Senior Safety Instrumented System (SIS) Engineer
Archer Daniels Midland
Senior Safety Instrumented System (SIS) Engineer
This is a permanent, full-time, exempt-level position.
**Ideal work locations for this position include Houston, TX; Decatur, IL, or another larger ADM site. This is not a remote work opportunity as the individual needs to report into an ADM facility.
Position Description:
ADM is seeking a Senior Electrical Instrumentation SIS Engineer to provide technical leadership for Safety Instrumented Systems (SIS) and critical instrumentation supporting power generation, utilities, and process operations.
This role sits within the Electrical Systems group and supports facilities across North America (with primary focus in Nebraska, Ohio, Iowa, and Illinois).
The position is accountable for ensuring that SIS are designed, maintained, tested, and modified in accordance with the Functional Safety Lifecycle (e.g., IEC 61511 / ISA 84) to achieve required risk reduction while maintaining high availability and reliability.
Primary Responsibilities:
Functional Safety & SIS Lifecycle Leadership
Own and administer the site and regional SIS Functional Safety Management System, including procedures for proof testing, bypass management, overrides, demand reporting, and documentation control
Lead and/or facilitate hazard and risk studies (PHA/HAZOP, LOPA, What if) to identify Safety Instrumented Functions and assign/confirm SIL targets; ensure alignment between initiating events, safeguards, and required risk reduction
Develop and maintain SIS Safety Requirements Specifications (SRS), Cause & Effect matrices, logic narratives, and setpoint documentation for SIFs (ESD, BMS, Fire & Gas, critical interlocks, and trip functions)
Perform or oversee SIL verification calculations (PFDavg / PFH, proof test intervals, common cause, hardware fault tolerance) and document assumptions, failure data, and test coverage; recommend redesigns where targets are not met
Plan and coordinate Functional Safety Assessments/Audits (FSA stages as applicable) for new projects and for existing SIS; track findings to closure via MOC / corrective action processes
Maintain a functional safety competence and training approach for engineers, technicians, and contractors who design, maintain, or test SIS
Reliability, Maintenance and Performance Management
Define and continuously improve SIS and critical instrumentation maintenance strategies, including proof test procedures, calibration standards, and test frequency optimization based on lifecycle reliability and risk
Ensure all SIS assets (logic solvers, I/O, networks, final elements, sensors) are accurately registered in the CMMS with correct hierarchy, attributes, spares, and preventive maintenance/work instructions
Monitor SIS performance (spurious trips, demand rates, bypass frequency, proof test compliance, instrument bad-actor lists) and report against established KPIs; drive targeted improvement plans
Lead root cause investigations for SIS demands, nuisance trips, and instrument failures; implement corrective and preventive actions and update safety requirements specification/proof tests where required
Partner with Operations, Maintenance, EHS/Process Safety, and IT to ensure SIS cybersecurity and change control practices support functional safety and availability
Capital Project and Modernization Support
Provide SIS and critical instrumentation leadership for capital projects from FEL through commissioning, ensuring SIS scope is clearly defined, budgeted, and delivered to functional safety requirements
Review and approve contractor deliverables including ISA datasheets, instrument index, loop drawings, wiring diagrams, P&IDs, logic diagrams, control narratives, shutdown keying philosophy, and commissioning/validation procedures
Ensure SIS design is consistent with applicable standards and good engineering practice (IEC 61511/ISA 84, IEC 61508 concepts, IEC 62443 where applicable, NFPA/NEC for electrical installations, hazardous area requirements)
Drive standardization and obsolescence management for SIS platforms and safety rated devices; develop roadmaps for migration, spares, lifecycle support, and test strategy continuity
Lead or support field commissioning, SIS validation, and functional testing; ensure comprehensive turnover packages (as-builts, SRS, proof tests, bypass lists, O&M, training, CMMS upload confirmation) are complete at handover
Governance, Risk Management and Technical Leadership
Serve as the subject matter expert for SIS/functional safety, providing technical guidance to engineers, technicians, consultants, and EPC partners; review engineering changes for functional safety impact
Develop and maintain contingency plans and short term operating procedures for abnormal SIS conditions (failed components, bypassed SIFs, partial functionality, communications failure) to preserve safety while restoring full protection
Maintain disciplined Management of Change (MOC) for SIS including setpoint changes, bypass approvals, configuration management, and periodic backups/restore tests for safety PLCs and associated infrastructure
Mentor and develop team members; contribute to standards, training, and continuous improvement across the Electrical Systems organization
Required Qualifications:
Bachelor’s degree (or higher) in Electrical Engineering/ Instrumentation and Control Engineering
7+ years of experience in industrial instrumentation and control systems with significant responsibility for SIS/functional safety in operating facilities
Demonstrated experience leading functional safety lifecycle activities: SRS development, SIL verification, proof test development/execution governance, MOC, and incident investigations
Hands on knowledge of SIS platforms and architectures (safety PLCs/logic solvers, safety I/O, networks, final elements, and sensor technologies) and integration with DCS/PLC environments
Experience supporting capital projects (scope, schedule, cost, technical risk) and leading commissioning/validation/turnover
Working knowledge of IEC 61511 / ISA 84 functional safety requirements and the practical application of SIL concepts in design and maintenance
Ability to interpret and develop P&IDs, control narratives, Cause & Effect matrices, loop sheets, logic diagrams, and wiring schematics
Familiarity with hazardous area classifications (Class/Division and/or Zone), IP/NEMA enclosure ratings, and field installation practices
Strong analytical and troubleshooting capability for instrument malfunctions, control/safety logic behaviors, and field device performance
Ability to travel to manufacturing facilities as needed (approximately 35%)
Preferred Qualifications:
Professional Engineer (P.E. / P.Eng) designation
Functional Safety certification (e.g., TUV Functional Safety Engineer/Professional or equivalent)
Project Management Professional (PMP) or demonstrated project leadership experience
Excited about this opportunity but don’t think you meet every requirement listed? Studies have shown that applicants may self "select-out" of consideration if they do not meet all posted qualifications. We encourage you to apply anyway. You may be just the right candidate for this role or another one of our openings.
ADM requires the successful completion of a background check. Relocation assistance is available for this opportunity.
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