Sr. Process Controls Engineer, Solar Cell Factory (Starlink) Verified today
The Role
The Solar Cell team manufactures high-efficiency solar cells for Starlink constellations, launch vehicles, and beyond. As Sr. Process Controls Engineer, you will design, build, and optimize controls and automation systems for critical gas and chemical delivery in solar cell fabrication. You'll ensure safe, reliable control code and instrumentation for processes like vacuum deposition and etching in a high-volume manufacturing environment.
Responsibilities
- Design, implement, and maintain automation systems including PLC programming and SCADA development for gas farm operations (vaporizers, storage, transfer systems) and wastewater treatment (solids separation, clarification, chemical dosing)
- Develop and program PLC control logic, PID loops, and interlocks for centralized control of distributed subsystems, optimizing real-time monitoring of pressure, temperature, flow, pH, and effluent quality
- Select, calibrate, and integrate field instrumentation (transmitters, sensors, analyzers) in hazardous environments, ensuring compliance with SIL, ATEX, and EPA/NPDES standards
- Lead commissioning, FAT/SAT testing, and troubleshooting of control systems with root-cause analysis to minimize downtime and support 24/7 operations
- Design electrical systems compliant with NEC, NFPA, and UL508A regulations
Basic Qualifications
- Bachelor's degree in engineering, physics, or chemical discipline
- 5+ years experience with fluids/systems manufacturing, controls, automation, and/or programming
Preferred Skills and Experience
- Expertise in hazardous process control in aerospace, oil and gas, or chemical industry with high-pressure or hazardous fluid/gas systems
- Electrical/Industrial Controls: motor and valve sizing, VFDs, motor starters, fail-safe circuit design, troubleshooting with multimeters and oscilloscopes, electrical schematics (EPLAN preferred), fieldbus networks (Profinet, Ethernet), NEC/NFPA/UL508A compliance
- Industrial Software: PLC programming (Siemens TIA Portal structured text and ladder preferred), HMI/SCADA/IoT (MQTT, OPC-UA, Ignition), fieldbus protocols (EtherCAT, Profinet, Profisafe, Ethernet/IP), robotics programming (ABB preferred), system safety checkout procedures
- Ability to solve complex problems with simple solutions in design and implementation
- Strong written and verbal communication with cross-functional collaboration
- Creative problem-solving while adhering to ANSI/RIA15.06/OSHA safety requirements
- Willingness to learn fundamentals of unfamiliar disciplines within the role
Additional Requirements
- Ability to work long hours and weekends as necessary to support critical milestones
ITAR Eligibility
Applicant must be a U.S. citizen or national, U.S. lawful permanent resident (green card holder), Refugee under 8 U.S.C. 1157, or Asylee under 8 U.S.C. 1158, or be eligible to obtain required authorization from the U.S. Department of State.