S3 Engineer - Control Systems

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Our culture is all about encouraging you to think independently and to challenge convention to deliver the best result. That’s how we continue to achieve extraordinary things in extraordinary locations.

Job description:

Purpose

Support the S3 Control Systems Coordinator by ensuring the reliable operation, optimization, maintenance, and technical governance of all S3 Process Plant

Purpose of the role

Control Systems, including Siemens PCS7 DCS, industrial networks, and

Siemens Gearless Mill Drive (GMD) control systems.

The role ensures maximum plant availability, safe operation, statutory compliance, and continuous improvement of automation, protection, and electrical drive systems within a high-availability mining processing environment.

Key Responsibilities

Safety & Governance

• Promote and enforce a zero-harm culture.
• Develop and review SWIs and participate in HIRA/JSA processes.
• Ensure statutory records, safety logbooks and test equipment compliance.
• Report incidents promptly and comprehensively.

Control Systems Operations & Maintenance

• Install, configure, commission, maintain and optimize S3 Control Systems (Siemens PCS7, S7-400H, Profinet/Profibus, Scalance, virtualization and associated OT platforms).
• Ensure high system availability through redundancy validation, configuration backups and lifecycle management of hardware/software.
• Maintain accurate as-built documentation and adhere to Change Management procedures.
• Conduct proactive fault finding and structured root cause analysis to minimize production losses.
• Maintain critical spares and ensure system reliability in a high-availability environment.
• Provide dependable C&I engineering support to sustain plant stability and performance.

Support to Electrical Department (GMD & Protection Systems)

• Provide technical support on Gearless Mill Drive control philosophy, excitation systems, cycloconverters and associated auxiliary systems.
• Review and support electrical installations, protection schemes and interlocks to ensure statutory compliance and operational integrity.
• Assist with protection coordination (MV/LV switchgear, transformers, Siprotech, PADU, AVTs, Sinamics SL150 and associated drive systems).
• Support periodic protection audits, parameter validation and configuration backups.
• Ensure alignment with Zambia Mining Regulations and applicable national standards.

Performance Monitoring & Optimization

• Monitor plant performance via DCS, historian and drive systems.
• Analyse operational data to identify inefficiencies and implement corrective improvements.
• Optimize control loops, alarm systems, expert strategies and drive interactions.
• Support lifecycle planning and proactive equipment replacement strategies.

Training & Knowledge Transfer

• Deliver structured training on PCS7, PLC systems, GMD concepts, electrical drawings and protection philosophy.
• Mentor team members and foster a coaching culture.
• Identify specialized training needs and manage vendor remote support.
• Support operational alignment with Electrical and Process teams.

Reporting, Asset Management & Continuous Improvement

• Compile detailed activity, cost and performance reports.
• Maintain accurate maintenance and configuration records.
• Contribute to asset management strategy and system resilience.
• Drive automation improvements, cybersecurity strengthening and Industry 4.0 initiatives.
• Support the integrity of auxiliary systems, including cooling, lubrication, MCCs, transformers and cranes.

Qualifications

• Degree/Diploma in Electrical Engineering, Industrial Automation, or Instrumentation.
• Siemens PCS7 Certification.
• Strong knowledge of Siemens Gearless Mill Drive Systems.
• EIZ & ERB Registration preferred.
• Valid Driver’s Licence.
• Proficiency in VMware virtualisation.
• Knowledge of Sinema, Sinec, TIA Portal advantageous.

Experience

• Minimum 10–15 years in mining process plant automation and electrical drive systems.
• Extensive experience with:
  • Siemens PCS7 DCS
  • S7-400H PLC systems
  • Siemens Gearless Mill Drives
  • Profinet & Profibus networks
  • ABB MV switchgear & protection
  • Sinamics SL150 drives
  • Siprotech and related protection systems
  • OPC DA/UA and industrial communication protocols
  • IIoT and data management systems
• Strong knowledge of:
  • MV/LV systems and transformers
  • Variable Speed Drives and motor protection
  • Closed-loop control systems
  • Electrical drawings and P&IDs

Behavioural Traits

• Safety-Focused: Committed to a safe work environment.
• Strong Leadership: Guides and motivates the team to perform at high standards.
• Collaborative: Works effectively with cross-functional teams.
• Quality-Driven: Ensures excellence in all activities.
• Technical Expertise: Skilled in troubleshooting and optimizing equipment.
• Reliable: Dependable and accountable for team results.

Operational Requirements

• Standby and overtime when required.
• Exposure to noise, dust and varying temperatures.
• Ability to work independently under pressure.
• Strong written and verbal communication skills.
• Proficiency in CMMS systems.
• Contributes to continuous improvement and asset optimization initiatives.

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