Key Responsibilities and Required Skills for Electrical and Instrumentation Technician

🎯 Role Definition

The Electrical and Instrumentation Technician (E&I Technician) is responsible for the installation, maintenance, calibration, troubleshooting and commissioning of electrical, electronic and instrumentation systems used in industrial processes. This role combines hands-on field work with documentation, testing and close collaboration with operations, engineering and vendors to ensure reliable, safe and compliant process control systems. Primary focus areas include PLC/DCS and SCADA interfaces, field instruments (flow, pressure, level, temperature, analyzers), control valves and associated wiring, terminations and loop verification.

📈 Career Progression

Typical Career Path

Entry Point From:

Junior Electrician / Apprentice Electrician
Instrumentation Technician I / Maintenance Technician
Technical Diploma / Vocational Graduate in Electrical or Instrumentation

Advancement To:

Senior Electrical & Instrumentation Technician
Instrumentation Supervisor / Maintenance Supervisor
Control Systems Engineer / Automation Engineer

Lateral Moves:

PLC Programmer / Controls Technician
Reliability Technician / Condition Monitoring Specialist

Core Responsibilities

Primary Functions

Install, wire and terminate electrical and instrumentation devices, panels and junction boxes in accordance with electrical drawings, P&IDs, loop diagrams and national/regional electrical codes, ensuring correct cable routing, segregation and protection.
Perform instrument calibration and functional testing (pressure, temperature, level, flow, vibration, analyzers) using bench and field calibrators to verify accuracy and adjust instruments to vendor and process specifications.
Carry out FAT (Factory Acceptance Testing), SAT (Site Acceptance Testing) and commissioning activities for control systems, instrumentation packages and skids, documenting results and deviations and coordinating corrective actions with engineering and vendors.
Troubleshoot faults in PLC/DCS controlled systems including input/output modules, analog/digital signal conditioning, card replacements, and remediate wiring, grounding or configuration errors to restore process operations.
Conduct detailed loop checks and signal integrity verification across instrumentation loops to confirm proper sensor-to-controller-to-actuator functionality and to detect wiring, grounding or scaling issues.
Maintain and repair control valves, actuators and positioners (pneumatic, electric, electro-hydraulic), performing diagnostics, stroking, bench testing and calibration to achieve required control performance.
Install, configure and troubleshoot fieldbus and digital instrument communications such as HART, Foundation Fieldbus, Profibus and modbus-based networks, including commissioning of smart transmitters and network devices.
Perform preventive and predictive maintenance tasks per CMMS schedules — motor control centers (MCC), starters, VFDs, transformers, power distribution, conduit and cable inspections — and log maintenance records accurately.
Diagnose and repair electrical systems including troubleshooting of short circuits, ground faults, blown fuses, tripped breakers, loose connections and degraded insulation using multimeters, meggers and oscilloscopes.
Implement lockout/tagout, electrical isolation, confined-space entry, hot work and other site safety permits; lead pre-job safety briefings and ensure all work complies with HSE policies and local regulations.
Support shutdowns and turnarounds by executing planned instrumentation replacements, upgrades, loop modifications and testing with tight schedules and cross-functional coordination to minimize downtime.
Program, configure and update PLC and HMI parameters (Allen-Bradley, Siemens, Schneider, etc.) under supervision or in collaboration with control engineers to implement minor logic changes or I/O re-mapping.
Inspect and maintain analytical instrumentation (gas chromatographs, pH/ORP, conductivity, dissolved oxygen) including sampling systems, calibration gases, reagents and routine zero/span checks.
Execute cable pulling, dressing, ferruling, crimping and wire numbering practices to maintain high-quality terminations and ensure traceability of control and power circuits.
Prepare and maintain detailed as-built documentation, I/O lists, loop sheets, instrument datasheets and wiring diagrams; update drawing mark-ups and job completion reports in electronic document systems.
Coordinate with vendors and contractors for specialized repairs, spare parts procurement and warranty service; evaluate vendor proposals and support site acceptance of delivered equipment.
Perform vibration, insulation resistance and thermographic scanning as part of condition monitoring programs and report anomalies for follow-up corrective maintenance.
Support instrument and electrical engineering during design reviews, constructability assessments and field verification to ensure design intent is met during installation.
Train junior technicians and apprentices on correct installation practices, measurement techniques, safe work methods and company standard operating procedures.
Maintain spare parts inventory for critical instrumentation and electrical items, recommend stocking levels based on failure history and support procurement activities to reduce mean time to repair.
Participate in continuous improvement initiatives such as root-cause analysis (RCA), failure-mode-and-effects-analysis (FMEA) and preventive maintenance optimization to improve reliability and reduce costs.
Ensure compliance with regulatory requirements and industry standards (NEC, IEC, ISA, API, ATEX/IECEx where applicable) and support internal and third-party audits with required documentation and corrective actions.
Provide on-call support and rapid field response for critical process upsets or safety-related instrumentation failures, documenting actions taken and lessons learned.

