Job Summary:
The Senior Instrumentation & Control Technician is responsible for the design, installation, maintenance, troubleshooting, and optimization of complex industrial instrumentation and automation systems. This role requires extensive hands-on experience in PLCs, SCADA, DCS, field instrumentation, and process control systems across industries such as oil & gas, power generation, pharmaceuticals, manufacturing, and water treatment. The ideal candidate will possess leadership skills to mentor junior technicians and ensure the efficient operation of industrial control systems while adhering to industry standards and safety protocols.
Key Responsibilities:
- Lead the installation, commissioning, and maintenance of instrumentation and control systems.
- Design, configure, and troubleshoot PLCs, SCADA, and DCS for process automation.
- Perform advanced diagnostics and calibration of industrial sensors, transmitters, actuators, and controllers.
- Develop and implement control logic strategies, PID loop tuning, and process optimization.
- Interpret and modify P&ID diagrams, loop diagrams, and control schematics as required.
- Diagnose and resolve complex control system faults, electrical issues, and communication failures.
- Oversee industrial network communication protocols such as Modbus, Profibus, HART, Ethernet/IP, and Foundation Fieldbus.
- Conduct root cause analysis (RCA) and implement corrective actions for control system failures.
- Ensure compliance with ISA, IEC, ANSI, OSHA, and hazardous area classifications (ATEX, IECEx).
- Mentor and supervise junior technicians, providing training and guidance on troubleshooting and best practices.
- Maintain and update technical documentation, maintenance logs, and instrument calibration records.
- Work closely with engineering teams, operators, and project managers for system upgrades and modifications.
Skills and Knowledge Required:
- Expertise in industrial automation and instrumentation, including PLCs, SCADA, DCS, and HMI systems.
- Strong hands-on experience in calibrating and maintaining pressure, temperature, level, and flow measurement instruments.
- Advanced troubleshooting of control loops, PID controllers, and industrial communication networks.
- Strong knowledge of control panel wiring, fieldbus networks, and automation protocols.
- Proficiency in control system programming (Ladder Logic, Structured Text, Function Block Diagram, SFC).
- Understanding of safety and emergency shutdown (ESD) systems, fire & gas detection, and SIL-rated systems.
- Familiarity with industry best practices in preventive and predictive maintenance.
- Ability to develop maintenance strategies and optimize asset reliability.
- Strong documentation skills for compliance reporting, system modifications, and troubleshooting logs.
Educational Qualifications:
- Diploma / Bachelor's degree in Instrumentation Engineering, Electrical Engineering, Electronics Engineering, or a related field.
- Industry certifications (ISA Certified Control Systems Technician, CompEx, TÜV Functional Safety, or equivalent) are preferred.
Key Focus Areas:
- Advanced Process Automation & Control: Implementing and troubleshooting automation systems in process industries.
- Complex PLC & SCADA Integration: Programming, testing, and commissioning automation projects.
- Instrumentation Calibration & Reliability: Ensuring accurate measurement and process control.
- Industrial Safety & Compliance: Adhering to industry regulations and implementing safety measures.
- Technical Leadership & Mentorship: Guiding junior technicians and supporting continuous learning.
Experience:
- 7+ years of experience in instrumentation and control systems within industrial environments.
- Proven expertise in commissioning, maintenance, and troubleshooting of PLC/DCS systems.
- Experience in leading projects, team management, and system optimization.
- Hands-on exposure to shutdowns, turnarounds, and plant startups is a plus.
Tools and Equipment:
- Proficiency in PLC programming tools (Siemens TIA Portal, Allen-Bradley Studio 5000, Schneider Unity Pro, Yokogawa Centum VP).
- Expertise in SCADA/DCS platforms (Wonderware, WinCC, DeltaV, Honeywell Experion).
- Strong knowledge of calibration instruments (HART communicators, pressure calibrators, loop testers).
- Familiarity with industrial automation software (AutoCAD, EPLAN, ControlLogix, RSLogix 5000).
Other Requirements:
- Strong leadership and problem-solving skills.
- Excellent communication and collaboration with cross-functional teams.
- Willingness to work in field environments and travel for project requirements.
- Ability to handle high-pressure troubleshooting scenarios and emergency maintenance.