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Job Summary: The Industrial Instrumentation & Controls (I&C) Technician installs, maintains, calibrates, commissions, and troubleshoots instrumentation, control systems, and associated electrical and electronic equipment at heavy industrial customer facilities. This is a journeymen-level field role requiring the ability to work independently, interpret technical documentation, diagnose complex process-control problems, and complete work safely and professionally in active operating environments. The technician may support new construction, maintenance, shutdowns, turnarounds, system upgrades, commissioning, and emergency troubleshooting assignments.
Key Responsibilities:
- Install, inspect, maintain, repair, calibrate, and troubleshoot instruments that measure and control process variables, including pressure, flow, level, temperature, analytical properties, vibration, speed, position, motion, force, and other operating conditions.
- Install and service transmitters, switches, transducers, sensors, analyzers, gauges, control valves, actuators, positioners, solenoids, limit switches, junction boxes, marshalling panels, remote I/O, control panels, instrument tubing, and associated cabling and terminations.
- Read and interpret P&IDs, instrument loop diagrams, hook-up drawings, wiring diagrams, schematics, control narratives, cause-and-effect documents, logic diagrams, ladder logic, I/O lists, equipment data sheets, vendor manuals, and installation specifications.
- Configure, range, test, and calibrate smart and conventional field instruments using handheld communicators, vendor software, and appropriate precision test equipment.
- Perform point-to-point checks, continuity checks, loop checks, functional testing, alarm and trip verification, control-valve stroking, interlock testing, and commissioning or startup support.
- Troubleshoot complete control loops and identify faults in field devices, wiring, power supplies, PLC/DCS I/O, control panels, communication networks, software configuration, and final control elements.
- Use multimeters, process calibrators, milliamp sources, pressure pumps, manometers, deadweight testers, temperature simulators, insulation testers, tachometers, HART communicators, and other diagnostic or precision instruments.
- Support PLC, DCS, HMI, SCADA, historian, remote I/O, and industrial communication systems within the technician's training and authorization; coordinate programming or configuration changes with controls engineers or authorized programmers.
- Disassemble malfunctioning instruments, evaluate mechanical and electronic components, repair or replace defective parts, reassemble equipment, and verify conformance with manufacturer and project specifications.
- Perform preventive and predictive maintenance; identify developing equipment issues and recommend corrective actions or reliability improvements.
- Maintain accurate calibration records, inspection reports, test documentation, redlines, as-built markups, material usage, daily work records, deficiency lists, and turnover packages.
- Assist with job planning by reviewing scope, identifying required tools and materials, evaluating access or operational constraints, and communicating potential safety, quality, cost, or schedule concerns.
- Coordinate effectively with customer representatives, operators, maintenance personnel, engineers, programmers, electricians, project managers, superintendents, vendors, and other crafts.
- Provides clear turnover information and communicates equipment status, unresolved deficiencies, testing results, and operational limitations before placing systems into service.
- Maintains tools, test equipment, work areas, and company vehicles in a safe, organized, and serviceable condition.
- Produces legible, complete, and well-organized calibration records, test reports, redlines, deficiency lists, and daily work records.
- Works effectively across different customers, industries, control platforms, project phases, schedules, and site conditions.
- Represents the company professionally, protects customer operations, and communicates issues before they create safety, quality, schedule, or production impacts.
- Perform other duties consistent with the position and within the employee's training, qualifications, and authorization
Safety, Quality, and Customer-Site Expectations
- Performs all work in accordance with company procedures, customer requirements, approved work packages, manufacturer instructions, applicable codes and standards, and recognized industry practices.
- Comply with lockout/tagout, energized electrical work, arc-flash, fall protection, confined-space, hot-work, line-breaking, respiratory-protection, hazardous-material, and other site-specific safety requirements.
- Work on or near energized equipment only when authorized, properly trained, qualified, and equipped with the required personal protective equipment and approved work controls.
- Understand and apply applicable requirements of the National Electrical Code (NEC), NFPA 70E, OSHA regulations, hazardous-location practices, and customer engineering standards.
- Participate in pre-task planning, job hazard analyses, safety meetings, permit processes, quality inspections, and stop-work actions when unsafe or nonconforming conditions are identified.
- Protect operating equipment and customer property, maintain professional conduct, and follow site security, badging, housekeeping, environmental, and operational-control requirements.
- Verify instrument identification, calibration tolerances, wiring, polarity, grounding, shielding, range, fail position, alarm setpoints, and documentation before final acceptance or turnover.
Education and Certifications
- High school diploma or recognized equivalent.
- Technical, trade-school, military, apprenticeship, or equivalent on-the-job training in industrial instrumentation, electronics, electrical technology, process controls, or a related field.
Preferred Education and Certifications
- Associate degree in Instrumentation Technology, Electronics, Electrical Technology, Process Controls, or a closely related discipline.
- ISA Certified Control Systems Technician (CCST), NCCER Instrumentation Technician certification, recognized apprenticeship completion, or equivalent industry credential.
- ISA Certified Control Systems Technician (CCST), NCCER Instrumentation Technician certification, recognized apprenticeship completion, or equivalent industry credential.
- Current OSHA 10/30, MSHA, NFPA 70E, first-aid/CPR, confined-space, aerial-lift, or other relevant industrial credentials.
Experience:
- Minimum five years of progressive industrial instrumentation and controls experience, including field calibration, installation, troubleshooting, loop testing, and maintenance.
