Process Maintenance Electrician

Job Summary:

The Process Controls & PLC Technician is a highly skilled electrical, instrumentation, and controls technician responsible for troubleshooting, programming, maintenance, modification, and optimization of PLC-based industrial control systems supporting Process operations.

The position requires strong experience with Allen-Bradley PLC systems and Studio 5000 Logix Designer (formerly RSLogix 5000), including troubleshooting and modifying PLC programs, integrating new equipment and instrumentation, configuring I/O and tags, supporting HMI/operator interface changes, and establishing process and equipment trending points.

The PLC Technician works closely with Maintenance, Operations, and Engineering to troubleshoot equipment and process problems, perform root-cause analysis, implement approved control-system improvements, and improve equipment reliability and process performance.

While PLC and controls work is the primary focus, the employee must maintain the electrical and instrumentation skills necessary to perform Process Maintenance Electrician duties as needed, including troubleshooting, repairing, installing, and maintaining industrial electrical equipment, instrumentation, motors, motor controls, VFDs, and related systems.

Primary Duties & Responsibilities:

• Attends lineout and safety meeting.
• Troubleshoot, maintain, program, and modify Allen-Bradley PLC systems using Studio 5000 Logix Designer, including ladder logic, tags, alarms, permissives, interlocks, timers, counters, and equipment-control sequences.
• Diagnose PLC, I/O, instrumentation, communication, electrical, and process-control problems and determine appropriate corrective actions.
• Integrate new equipment, instrumentation, and field devices into existing PLC-controlled systems, including I/O configuration, programming, communications, controls, alarms, and equipment status.
• Add or modify equipment on existing HMI/operator interface pages and process displays, including controls, indications, alarms, setpoints, permissives, and process information.
• Create and configure PLC tags and measurement points for equipment and process trending, including pressure, flow, level, temperature, vibration, speed, motor current, equipment status, run time, and other operating parameters.
• Utilize PLC diagnostics and process trends to support troubleshooting, root-cause analysis, predictive maintenance, reliability improvement, and process optimization.
• Troubleshoot digital and analog I/O, sensors, transmitters, relays, solenoids, instrumentation, motor controls, VFDs, industrial communications, and other PLC-connected devices.
• Perform functional testing and commissioning following programming changes, equipment additions, instrumentation modifications, and control-system improvements.
• Maintain accurate documentation of PLC programming changes, I/O assignments, tags, instrumentation, equipment additions, and control-system modifications.
• Work with Maintenance, Operations, and Engineering to identify and implement approved automation, controls, reliability, and process improvements.
• Provide technical assistance and mentoring to electrical personnel regarding PLCs, controls, instrumentation, and advanced troubleshooting.
• Perform Process Maintenance Electrician duties as needed, including troubleshooting, installation, repair, testing, and preventive maintenance of industrial electrical and instrumentation systems, motors, motor controls, VFDs, and power-distribution equipment.
• Read and interpret electrical prints, schematics, wiring and control diagrams, PLC logic, technical manuals, and manufacturer documentation.
• Follow applicable electrical codes, safety requirements, Lockout/Tagout procedures, change-management requirements, SOPs, and company standards.
• Complete work orders, programming-change records, maintenance documentation, and equipment records accurately and in a timely manner.
• Perform additional PLC, controls, instrumentation, and electrical duties as required to support Process operations.

Knowledge, Skills, and Experience:

• Minimum five (5) years of industrial electrical, instrumentation, automation, or controls experience, including significant hands-on experience troubleshooting and modifying PLC-controlled systems.

• Advanced experience with Allen-Bradley PLC systems and Studio 5000 Logix Designer (formerly RSLogix 5000).

• Demonstrated ability to troubleshoot and modify PLC programs and ladder logic, including tags, alarms, permissives, interlocks, timers, counters, and control sequences.
• Experience integrating new equipment, instrumentation, and field devices into existing PLC-controlled systems.
• Experience configuring digital and analog I/O, PLC tags, communications, alarms, equipment controls, and process measurement points.
• Experience adding or modifying equipment and associated controls, status indications, alarms, and process information on existing HMI/operator interface screens.
• Ability to establish and use process and equipment trends for troubleshooting, condition monitoring, root-cause analysis, predictive maintenance, and reliability improvement.
• Strong knowledge of industrial instrumentation, sensors, transmitters, digital and analog signals, motor controls, VFDs, industrial communications, and PLC-connected field devices.
• Strong industrial electrical troubleshooting skills with experience maintaining and repairing electrical circuits, motors, controls, instrumentation, and related Process equipment.
• Ability to systematically diagnose complex PLC, electrical, instrumentation, and process-control problems and verify successful operation following repairs or programming changes.
• Ability to read and interpret PLC logic, electrical prints, schematics, wiring diagrams, control diagrams, technical manuals, and equipment documentation.
• Knowledge of industrial electrical safety practices, applicable electrical codes, Lockout/Tagout requirements, and safe use of electrical and instrumentation test equipment.
• Strong communication and teamwork skills with the ability to work effectively with Maintenance, Operations, Engineering, supervisors, and other personnel.
• Ability to provide technical guidance and mentoring to less-experienced electrical personnel.

Certifications: None Required.

Education: High School Diploma or equivalent