PLC/DCS Technician – Equipment Support

The Mid-Level PLC/DCS Technician is responsible for providing hands-on technical support for control systems integrated with various types of production, utility, or process equipment. This includes PLC/DCS troubleshooting, supporting small logic modifications, conducting I/O validation, and coordinating with maintenance and process teams to resolve automation-related equipment issues.

This role is ideal for technicians who can independently handle automation faults, perform control system checks, and collaborate with engineering teams to improve equipment performance.

Key Responsibilities:

• Diagnose and resolve faults in PLC/DCS-controlled equipment (e.g., pumps, valves, mixers, fillers, reactors).

• Perform I/O checks, signal tracing, and root cause analysis of alarms and automation issues.

• Make minor logic updates (under supervision) in ladder diagrams, function blocks, or SFC as per change control.

• Support new equipment commissioning and loop testing activities in coordination with project teams.

• Maintain PLC/DCS program backups, wiring documentation, and control system logs.

• Interface with HMIs/SCADA systems to assist in display modifications and alarm troubleshooting.

• Assist in execution of preventive maintenance routines on automation hardware (PLCs, DCS I/O cards, power supplies).

• Collaborate with instrumentation and process teams for process tuning or interlock verification.

Key Focus Areas:

1. PLC/DCS Support & Diagnostics

   • Troubleshoot PLC/DCS issues using:

     • Siemens (TIA Portal/STEP7), Allen-Bradley (RSLogix/Studio 5000), Schneider, DeltaV, etc.

     • HMI/SCADA interfaces like WinCC, FactoryTalk, iFix, or Wonderware

2. Field I/O & Equipment Integration

   • Validate:

     • Analog and digital signals

     • Sensors, actuators, limit switches, and interlocks

     • Safety-related wiring and controls (emergency stops, interlocks)

3. Automation Documentation

   • Maintain:

     • Wiring schematics, tag lists, loop diagrams

     • Program revision logs and version control documentation

4. System Improvements & Change Management

   • Suggest or implement small improvements in control logic under supervision

   • Participate in change control procedures (CCRs, MOCs) in GMP-compliant environments

5. Compliance & Cross-Functional Coordination

   • Support QA/Validation during:

     • Equipment IQ/OQ, audit readiness, and automation data traceability

   • Ensure adherence to GMP, GDP, and safety regulations

Qualifications:

• Education:

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

• Experience:

  • 3–6 years of hands-on experience in PLC/DCS support roles within industrial plants

• Technical Skills:

  • Proficient in:

    • PLC/DCS troubleshooting, basic logic editing

    • Reading control wiring diagrams and loop drawings

    • Working knowledge of sensors, relays, analog/digital signal diagnostics

• Soft Skills:

  • Strong communication and teamwork skills

  • Detail-oriented with ability to document and follow SOPs

  • Able to work independently and escalate issues when required