Senior Engineer, Generator Systems - Hyliion

Job Purpose

The Senior Engineer, Generator Systems will lead the design and development of large-scale generator systems (megawatt scale). This position works across the entire project lifecycle from design through commissioning, ensuring that both control systems and power systems are optimized for performance, safety, and reliability.

Duties and Responsibilities

Design and Development of Large-Scale Generator Systems

• Lead the design, development, and implementation of large-scale generator systems (megawatt scale) focusing on efficiency, reliability, and scalability.
• Perform load analysis, fault studies, and risk assessments to ensure system performance and safety.
• Collaborate with project teams to integrate generator systems into industrial or commercial power networks.

SCADA and PLC Integration

• Design, configure, and implement SCADA systems for real-time monitoring and control of generator systems.
• PLC integration:
  • Program and configure PLCs (e.g., B&R, Siemens, Allen-Bradley, Schneider Electric) for generator control, with a focus on integrating fuel, air, cooling, and pressure instrumentation.
  • Develop control logic for managing fuel injection systems, air intake systems, cooling systems (water/air-cooled), and pressure monitoring devices to optimize generator operation.
  • Ensure accurate control and synchronization between fuel supply, air flow, cooling rates, and pressure feedback for optimal system performance and efficiency.
  • Troubleshoot and resolve PLC-related issues in real-time control, ensuring communication between all subsystems (fuel, air, cooling, and pressure) is stable and efficient.
• Manage communication protocols (e.g., Modbus, DNP3, Ethernet/IP, Profibus) for smooth interaction between instrumentation, control systems, and remote monitoring stations.

Networking and Communication

• Design and maintain network architectures, including managing TCP/IP, Ethernet/IP, OPC UA, and Modbus TCP/IP protocols to ensure reliable communication across devices and systems.
• Implement robust network solutions, incorporating redundancy, fault tolerance, and security to ensure system integrity.
• Oversee system updates and ensure all data communication channels are secure and optimized for efficiency.

System Modeling

• Model and simulate electrical power systems, control algorithms, and the dynamic behavior of generator systems.
• Perform simulations to optimize control strategies related to fuel, air, cooling, and pressure subsystems.
• Leverage software such as Simulink to troubleshoot system issues and validate performance improvements before implementing physical changes.

Compliance with UL Standards

• Ensure all designs and systems comply with UL standards, as well as NEC and IEEE codes.
• Prepare detailed technical documentation to support UL certification and other regulatory approvals.
• Implement safety measures such as arc flash analysis and short circuit studies, ensuring all designs meet regulatory and safety requirements.

Project Management and Leadership

• Manage large-scale generator projects from design through to on-site installation, testing, and commissioning.
• Provide technical leadership to cross-functional teams and serve as a subject matter expert on PLC integration, instrumentation, and SCADA systems.
• Mentor junior engineers, particularly in areas such as fuel, air, cooling, and pressure instrumentation integration with PLC and SCADA systems.

System Testing, Commissioning, and Troubleshooting

• Lead on-site system testing, commissioning, and troubleshooting, including SCADA-PLC integration and performance of fuel, air, cooling, and pressure systems.
• Use Simulink models in tandem with field data to optimize system behavior during commissioning phases.
• Ensure generator systems and their associated subsystems (fuel, air, cooling, pressure) function according to design specifications and are integrated seamlessly into the control network.

Qualifications

Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Qualifications include:

• Education, Experience and Certifications
• Bachelor's degree in Electrical Engineering required.
• Masters degree in Electrical Engineering preferred.
• 10+ years of experience in electrical engineering, with specific experience in PLC integration, instrumentation, and SCADA systems for generator systems.
• Experience designing, developing, and commissioning generator systems in the Megawatt range.
• Hands-on experience with PLCs such as B&R, Siemens, Allen-Bradley, or Schneider Electric.
• Experience with SCADA communication protocols (Modbus, DNP3, Ethernet/IP, OPC UA) and networking best practices.
• Some experience with Simulink for simulating and analyzing power systems, generator dynamics and control algorithms is preferred.

• Skills and Abilities
• Expertise in integrating fuel systems (fuel pumps, flow meters, valves), air systems (air compressors, flow sensors, throttle controls), cooling systems (water/air-cooled exchangers, temperature sensors), and pressure instrumentations (pressure sensors, transducers) into control strategies.
• Proficiency in designing and configuring control systems, including data acquisition, control logic, and HMI interfaces.
• Excellent troubleshooting and problem-solving skills, specifically in PLC and instrumentation integration.
• Familiarity with electrical design tools such as AutoCAD Electrical, or similar for creating schematics and layouts.
• Effective communication skills, both written and verbal, for technical and non-technical stakeholders.
• Strong leadership and project management abilities.
• Ability to mentor and train junior engineers

Role Classification and Working Conditions

This is a salaried, exempt-level position. This position typically works in an office environment; and given the nature of our business is also exposed to operations/warehouse/production environments.

We are not accepting candidates who require sponsorship for this position at this time.