Job Overview
We are seeking an experienced Lead Controls Engineer (Sr. Project Engineer IV) to join the Controls Engineering team at the Mumbai Technology Center (MTC). This role serves as the senior technical individual contributor and design lead for Managed Pressure Drilling (MPD) control systems, providing deep technical ownership and leadership without formal people-management responsibility.
The Lead Controls Engineer will be responsible for the architecture, design, development, validation, and deployment of complex control systems, including PLC/RTU systems, control panels, instrumentation, sensors, actuators, and safety-critical applications. The role will also mentor junior engineers, drive engineering best practices, support new product development and sustaining engineering efforts, and collaborate with global RD&E teams to strengthen controls engineering capabilities and support Weatherford's product development strategy.
Key Responsibilities
- Lead the design, architecture, development, and validation of MPD control systems and automation solutions.
- Design, develop and test PLC and HMI applications for Siemens SIMATIC S7 - 1200/S7- 1500 platforms,using TIA portal, Ladder Logic, SCL, FBD and Graph programming languages
- Own technical design reviews, risk assessments (FMEA), validation plans, qualification activities, and system integration efforts.
- Ensure compliance with API, IECEx, ATEX, SIL, IEC 60079, and Weatherford engineering standards.
- Anticipate system failure modes and implement robust mitigation strategies based on field performance and reliability data.
- Serve as the technical interface between hardware, software, electrical, electronics, automation, firmware, and mechanical engineering teams.
- Provide technical leadership, coaching, mentoring, and design review support to junior controls engineers.
- Contribute to competency development, engineering best practices, design standards, and reusable engineering libraries.
- Lead controls engineering workstreams across new product development, sustaining engineering, and product upgrade projects.
- Plan and execute engineering activities to meet cost, quality, and schedule objectives while managing technical risks and dependencies.
- Collaborate with Product Lines, Manufacturing, Supply Chain, Test Labs, and Field Operations to ensure successful project execution and deployment.
- Drive continuous improvement initiatives related to engineering processes, test coverage, design quality, and standardization.
- Support audits, qualification reviews, regulatory compliance activities, and customer technical engagements.
- Provide engineering support during commissioning, testing, field deployment, troubleshooting, and performance evaluations.
- Analyze field performance data and drive lessons learned into future design improvements.
- Assess technical and cost implications of design changes and support engineering estimates and business cases.
Promote company HSE policies and maintain the highest standards of safety, ethics, and compliance.
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Skills
- Control Systems Engineering
- PLC/RTU Programming (Siemens SIMATIC S7-1200/S7-1500)
- TIA Portal
- HMI Development
- Ladder Logic, SCL, FBD & Graph Programming
- Industrial Automation & Motion Control
- Control System Architecture & Design
- Instrumentation, Sensors & Actuators
- Functional Safety & SIL Systems
- Industrial Communication Protocols (Modbus, Profinet, Profibus)
- IT/OT Integration
- Electrical Design Software (EPLAN, E3 Series, AutoCAD Electrical)
- Product Qualification & Validation Testing
- FMEA & Risk Assessment
- Hazardous Area Design (IECEx, ATEX, IEC 60079)
- Root Cause Analysis & Troubleshooting
- Technical Leadership & Mentoring
- Project Planning & Execution
- Cross-Functional Collaboration
- Technical Problem Solving
- Continuous Improvement Mindset
- Stakeholder Management
Technical Documentation & Reporting
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Qualifications
