17 Process Control Engineer Interview Questions and Answers

Process control engineers are responsible for the development, implementation, and maintenance of process control systems. These systems are used to monitor and optimize industrial processes, such as chemical, oil, and gas production.

If you’re a process control engineer, you may be asked to interview for a job with a new company. During the interview, the hiring manager will ask you process control engineer interview questions to assess your technical knowledge and skills. They will also ask behavioral interview questions to get a sense of your work style and attitude.

To help you prepare for your next interview, we’ve compiled a list of the most common process control engineer interview questions and answers.

Are you comfortable working with complex industrial processes?

This question can help the interviewer determine if you have the skills and experience to succeed in this role. Use your answer to highlight your ability to work with complex processes, systems and machines. You can also share a specific example of how you used your skills to complete a process control engineering project.

Example: “I am very comfortable working with complex industrial processes because I’ve been doing it for several years now. In my last position, I was responsible for overseeing the production line at a manufacturing facility. The company had recently upgraded their equipment, so I worked with other engineers to ensure that all new processes were properly integrated into the system. We developed a plan to test each component of the production line before integrating them into the entire system.”

What are some of the most important skills for a process control engineer to have?

This question can help the interviewer determine if you have the skills necessary to succeed in this role. When answering, it can be helpful to mention a few of your strongest skills and how they relate to process control engineering.

Example: “The most important skill for a process control engineer is problem-solving. This is because I often work with engineers who are designing new processes or improving existing ones. In these situations, there may be issues that need to be solved. Having strong problem-solving skills allows me to find solutions quickly so we can move forward with our projects.”

How would you troubleshoot a problem with a process that you’re responsible for overseeing?

This question is an opportunity to show the interviewer that you have a process for solving problems and making decisions. Use your answer to highlight your problem-solving skills, ability to make quick decisions and willingness to take on responsibility.

Example: “When troubleshooting a problem with a process I’m responsible for overseeing, I first look at all of the data points to see if there are any patterns or anomalies. If I notice something unusual, I will investigate it further by checking the equipment involved in the process and reviewing the system logs. Once I understand what caused the issue, I can implement a solution to prevent similar issues from occurring in the future.”

What is a PID controller and how would you use one in your work as a process control engineer?

The interviewer may ask you a question like this one to assess your knowledge of process control engineering and the tools you use in your work. In your answer, try to explain what PID stands for and how it can be used in your role as a process control engineer.

Example: “PID stands for proportional-integral-derivative controller. It’s an algorithm that uses three different elements to regulate processes within industrial facilities. The first element is error correction, which measures the difference between the set point and the actual value of the process. Then, it calculates the required change to bring the process back into balance. The second element is integral action, which adds up all the small changes over time to make larger adjustments. Finally, there’s derivative action, which makes smaller adjustments based on the rate of change.”

Provide an example of a time when you had to make a difficult decision regarding a process you were in charge of.

When answering this question, it can be helpful to provide an example of a time when you had to make a decision that was unpopular or not the most efficient. This can show your ability to make tough decisions and how you used your critical thinking skills to come up with a solution.

Example: “In my last position as a process control engineer, I was in charge of monitoring the temperature levels of a large warehouse. One day, while checking the system, I noticed that the temperature inside the warehouse was much higher than what we were expecting. After investigating further, I found out that one of our employees accidentally left the door open overnight, causing the temperature to rise significantly.

I knew that if I didn’t do something about the situation, there could be serious consequences for the company. However, I also knew that shutting off the heat entirely would cause even more problems. Instead, I decided to lower the temperature by five degrees until we could find a permanent solution. The employee who left the door open agreed to work overtime to help cover the cost of the extra energy needed to cool down the warehouse.”

If you were in charge of overseeing a chemical plant, what would be your top priorities?

This question is a great way to assess your priorities and values as a process control engineer. It also allows the interviewer to see how you would prioritize tasks in an important role like overseeing a chemical plant. In your answer, try to highlight your attention to detail, ability to multitask and commitment to safety.

Example: “My top priority if I were overseeing a chemical plant would be ensuring that all of the processes are running smoothly and safely. To do this, I would make sure that my team was well-trained on the equipment and procedures for each task they perform. I would also ensure that we have proper documentation for every aspect of the plant’s operations so that we can refer back to it when necessary.”

What would you do if you noticed that a process you were monitoring had started to produce waste materials?

This question can help interviewers understand how you would respond to a potentially dangerous situation at work. In your answer, try to explain what steps you would take to ensure the safety of those working in the facility and minimize any environmental damage caused by the waste materials.

Example: “If I noticed that a process was producing waste materials, I would first make sure everyone in the area was safe. Then, I would shut down the entire system so no more waste could be produced. Next, I would analyze the cause of the problem and implement solutions to prevent it from happening again. Finally, I would restart the system and monitor it closely to ensure everything was running smoothly.”

How well do you understand the safety protocols for the processes you oversee?

The interviewer may ask this question to assess your knowledge of the safety protocols for process control engineers. Use examples from past projects where you implemented or improved upon safety protocols and procedures.

