Senior DeltaV Controls Consultant
Location: Raleigh, NC (On-site)
Role Overview:
As a Senior DeltaV Controls Consultant, you will lead the design, implementation and project management of large-scale capital automation projects within the Life Sciences industry. You will leverage your deep Emerson DeltaV expertise and cGMP-compliant automation background to optimize biopharmaceutical and medical device manufacturing processes from concept through commissioning and validation.
Responsibilities
- Design and implement DeltaV control systems for complex Life Sciences capital projects
- Develop and manage project schedules, budgets and resources to ensure on-time, within-budget delivery
- Lead system architecture development and control strategy definition to enhance manufacturing efficiency
- Create batch sequencing, phase logic and recipe structures compliant with ISA-88 and regulatory requirements
- Develop DeltaV graphics using DeltaV Live and DeltaV Operate in accordance with ISA-101 HMI guidelines
- Apply class-based configuration approaches to maximize scalability and standardization
- Specify and procure instrumentation, hardware components and system licensing based on user and project scope
- Design electrical systems including power distribution, panel layouts, MCCs, VFDs and grounding strategies
- Design and implement industrial networking solutions (Ethernet/IP, Modbus TCP/IP, Profibus, Foundation Fieldbus)
- Integrate third-party equipment via protocols such as OPC UA, Ethernet/IP and Modbus
- Define computing infrastructure requirements (server architecture, virtualization, cybersecurity, redundancy)
- Oversee full project lifecycle: requirements gathering, commissioning, Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT)
- Ensure compliance with GAMP5, cGMP, 21 CFR Part 11 and industry best practices
- Mentor junior engineers and collaborate with cross-disciplinary teams
- Troubleshoot complex automation challenges and drive continuous improvement
- Travel up to 25% for on-site support, commissioning and client engagement
Qualifications
Must Have
- Bachelors degree in Electrical Engineering, Control Systems Engineering, Chemical Engineering or related field
- 815 years of automation and control-system engineering experience in the Life Sciences or pharmaceutical industry
- Hands-on expertise with Emerson DeltaV systems (design, implementation, configuration)
- Proficiency in DeltaV Live and DeltaV Operate, with strong ISA-101 HMI design skills
- Proven experience with ISA-88 batch processing and class-based configuration
- Deep understanding of GAMP5, cGMP and 21 CFR Part 11 compliance requirements
- Demonstrated ability to lead full project lifecycles from design through commissioning and validation
- Expertise integrating automation protocols (Ethernet/IP, Modbus TCP/IP, Foundation Fieldbus, Profibus, OPC UA)
- Strong knowledge of industrial networking and server infrastructure (virtualization, redundancy, cybersecurity)
- Experience planning and executing FAT and SAT activities
- Solid electrical design skills: MCCs, VFDs, control panels, power distribution
- Excellent leadership, organizational and communication skills
- Willingness to travel up to 25% and work extended hours or weekends as needed
Nice to Have
- Experience with other DCS/SCADA platforms (Rockwell, Siemens PCS7, Ignition)
- Exposure to historian solutions and advanced data analytics
- Familiarity with IO-Link and modern sensor communications
- Working knowledge of alarm management strategies
- Certifications in DeltaV, project management or relevant automation standards
Working Conditions
- Office desk/cubicle environment with frequent use of computers and engineering tools
- On-site presence required in Raleigh, NC, with periodic client-site visits for commissioning and support