- Demonstrated experience working in active heavy industrial environments such as power generation, mining, manufacturing, chemical processing, pulp and paper, metals, cement, water/wastewater, or similar process facilities.
- Experience with process analyzers, vibration monitoring, burner-management systems, turbine or boiler controls, weigh systems, variable-frequency drives, or protective control interfaces.
- Experience with 480-volt industrial equipment and medium-voltage control or protection interfaces, when properly qualified and authorized.
- Commissioning, startup, outage, turnaround, or brownfield cutover experience.
Preferred - Experience
- Experience with Allen-Bradley/Rockwell, Siemens, Emerson, Honeywell, Schneider Electric, GE, or other industrial PLC, DCS, HMI, or SCADA platforms.
- Experience with HART, Foundation Fieldbus, Modbus RTU/TCP, Ethernet/IP, Profibus/Profinite, Device Net, or other industrial communication protocols and networks.
- Experience installing and maintaining instrumentation and electrical equipment in classified or hazardous locations.
- Experience with process analyzers, vibration monitoring, burner-management systems, turbine or boiler controls, weigh systems, variable-frequency drives, or protective control interfaces.
- Experience with 480-volt industrial equipment and medium-voltage control or protection interfaces, when properly qualified and authorized.
- Commissioning, startup, outage, turnaround, or brownfield cutover experience.
Knowledge Skills & Abilities:
- Ability to independently read and apply technical drawings, instrument documentation, electrical schematics, and vendor information.
- Working knowledge of process-control fundamentals, analog and discrete signals, 4-20 mA loops, instrument power supplies, relay logic, control-valve operation, and common field-device failure modes.
- Working knowledge of industrial electrical components and motor-control interfaces associated with instrumentation and control systems.
- Ability to safely use hand tools, power tools, precision test equipment, computers, tablets, and electronic maintenance or documentation systems.
- Ability to communicate clearly, document work accurately, follow written and verbal instructions, and work effectively with customers and multidisciplinary teams.
- Ability and willingness to travel to customer locations, including overnight and extended-duration assignments, and to work overtime or alternate shifts when project conditions require.
- Ability to satisfy company and customer site-access requirements, which include background screening, drug and alcohol testing, and may include security badging, training, and medical or respirator-clearance requirements.
- Technical troubleshooting: Uses a structured approach to isolate process, instrument, wiring, configuration, communication, and mechanical causes of failure.
- Attention to detail: Accurately follows drawings, tolerances, tag numbers, ranges, test procedures, and documentation requirements.
- Safety judgment: Recognizes hazards, understands personal limitations, follows approved procedures, and stops work when conditions are unsafe or unclear.
- Communication: Explains technical issues clearly to supervisors, engineers, operators, customers, and other crafts; provides complete and timely turnover information.
- Mathematical ability: Applies basic algebra, percentages, unit conversions, scaling, signal relationships, and process-control calculations during calibration and troubleshooting.
- Mechanical aptitude: Understands valves, actuators, linkages, tubing systems, fittings, mounting arrangements, and the mechanical effects of process conditions.
- Valid driver's license and acceptable driving record for assigned company or rental vehicles.
Work Location and Travel:
- Wok locations vary depending on job assignment.
- Travel requirements vary by assignment and may range from local daily travel to extended out-of-town work. Some positions or projects may require travel approaching 100 percent.
- The employee must be able to report to assigned locations on time and remain flexible when customer operations, commissioning activities, or project conditions require schedule changes.
Work Environment:
- Work is performed in operating industrial facilities, construction areas, shops, outdoor locations, equipment rooms, substations, process areas, and other environments that may be hot, cold, wet, dusty, noisy, congested, elevated, or exposed to weather.
- Work is performed at heights, in confined spaces, around rotating equipment, near energized electrical systems, and in proximity to hazardous chemicals or process conditions when trained, authorized, and protected by the required controls.
Physical Requirements:
Physical Requirement | Frequency | Example of Job-Related Activity | |
Talking/Hearing | Continuously | Ability to communicate and understand workplace safety signals, alarms, verbal instructions, and other information. | |
Standing/Walking | Continuously | Must walk well enough to traverse indoor and outdoor terrains, of various conditions, elevations and ground coverings | |
Use of Hands and Fingers | Continuously | Must use hands and fingers for fine manipulation, wiring, instrument adjustments, tool operations and test equipment connections while wearing required PPE | |
Climbing | Frequently | climb stairs, ladders, scaffolds, and structures | |
Stooping, Kneeling | Frequently | Must be able to adjust body to work, reach and balance while working in awkward spaces. | |
Kneeling | Frequently | Must be able to adjust body to work, reach and balance while working in awkward spaces. | |
Crouching or Crawling | Frequently | Must be able to adjust body to work, reach and balance while working in awkward spaces. | |
Vison | Continuously | Posses sufficient close, distance, peripheral, depth, and color vision to read instruments, distinguish conductors and indicator states, interpret drawings, and perform safe inspections. | |
Carrying or lifting to 50 Pounds | Frequently | Lift and carry tools, test equipment, materials, and components weighing up to 50 pounds; heavier items must be handled using approved assistance or lifting equipment. | |
Balance | Frequently |
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This job description summarizes the principal duties and requirements of the position and is not intended to be an exhaustive list of every task or responsibility. Duties may change based on business needs, project requirements, customer expectations, and the employee's training and qualifications. Reasonable accommodations may be made to enable qualified individuals with disabilities to perform the essential functions of the position.
Must be legally authorized to work in the United States.
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