Role Purpose

The Control Systems Engineer is responsible for the reliability, performance, and lifecycle management of all plant automation, instrumentation, and control infrastructure within the Phase 2 concentrator. The role ensures stable plant operation through reliable programmable logic controller systems, supervisory control and data acquisition systems, and instrumentation networks while supporting process optimisation, digital integration, and automation governance.

Key Accountabilities

Control System Governance

• Maintain and support plant automation platforms including programmable logic controllers, supervisory control and data acquisition systems, and operator interface systems.
• Develop and modify programmable logic controller logic, interlocks, and control algorithms.
• Maintain operator interface graphics and alarm systems.
• Ensure system backup, version control, and documentation governance.
• Maintain redundancy and fail-safe operation of critical automation infrastructure.

Instrumentation Reliability

• Provide engineering oversight for field instrumentation including flow, pressure, temperature, and level transmitters.
• Support variable speed drives, control valves, actuators, weigh feeders, belt scales, and gas detection systems.
• Ensure calibration programmes and verification processes are executed.
• Investigate instrumentation failures and implement reliability improvements.
• Ensure signal integrity and accurate data acquisition from process instruments.

Process Control Optimisation

• Work closely with metallurgists and operators to optimise plant control performance.
• Tune proportional-integral-derivative control loops.
• Improve control logic and setpoint strategies.
• Optimise grinding circuit control stability.
• Improve flotation level and reagent dosing control.
• Reduce process variability through automation improvements.

Industrial Network and Cybersecurity

• Ensure reliability and integrity of industrial automation networks.
• Maintain programmable logic controller communication infrastructure.
• Manage control system servers and industrial network switches.
• Implement cybersecurity controls and access management.
• Maintain disaster recovery and backup strategies.

Projects and System Upgrades

• Develop control philosophies and control narratives for new equipment.
• Prepare instrumentation and automation technical specifications.
• Participate in design reviews and technical bid evaluations.
• Support factory acceptance testing and site acceptance testing.
• Lead automation commissioning and system integration.

Data and Digital Systems Integration

• Maintain plant historian connectivity and data integrity.
• Support process data analytics and performance dashboards.
• Integrate automation systems with reliability and maintenance platforms.
• Support digitalisation initiatives and advanced process monitoring systems.

Safety and Compliance

• Ensure automation systems comply with Mine Health and Safety Act requirements.
• Maintain integrity of emergency stop circuits and safety interlocks.
• Participate in hazard and operability studies and risk assessments.
• Ensure engineering change management procedures are followed.

Documentation and Technical Governance

• Maintain updated piping and instrumentation diagrams.
• Maintain control loop diagrams and instrument datasheets.
• Maintain panel wiring diagrams and system architecture drawings.
• Ensure all automation changes are documented and traceable.

Training and Technical Support

• Provide technical guidance to instrument technicians and electricians.
• Support control room operators with automation troubleshooting.
• Deliver training on alarm management and system operation.
• Promote best practices in automation reliability and control stability.

Qualifications and Experience

Education

• Degree or Diploma in Electrical Engineering, Control Engineering, Instrumentation Engineering, or Automation Engineering.

Experience

• Five to eight years experience in mineral processing or heavy industrial automation environments.
• Strong experience with programmable logic controllers, supervisory control systems, and instrumentation.
• Experience with crushing, milling, flotation, and tailings process control systems.
• Experience with industrial networks and automation troubleshooting.

Preferred

• Experience in base metal processing plants.
• Professional registration with the Engineering Council of South Africa advantageous.
• Vendor certifications for programmable logic controller platforms such as ABB, Siemens or Allen-Bradley.
• Experience with process historians and structured query language databases.

Performance Indicators

• Automation system availability and reliability.
• Reduction in control system related plant downtime.
• Instrumentation accuracy and availability.
• Alarm system effectiveness and operator usability.
• Successful commissioning of automation upgrades.
• Data integrity and historian system reliability.