Senior Control System Engineer

About us

Worley is a global company of energy, chemicals and resources experts headquartered in Australia. We partner with our customers to deliver projects and create value across the life of their assets. We specialize in consulting, engineering, procurement and construction across the project lifecycle, with services extending through to operations and decommissioning. Leveraging extensive experience and AI-enabled delivery, we support customers in navigating complexity as they meet today's needs and transition to more sustainable solutions.

Purpose : We are seeking an experienced Process Control Engineer with deep expertise in materials handling automation, constraint control, and throughput optimisation, capable of translating plant operating objectives into robust control strategies that consistently maximise production while maintaining stable and safe operation. Experience in large-scale mining operations would be highly advantageous.
The role is responsible for the design, implementation, tuning, and continuous improvement of constraint-based control strategies that maximise plant throughput while maintaining stable and safe operation. The role focuses on coordinating process control systems across the entire materials handling and processing circuit, ensuring production rates are optimised without causing equipment overload, blockages, or spillage. The successful candidate will combine strong advanced process control, automation, and optimisation experience with expertise in bulk materials handling systems. They will have demonstrated capability in developing and commissioning constraint-based control strategies, analysing process performance, and delivering plant-wide throughput improvements through effective application of control theory, process modelling, and data-driven optimisation techniques. To design, review, and deliver secure and resilient OT network architectures and engineering solutions that support industrial control systems, telecommunications infrastructure, digital platforms, and production-critical operational services. The role ensures that OT network designs are aligned with client requirements, engineering standards, cybersecurity principles, industrial protocols, operational performance expectations, and project delivery objectives. The Role

As a Senior Control System Engineer with Worley, you will work closely with our existing team to deliver projects for our clients while continuing to develop your skills and experience etc.

• Design and implement plant-wide constraint control strategies.
• Develop, configure, and commission advanced process control algorithms.
• Optimise materials handling systems to maximise throughput and minimise operational disturbances.
• Coordinate interactions between multiple process areas and control systems.
• Configure and tune PLC/DCS regulatory and supervisory control loops.
• Analyse process data to identify bottlenecks and improvement opportunities.
• Develop process simulations and material flow models to validate control strategies.
• Support commissioning, performance testing, and continuous improvement initiatives.
Work closely with operations personnel to establish and maintain production targets.

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About You
To be considered for this role it is envisaged you will possess the following attributes: Job Specific Skills:

• Advanced Process Control & Optimisation:
  • Constraint Control Strategy (CCS) design, implementation, and optimisation
  • Advanced Process Control (APC) methodologies
  • Plant-wide throughput optimisation
  • Bottleneck and constraint identification
  • Push-pull control philosophies
  • Production rate optimisation and load balancing
  • Regulatory and supervisory control systems
  • Process performance monitoring and continuous improvement
• Process Control Engineering:
  • Process dynamics and control theory
  • PID control loop design, tuning, and optimisation
  • Model-based control strategies
  • Control system stability analysis
  • Process commissioning and performance testing
  • Statistical Process Control (SPC)
  • Control narrative and functional specification development
  • Alarm management and control system diagnostics
• Materials Handling Systems:
  • Conveyor systems control
  • Crusher, screen, stockpile, and reclaim systems
  • Ore handling facilities and process plants
  • Weightometer-based flow control
  • Bulk materials flow optimisation
  • Throughput and inventory management
  • Overload and spillage prevention strategies
  • Route and equipment coordination
• Control Systems & Automation:
  • PLC programming, configuration, and troubleshooting
  • DCS configuration and optimisation
  • ABB 800xA (highly desirable)
  • SCADA systems
  • Industrial communications and interfaces
  • Control system testing and commissioning
  • Functional design specifications (FDS)
  • Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT)
• Process Simulation & Analytics:
  • Process modelling and simulation
  • Material flow modelling
  • MATLAB/Simulink (desirable)
  • Data analysis and visualisation
  • Historian data interpretation
  • Performance analytics and KPI development
  • Production forecasting and scenario analysis
  • Root cause analysis
• Instrumentation:
  • Flow, level, pressure, and weight measurement systems
  • Weightometer calibration and utilisation
  • Process instrumentation selection and application
  • Instrument loop testing
  • Field commissioning and troubleshooting
  • Instrument reliability and maintenance considerations
• Mining & Industry Knowledge:
  • Iron ore processing and materials handling
  • Mining process plants
  • Production management principles
  • Safe and sustainable operations
  • Asset utilisation and operational excellence
  • Brownfield optimisation projects

Qualifications / Requirements:
Essential:

• Bachelor degree in Electrical Engineering, Communications Engineering, Computer Science, Systems Engineering, Control Systems, or a related discipline.
• 10+ years' experience in process control and automation.
• Strong background in bulk materials handling and plant-wide optimisation.
• Demonstrated experience with Advanced Process Control (APC) and constraint control strategies.
• Strong understanding of process dynamics, instrumentation, and control theory.
• Experience in data analytics and statistical process control.
• Proficiency in PLC and DCS configuration, programming, testing, and commissioning.
• Experience tuning control loops and improving process control algorithms.
• Ability to analyse process bottlenecks and optimise production systems.

Preferred:

• Iron ore processing and materials handling experience.
• ABB 800xA experience.
• MATLAB modelling and simulation experience.
• Mining conveyor, crushing, screening, stockyard, and reclaim systems experience.
• Plant-wide throughput optimisation and load-shedding strategies.

Typical Technologies:

• ABB 800xA
• PLC platforms (ABB, Rockwell, Siemens, Schneider)
• Advanced Process Control (APC)
• MATLAB/Simulink
• Weightometers and process instrumentation
• Historian and analytics systems
• Conveyor and materials handling control systems

Other Attributes:

• Highly organised, reliable, practical, and delivery-focused.
• Able to work under pressure, manage competing priorities, and maintain accuracy and attention to detail in operationally critical environments.
• Strong relationship-building skills with clients, vendors, peers, senior management, and multidisciplinary project teams.
• Able to protect sensitive, proprietary, and security-related information.
• Proactive, service-minded, collaborative, and willing to challenge assumptions constructively to improve technical outcomes.
Committed to quality, safety, operational reliability, and Worley values.

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Moving forward together

We want our people to be energized and empowered to drive sustainable impact. So, our focus is on a values-inspired culture that unlocks brilliance through belonging, connection and innovation. We're building a diverse, inclusive and respectful workplace. Creating a space where everyone feels they belong, can be themselves, and are heard.

And we're not just talking about it; we're doing it. We're reskilling our people, leveraging transferable skills, and supporting the transition of our workforce to become experts in today's low carbon energy infrastructure and technology. Whatever your ambition, there's a path for you here.