Example: “I understand that safety is a top priority in my role as a process control engineer, so I always make sure to follow all safety protocols when working on a project. For example, during my last project at ABC Company, we were tasked with improving the safety measures for our company’s oil refinery. We developed a new system that would automatically shut down operations if it detected unsafe conditions, which helped us meet the client’s requirements while also ensuring employee safety.”

Do you have experience working with large teams to monitor and adjust processes?

This question can help interviewers understand how you might fit into their company culture. In your answer, try to highlight any teamwork skills that will be useful in this role and the importance of collaboration with other team members.

Example: “In my previous position as a process control engineer at a large chemical plant, I worked closely with several teams to monitor and adjust processes throughout the day. For example, when there was an issue with one part of the production line, I would work with the maintenance team to identify the problem and then coordinate with the operations team to implement solutions. This helped me develop strong communication and collaboration skills.”

When monitoring a process, what is the smallest change you would notice?

This question can help the interviewer determine your level of attention to detail and how you react to changes in a process. Your answer should show that you are able to notice even small changes, which can be an important skill for a process control engineer.

Example: “I would definitely notice any change in a process no matter how small it is. Monitoring a process requires me to pay close attention to every aspect of it so I can make sure everything is running smoothly. If there was a slight change in pressure or temperature, I would immediately check the equipment to see if something needed to be adjusted.”

We want to improve the efficiency of our processes. What are some of the strategies you would use?

This question is an opportunity to show your problem-solving skills and ability to make improvements. You can answer this question by giving examples of how you would improve efficiency in a process.

Example: “I would start by analyzing the current processes, looking for areas where I could reduce waste or increase productivity. For example, if there are any bottlenecks that slow down production, I would find ways to eliminate them. If there are unnecessary steps in the process, I would remove them. Another strategy I use is implementing new technology into the process. Technology like sensors and automation can help me monitor and control the process more efficiently.”

Describe your experience with using computer-aided design tools to develop new processes.

The interviewer may ask you this question to learn more about your experience with using computer-aided design (CAD) tools. This can help them understand how comfortable you are working with technology and the level of expertise you have in a variety of software programs. When preparing for this question, think about which CAD tools you’ve used in the past and what projects you worked on while using these tools.

Example: “I’ve been using AutoCAD since I graduated from college. In my last role as a process control engineer, I was responsible for creating new designs for equipment that would improve processes at our manufacturing facility. Using AutoCAD, I could create detailed drawings of the equipment I wanted to implement and then send those files to engineers who built the equipment.”

What makes you the best candidate for this position?

Employers ask this question to learn more about your qualifications and why you are the best person for the job. Before your interview, make a list of all of your skills and experiences that relate to this position. Focus on highlighting your most relevant skills and how they can benefit the company.

Example: “I am the best candidate for this position because I have five years of experience in process control engineering. In my previous role, I was responsible for designing new systems and improving existing ones. I also worked with other engineers to create efficient processes that saved our company money. My communication skills and problem-solving abilities make me an excellent choice for this role.”

Which industries have processes that interest you?

This question can help the interviewer understand your career goals and how you plan to achieve them. Your answer should include a brief description of industries that interest you, along with why they do.

Example: “I’m interested in working for an oil company because I enjoy the challenge of maintaining processes while also ensuring safety. In my previous role as a process control engineer, I worked on a team that helped develop new ways to extract oil from wells. This was challenging but rewarding work, and I would like to continue doing it.”

What do you think will be the biggest challenge in this position?

Employers ask this question to see if you are aware of the challenges that come with a role like this. They want someone who is willing to take on these challenges and use their skills to overcome them. In your answer, explain what you think will be the biggest challenge in this position and how you plan to overcome it. Show that you have the skills necessary to succeed in this role by explaining how you would handle this challenge.

Example: “I think the biggest challenge in this position will be working with different teams. I know there are many people involved in process control engineering, so I am prepared to work with other engineers, technicians and operators. I also understand that everyone has a unique skill set, so I plan to learn more about each person’s background and experience to help me better communicate with them.”

How often do you make adjustments to processes?

This question can help the interviewer understand how often you make adjustments to processes and what your process is for making these changes. You can answer this question by describing a specific time when you made an adjustment to a process and explaining why you did so.

Example: “I usually make adjustments to processes every few months, but I recently adjusted a process that was working well because of new information we received about the project. The client had requested more detailed reports on our progress, which led me to adjust the current process to include more frequent reporting. This change helped us meet the client’s needs while also allowing us to continue working on other aspects of the project.”

There is a bug in the code for a process controller you’ve designed. What would you do?

Bugs are a common occurrence in the software development process. An interviewer may ask you this question to see how you would handle an issue that could potentially affect their company’s production. In your answer, explain what steps you would take to identify and fix the bug as quickly as possible.

Example: “If there was a bug in my code, I would first try to replicate it on one of my own computers. If I couldn’t find the problem, I would then check for bugs in other parts of the system. Once I found the source of the bug, I would work with the team to create a solution. We would implement the new code into the system and test it before implementing it permanently.”