and connection issues
• Familiarity with AV tools and remote support systems
• Excellent problem-solving and analytical skills, with the ability to diagnose and resolve complex control system issues.
• Training and coaching abilities.
• Ability to communicate fluently and effectively with international stakeholders in English. French language skills are preferred for French plants supporting resources.
• A proactive team player who thrives in a supportive, high-energy environment.
• Strong training, coaching, communication, and leadership skills.
• A work certificate applicable to work in France is an advantage.

Work Week: European