Loop Testing Technician – CIP/SIP and Process Zones

The Senior Loop Testing Technician is responsible for leading, executing, and documenting complex instrumentation loop checks across CIP/SIP systems, process skids, and cleanroom zones. This role ensures control system integration accuracy, supports equipment validation (IQ/OQ), resolves instrumentation signal issues, and ensures compliance with GMP and automation standards. The technician also mentors junior staff and coordinates across multiple departments during projects and audits.

Key Responsibilities:

• Lead and execute complete loop testing cycles, ensuring signal accuracy from field instruments to PLC/DCS/SCADA.

• Review and validate I/O lists, loop diagrams, wiring layouts, and instrument data sheets.

• Perform advanced diagnostics on loop faults including signal loss, incorrect scaling, polarity errors, grounding issues, and I/O mismatches.

• Validate process-critical instrumentation in CIP/SIP skids, reactors, bioreactors, blending tanks, and transfer lines.

• Supervise loop test teams during commissioning, and ensure closure of punch points in a timely manner.

• Collaborate closely with automation, validation, QA, and control system teams for FAT/SAT, IQ/OQ execution.

• Maintain documentation for audits – including redlining drawings, updating loop folders, and ensuring GDP compliance.

• Train and mentor junior loop technicians and support their development in troubleshooting and GMP compliance.

Key Focus Areas:

1. Leadership in Loop Testing Execution

   • Ownership of:

     • Signal verification (analog/digital, 4-20 mA, HART, pulse)

     • Alarm simulation, fail-safe testing, PID loop validation

     • Instrument-to-PLC/DCS mapping and validation

2. CIP/SIP & Process Instrument Expertise

   • Deep understanding of instruments like:

     • RTDs, thermocouples, pressure and flow transmitters, conductivity sensors, control valves, and proximity switches

   • Ensuring accurate performance during cleaning, sterilization, and batching phases

3. Instrumentation Qualification & Validation Support

   • Support for:

     • Instrument IQ/OQ, signal traceability, system readiness for QA validation

   • Ensuring compliance with GAMP5, FDA, GMP, and internal SOPs

4. Documentation & Compliance

   • Review and sign-off of:

     • Loop test sheets, calibration logs, deviation reports, and test protocols

   • Ensuring Good Documentation Practices (GDP) and audit readiness

5. Cross-Functional Coordination

   • Serve as technical lead during:

     • Commissioning of new process skids, utility integrations, and control system changes

   • Coordinate with vendors, project engineers, and site QA

Qualifications:

• Education:

  • Diploma / B.E. / B.Tech in Instrumentation, Electrical, Electronics, or Mechatronics

• Experience:

  • 6–10 years of hands-on experience in loop testing and instrumentation commissioning in regulated manufacturing or project environments

• Technical Expertise:

  • In-depth knowledge of:

    • Instrument loop testing practices

    • HART/Fieldbus communication

    • PLC/DCS I/O (Siemens, Rockwell, DeltaV, Schneider, etc.)

    • Electrical safety and ATEX/Ex-zone practices (if applicable)

• Soft Skills:

  • Strong troubleshooting and decision-making skills

  • Team leadership, mentoring abilities

  • Excellent coordination and documentation discipline