Secondary Functions

Assist operations and engineering teams with technical clarifications during process changes and minor loop modifications.
Support procurement and vendor evaluation for instrumentation and electrical materials; review vendor datasheets and ensure compliance with local standards.
Maintain and update CMMS work orders, spare parts records and calibration certificates to ensure audit readiness.
Participate in safety committees, toolbox talks and mentorship programs to strengthen site safety culture and workmanship standards.
Prepare job estimates, activity duration assessments and materials lists to support turnaround and project planning activities.

Required Skills & Competencies

Hard Skills (Technical)

Instrument calibration and loop checking (pressure, level, temperature, flow, analyzers) with field and bench calibrators (e.g., Fluke, Beamex).
PLC/DCS interface experience — commissioning, basic troubleshooting and I/O diagnostics (Allen-Bradley, Siemens, Schneider, Honeywell, Emerson DeltaV).
Knowledge of HART, Foundation Fieldbus, Profibus and Modbus digital communication protocols and smart transmitter commissioning.
Control valve diagnostics, actuator maintenance, positioner calibration and valve stroking/bench testing.
Electrical troubleshooting: multimeter, insulation resistance testing (megger), oscilloscope and power quality analysis.
Installation skills: cable pulling, termination, ferruling, junction box work, conduit installation and cable tray best practices.
VFD, starter and MCC maintenance and diagnostics, including motor testing and phase checks.
Reading and interpreting P&IDs, loop drawings, wiring schematics, single-line diagrams and instrument datasheets.
Use of CMMS/EAM systems for work order creation, scheduling and history logging; familiarity with SAP, Maximo or similar preferred.
Experience with FAT/SAT, commissioning protocols, commissioning checklists and punch-list closure.
Knowledge of safety systems and standards: lockout/tagout, confined-space entry, hot work permits, ATEX/IECEx, NEC/IEC compliance.
Basic PLC/HMI configuration and parameter changes using vendor tools (RSLogix, TIA Portal, Unity Pro, etc.).
Analytical instrument maintenance: gas analyzers, pH/ORP sensors, conductivity, TOC, GC systems.
Fieldbus network diagnostics and field device replacement procedures.

Soft Skills

Strong troubleshooting and analytical problem-solving with an ability to isolate root causes under time pressure.
Clear verbal and written communication for handovers, technical reports and cross-discipline coordination.
Attention to detail and high-quality workmanship with a pride in neat terminations and accurate documentation.
Safety-first mindset with the ability to coach and enforce safe work practices in the field.
Time management and planning to meet turnaround schedules and maintenance windows.
Team player who collaborates with operations, engineering, procurement and contractors.
Adaptability to changing priorities during outages, startups and shifts in production demand.
Customer-focused orientation — responsive to operations’ needs and committed to minimizing downtime.
Continuous improvement mindset; participates in lessons-learned and implements best practices.
Mentoring ability to train apprentices and upskill junior technicians.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or equivalent with completed technical/vocational training in electrical or instrumentation trades.

Preferred Education:

Associate degree or diploma in Electrical Engineering Technology, Instrumentation & Control, Mechatronics or equivalent.
Trade certification or journeyman electrician/instrumentation license preferred.
Additional certifications: HART Foundation certification, ATEX/IECEx, OSHA 10/30, Confined Space, First Aid/CPR.

Relevant Fields of Study:

Electrical Engineering Technology
Instrumentation & Control Technology
Mechatronics / Industrial Electronics
Process Technology

Experience Requirements

Typical Experience Range: 3 - 7 years of hands-on instrumentation and electrical experience in industrial environments (manufacturing, oil & gas, chemical, power, water/wastewater).

Preferred: 5+ years supporting commissioning, preventive maintenance and troubleshooting of PLC/DCS-controlled process plants with documented experience in calibration, loop checks, control valve maintenance and digital instrumentation protocols.