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Key Responsibilities and Required Skills for Instrumentation and Controls Engineer

💰 $80,000 - $130,000

EngineeringControlsInstrumentationAutomation

🎯 Role Definition

The Instrumentation and Controls (I&C) Engineer is responsible for designing, specifying, commissioning, troubleshooting and maintaining control and instrumentation systems that ensure safe, efficient and reliable operation of industrial processes. This role covers the full lifecycle of control systems—from instrument specification and loop design to PLC/DCS programming, HMI/SCADA deployment, testing (FAT/SAT), calibration, and continuous improvement. The I&C Engineer collaborates with process, mechanical, electrical, and safety teams, vendors and contractors to deliver projects on time, within budget, and to required safety and quality standards. Key focus areas include control strategy development, field device configuration (HART, FOUNDATION Fieldbus, PROFIBUS), alarm management, cybersecurity best practices for OT, and compliance with industry codes and standards (IEC, ISA, API, NFPA, NEC).

📈 Career Progression

Typical Career Path

Entry Point From:

  • Junior Instrumentation Technician
  • Controls Technician or PLC Technician
  • Electrical Engineer (entry level) with instrumentation exposure

Advancement To:

  • Senior Instrumentation and Controls Engineer
  • Lead Controls Engineer / Control Systems Architect
  • Automation Engineering Manager / Controls Engineering Manager

Lateral Moves:

  • Process Control Engineer
  • Safety Instrumented Systems (SIS) Engineer
  • SCADA/HMI Specialist
  • Project Controls/Commissioning Lead

Core Responsibilities

Primary Functions

  • Lead the specification, selection and procurement of field instruments (pressure, temperature, level, flow, analyzers) and control valves, producing detailed instrument datasheets, loop diagrams and bill of materials to meet process and safety requirements.
  • Develop and implement control philosophy and control narratives for units and systems, translating process requirements into PLC/DCS logic, sequence of operations and interlock diagrams.
  • Design and program PLC and DCS control strategies using vendor-specific platforms (e.g., Allen-Bradley/Rockwell, Siemens, Honeywell, Emerson DeltaV, Schneider) and implement ladder logic, function block, and structured text as required.
  • Configure and build HMI and SCADA screens, trends, and alarm displays that provide operators with intuitive situational awareness, ensuring alignment with alarm management best practices (ISA 18.2).
  • Perform loop tuning and control optimization, including PID tuning, cascade and feedforward implementations, to improve process stability, reduce variability and increase throughput.
  • Lead FAT (Factory Acceptance Testing) activities with vendors, creating test procedures, witnessing factory tests, documenting results and driving corrective actions to ensure system conformance before site delivery.
  • Plan and execute onsite SAT (Site Acceptance Testing), pre-commissioning and commissioning activities including field wiring verification, instrument calibration, bench-testing, I/O checks, and integrated system tests to validate performance.
  • Conduct field instrument calibration, verification and troubleshooting using HART communicators, calibrators, multimeters and flow/pressure standards to ensure accuracy and repeatability of measurements.
  • Implement and maintain instrument loop diagrams (ILDs), P&IDs, wiring schematics and as-built documentation, ensuring accurate configuration in control system databases and CMMS.
  • Lead vendor and contractor coordination for installation, wiring, marshalling, junction box configuration and loop testing, enforcing workmanship and documentation standards.
  • Design and implement safety instrumented systems (SIS) including logic solvers, sensors, and final elements, perform SIL determination and verification, and support LOPA and HAZOP sessions to meet functional safety requirements.
  • Develop and maintain instrumentation and control system wiring diagrams, cable schedules, junction box and marshalling layouts, and perform electrical interface coordination to minimize installation risks.
  • Perform root cause analysis (RCA) for instrumentation and control system failures, using structured problem-solving techniques to identify corrective and preventive actions.
  • Implement control system cybersecurity and network segmentation best practices, coordinate with IT/OT security teams to apply patching, access controls, secure remote access and VPN configurations.
  • Support process safety and regulatory compliance by ensuring instrumentation and control changes follow MOC procedures and that calibration and preventive maintenance programs meet audit requirements.
  • Create and maintain test plans, commissioning procedures, checklists and traceability matrices for control system components and ensure systematic handover to operations with full documentation and training.
  • Provide on-the-job technical guidance and mentoring to technicians, junior engineers and contractors on instrumentation best practices, calibration methods and safe work procedures.
  • Analyze historical process and alarm data to identify opportunities for alarm rationalization, control loop performance improvements and energy savings; recommend and implement changes in coordination with process owners.
  • Integrate third-party analyzers and smart field devices (HART, Modbus, FOUNDATION Fieldbus) into control systems and perform device configuration and diagnostics using device description tools.
  • Support capital projects by preparing cost estimates, technical scopes, and schedules for instrumentation and controls packages and participate in project risk assessments and value engineering activities.
  • Maintain spare parts strategies and lifecycle plans for critical I&C assets, optimize stock levels and lead replacement or obsolescence mitigation plans for aging control equipment.
  • Provide tier-2/3 field support for operations by responding to escalated incidents, providing technical troubleshooting guidance during outages, start-ups and process upsets to restore production quickly and safely.
  • Ensure continuous improvement of I&C standards and templates (control modules, naming conventions, faceplate libraries) to reduce engineering rework and speed future project execution.

