Commissioning Engineer – Instrumentation & Controls (I&C)Location: Ludington Pumped Storage Facility, Western MichiganTravel: Occasional travel to Pittsburgh, PA for Factory Acceptance Testing (FAT)Schedule: Initially flexible (4x10 or 5x8), transitioning to extended workweeks (up to 6–7 days/week) during peak project phasesDuration: Multi-year project through January 2027, with possibleextensions through 2029Start Date: As soon as possibleProject Overview:This role supports a major capital project to upgrade control systems at the Ludington Pumped Storage Facility, one of the largest pumped storage hydroelectric plants in the world. The initiative aims to replace outdated hardwired systems with a modern DCS to improve efficiency, monitoring, and reliability.The work will be executed in three major phases over several years. This is a high-impact position critical to the successful commissioning and integration of new systems.About the Role:Consumers Energy is seeking a Senior Commissioning Engineer with a strong background in Instrumentation and Controls (I&C) to support a multi-phase control system integration project at the Ludington Pumped Storage Facility. This individual will be instrumental in transitioning the facility's hardwired control systems to an Emerson Ovation Distributed Control System (DCS).You will be responsible for developing, executing, and overseeing all aspects of the commissioning process for a high-risk, technically complex modernization effort involving six turbine-generator units over multiple project phases.Key Responsibilities:Planning & Documentation
- Develop commissioning plans, checklists, procedures, and documentation based on project drawings, vendor manuals, and internal guidelines.
- Review and understand detailed engineering designs and logic diagrams.
- Coordinate with project engineers and internal stakeholders for testing scope and requirements.
Field & Factory Testing
- Lead and participate in Factory Acceptance Testing (FAT) with vendors (primarily Emerson) in Pittsburgh, PA.
- Oversee pre-commissioning and commissioning fieldwork including:
- Calibration
- Loop checks
- Configuration and functional testing
- System checkout
Execution & Oversight
- Direct day-to-day activities of a field team of 2–4 contract technicians (IC and power/protection technicians).
- Coordinate testing timelines and scope with construction and project management teams.
- Monitor and manage budgets, schedules, and resourcing requirements.
System Integration & Validation
- Support integration of Emerson Ovation DCS with field instrumentation and auxiliary systems.
- Validate as-built installations against designs.
- Support updates to operating procedures in coordination with procedure writers and engineering.
Post-Commissioning
- Collaborate with operations to release safety tagging and ensure functional readiness.
- Document and validate all testing results and performance data.
Required Qualifications:
- Bachelor's degree in Electrical, Controls, or Instrumentation Engineering (preferred)
- OR
- Extensive field commissioning experience in lieu of degree (minimum 10+ years)
- 5+ years of experience commissioning I&C systems in power generation or industrial facilities.
- Demonstrated experience with:
- Emerson Ovation DCS
- Rosemount field devices (pressure, level, temperature transmitters)
- Loop and functional testing
- Writing and executing test procedures
- Experience overseeing contract teams and coordinating with construction management.
- Strong understanding of startup and commissioning safety practices.
- Excellent communication skills, both written and verbal.
Preferred Qualifications:
- Prior experience working on hydro-electric or pumped storage systems.
- Experience with GE Bentley Nevada turbine supervisory instrumentation.
- Familiarity with high-voltage power protection systems (nice to have, but not core to this role).
- PMP or similar project coordination experience.
Additional Details:
- Travel to Emerson's facility in Pittsburgh is required for FAT (approx. 2–3 weeks per unit; up to 6 weeks total across the project)
- All travel expenses for approved trips will be fully reimbursed (lodging, mileage, etc.)
- Strong potential for long-term engagement beyond the first two units, through 2029