Job Purpose

To provide technical support, maintenance, and troubleshooting of all field instrumentation, control loops, automation devices, and process monitoring systems on a shift basis. The Instrumentation Shift Technician ensures reliable operation of critical equipment to support safe, efficient zinc production with minimal downtime.

Key Responsibilities

Instrumentation Maintenance & Troubleshooting

Perform repairs, calibration, and loop testing on:

• Pressure, temperature, flow, and level transmitters
• pH, DO, density, and conductivity meters
• Belt scales, weigh feeders, and load cells
• Control valves, positioners, and I/P converters
• Gas detection systems
• VSD instrumentation & interlocks
• Diagnose and resolve breakdowns on instrumentation systems across the processing plant.
• Responsible for the calibration, repair and maintenance of control gear/instrumentation in the manufacturing process.
• Devises, selects, sets up and operates electronic instrumentation and related electromechanical or electrohydraulic apparatus used for operational and environmental testing of mechanical, structural or electrical equipment and translates test data for engineering staff.
• Selects, installs, calibrates and checks sensing, telemetering and recording instrumentation and circuitry and develops specifications for non-standard apparatus according to engineering data, characteristics of equipment under test and capabilities of procurable test apparatus.

Shift Support for Operations

Provide on-call support for control room and field operations during equipment trips or alarms.

Assist control operators with:

• PID loop tuning
• Setpoint adjustments
• Alarm management
• Ensure instrumentation contributes to stable process control (throughput, recovery, consistency).

Preventative Maintenance

• Execute scheduled inspections, calibrations, and preventive maintenance tasks.
• Complete shift checklists and detailed maintenance records.
• Identify equipment nearing failure and escalate accordingly.

Control System Interface Support

Support PLC/DCS/SCADA (ABB)system functionality by ensuring correct field signals.

Verify integrity of:

• 4–20 mA loops
• Profibus/Profinet devices
• Modbus instrumentation
• Analogue/digital I/O modules
• Assist Control Engineer with logic testing during plant modifications.

Safety & Compliance

• Apply safe work practices including:
• Lock-out/Tag-out (LOTO)
• Permit-to-work
• Hazard identification (HIRA)
• Maintain all instrumentation in compliance with MHSA and site engineering standards.
• Ensure accuracy and certification of critical safety systems.

Documentation & Reporting

Complete:

• Shift logs
• Calibration sheets
• Task cards
• Fault reports
• Maintain up-to-date records for traceability and regulatory compliance.

Support for Projects & Improvements

• Assist during commissioning of new instrumentation or plant upgrades.
• Provide feedback on recurring problems to support continuous improvement.
• Participate in RCA (Root Cause Analysis) investigations.

Required Skills & Competencies

Technical Competencies

Strong understanding of:

• Process instrumentation principles
• Analogue/digital control systems
• Control valve operation
• Industrial sensors and transmitters

SCADA/PLC interfaces

Ability to read:

• P&IDs
• Loop diagrams
• Instrument datasheets
• Wiring/cable schedules
• Skilled in fault-finding across multiple systems.
• Behavioural Competencies
• Strong safety culture and situational awareness.
• Good communication skills for shift handovers.
• Ability to work under time pressure during breakdowns.
• Teamwork and collaboration with operations and maintenance crews.

Qualifications & Experience

• Minimum Requirements
• Trade Test: Instrumentation Mechanician (Red Seal).
• 3–5 years' experience in mineral processing or heavy industrial environment.
• Experience with transmitters, control valves, PID loops, and SCADA/PLC interfaces.
• Willingness to work rotating shifts and respond to after-hours callouts.

Preferred

• Experience in a zinc, copper, lead, or base metal processing plant.
• Instrumentation training on ABB, Yokogawa, Honeywell, or Siemens devices.
• Experience with industrial networks (Profibus, AS-i, Profinet).
• Knowledge of metallurgical processes (crushing, milling, flotation).
• Physical & Environmental Conditions
• Work in noisy, dusty, and high-vibration plant areas.
• Must be physically fit and able to climb structures and work at heights.
• Exposure to chemicals and process gases (with PPE).
• Required to work shifts, overtime, and standby.

Key Performance Indicators (KPIs)

• Instrumentation system availability and reliability.
• Reduction in instrumentation-related plant downtime.
• Quality and accuracy of calibrations and maintenance work.
• Timeliness of breakdown response.
• Safety compliance and incident-free performance.
• Quality of shift reporting and documentation.