Secondary Functions

  • Support ad-hoc data requests and exploratory data analysis.
  • Contribute to the organization's data strategy and roadmap.
  • Collaborate with business units to translate data needs into engineering requirements.
  • Participate in sprint planning and agile ceremonies within the data engineering team.
  • Participate in HAZOP, LOPA, and safety reviews to provide instrumentation expertise and implement recommended mitigations.
  • Prepare and deliver technical training, handover packages and SOPs for operations and maintenance teams related to instrumentation and controls.
  • Coordinate with procurement to evaluate technical proposals, review FAT documentation from suppliers and ensure contractual deliverables align with technical specifications.
  • Support management of change (MOC) and document control processes for all instrumentation and control modifications.

Required Skills & Competencies

Hard Skills (Technical)

  • PLC/DCS Programming (Allen-Bradley/Rockwell ControlLogix, Siemens S7, Emerson DeltaV, Schneider) — development, testing and commissioning of control logic.
  • HMI/SCADA design and configuration (Wonderware, Ignition, FactoryTalk, WinCC) — operator graphics, alarm handling and trending.
  • Instrumentation selection and specification — pressure, temperature, level, flow, analytical instruments and control valves with actuation.
  • Control theory and loop tuning (PID, cascade, feedforward, model-based controls) and control performance optimization.
  • Instrument calibration and diagnostics — HART communicator, field calibrators, loop checks and test equipment proficiency.
  • Safety Instrumented Systems (SIS) design and SIL verification — knowledge of IEC 61508 / IEC 61511 and LOPA methodology.
  • Instrument and control system documentation — P&IDs, loop diagrams, IO lists, cable schedules and as-built record keeping.
  • Communication protocols and fieldbus technologies — HART, Modbus RTU/TCP, PROFIBUS, Ethernet/IP, FOUNDATION Fieldbus.
  • FAT/SAT/Test procedure development and execution — writing test scripts, acceptance criteria, and witness testing.
  • OT network architecture and cybersecurity fundamentals for industrial control systems — VLANs, firewalls, VPNs, secure remote access.
  • Electrical wiring and marshalling knowledge — junction boxes, termination, cable trays and grounding practices.
  • Vendor and contractor management — scope review, technical bid evaluation, and vendor FAT oversight.
  • Root cause analysis (5 Whys, Fishbone) and structured problem-solving for field incidents.
  • Alarm management and rationalization best practices (ISA 18.2 / IEC 62682).
  • Data historian and industrial analytics familiarity (OSIsoft PI, Wonderware Historian, Ignition).

Soft Skills

  • Strong written and verbal communication — prepare crisp technical reports, specifications and handover documentation.
  • Cross-functional collaboration — ability to work effectively with process, electrical, mechanical, safety and operations teams.
  • Project management and organization — prioritize tasks, manage multiple deliverables and meet project milestones.
  • Analytical thinking and troubleshooting — systematic approach to diagnose control and instrumentation issues under pressure.
  • Mentoring and team leadership — coach technicians and junior engineers; foster knowledge transfer and skills development.
  • Attention to detail and quality focus — enforce standards, perform thorough inspections and maintain accurate documentation.
  • Adaptability and continuous learning — keep current with control system releases, instrumentation technology and standards.
  • Stakeholder management — manage expectations, negotiate technical trade-offs and present solutions to non-technical audiences.
  • Time management and resilience — work effectively during start-ups, shutdowns and commissioning windows.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor of Science in Electrical Engineering, Control Systems Engineering, Instrumentation Engineering, Chemical Engineering (with strong controls focus) or related engineering discipline.

Preferred Education:

  • Bachelor’s or Master’s degree in Control Systems, Instrumentation, Electrical or Chemical Engineering with coursework in control theory, automation and instrumentation.
  • Professional certifications such as ISA Certified Control Systems Technician (CCST), Certified Automation Professional (CAP), or relevant vendor certifications (Rockwell, Siemens, Emerson).

Relevant Fields of Study:

  • Control Systems Engineering
  • Instrumentation and Measurement
  • Electrical Engineering
  • Chemical or Mechanical Engineering with automation coursework
  • Industrial Automation and Process Control

Experience Requirements

Typical Experience Range: 3–10+ years of progressive instrumentation and controls experience in process industries such as oil & gas, petrochemical, chemical, power generation, water/wastewater, pharmaceuticals or manufacturing.

Preferred:

  • 5+ years designing and commissioning PLC/DCS systems and instrumentation in continuous or batch processing environments.
  • Demonstrated experience with FAT/SAT execution, vendor management, SIS implementation and commissioning large-scale projects.
  • Proven track record of field troubleshooting, loop tuning, instrument calibration, and successful operational handovers.
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