Key Responsibilities and Required Skills for Jet Engine Control Operator

🎯 Role Definition

The Jet Engine Control Operator (also known as Engine Test Cell Operator or Test Cell Technician) is responsible for safely planning, executing, monitoring and documenting ground runs and acceptance tests of turbine engines (turbojet, turbofan, turboshaft). This role operates engine test cells and associated control systems, captures high-fidelity performance data, enforces strict safety and environmental procedures, troubleshoots anomalies in real time, and partners with engineers and maintenance teams to validate engine health and performance.

Key SEO phrases: jet engine control operator, engine test cell operator, turbine engine run, data acquisition, engine performance testing, test cell safety procedures, vibration analysis, engine start/stop sequences.

📈 Career Progression

Typical Career Path

Entry Point From:

Aircraft Maintenance Technician / A&P Mechanic
Test Technician or Lab Technician (mechanical/electrical)
Engine Overhaul Technician or Field Service Technician

Advancement To:

Senior Engine Test Cell Operator / Lead Operator
Test Cell Supervisor or Test Cell Manager
Engine Performance/Test Engineer or Field Service Engineer

Lateral Moves:

Maintenance Planner / Shop Foreman
Field Service Representative / On-wing Support Technician

Core Responsibilities

Primary Functions

Execute controlled engine start-up and shut-down sequences on test cells and mobile test rigs, following approved procedures and safety checklists to mitigate thermal and mechanical risks.
Operate and monitor test cell control consoles, PLCs, SCADA systems and human-machine interfaces (HMIs) to manage fuel flow, ignition, bleed air, and thrust settings during all phases of engine runs.
Program, configure and supervise data acquisition systems (DAQ) and instrumentation to record thermocouples, pressure transducers, tachometers, vibration sensors, fuel flow meters and other channels at required sampling rates and resolutions.
Continuously monitor engine parameters (EPR, N1, N2, EGT, oil pressure/temperature, fuel flow, vibration spectra) and interpret trends to ensure engines remain within approved limits during steady-state and transient conditions.
Perform pre-test inspections and readiness checks on test cell infrastructure including fuel supply, purge systems, exhaust ducting, silencers, cooling, fire suppression, electrical distribution and safe access/egress.
Follow emergency shutdown and rapid safe-stop procedures including remote shutdown systems, fire suppression activation, and coordinated communication with maintenance and safety personnel when anomalies or alarm conditions occur.
Collect, validate and deliver high-quality run-by-run performance reports including raw DAQ files, processed performance curves, computed metrics (thrust, specific fuel consumption, compressor map points), and run log narratives to engineering stakeholders.
Execute engine acceptance tests, build and production verification runs, and post-repair functional checks according to engine OEM, customer and regulatory specifications.
Troubleshoot instrumentation, sensor failures and control logic issues during tests; coordinate immediate corrective actions such as sensor replacement, recalibration or reconfiguration with technicians and engineers.
Apply vibration analysis (time waveform, FFT), bearing health assessment and rotor dynamics checks to identify early signs of imbalance, rubbing, or hardware degradation.
Control fuel system operations including fuel filtration checks, safe fuel handling, priming routines, and accurate fuel metering to protect engine components and collect trustworthy performance data.
Maintain accurate shift logs, tool control records, calibration certificates and equipment configuration records to ensure traceability and compliance with quality management systems (e.g., ISO, AS9100).
Execute throttle programming, transient schedules and operational envelopes during endurance tests and cyclic fatigue runs, ensuring rate-of-change and dwell times meet test protocols.
Coordinate with maintenance and engineering to isolate test cell failures, schedule corrective actions, and provide technical feedback for root cause investigations on engine or test cell anomalies.
Perform post-run inspections including borescope coordination (if required), external hardware checks, fluid leaks inspection and documentation of any visible damage or abnormal conditions.
Ensure environmental and emissions monitoring compliance during runs, maintaining records for exhaust sampling, noise measurements and any required permits or reporting.
Conduct routine calibration checks and functional tests on critical sensors and instrumentation, escalating out-of-tolerance conditions and maintaining calibration logs.
Operate auxiliary systems such as starters (air or electric), hydraulic and pneumatic supplies, ground support equipment, and cell HVAC systems to sustain safe operating environments.
Enforce and coach adherence to site-specific safety policies: hot work permits, confined space entry, lockout/tagout (LOTO), PPE requirements, and emergency response drills.
Maintain clear, professional radio and line-of-sight communication with test team members, engineers, safety officers and control room personnel during live operations.
Provide on-the-job training and mentorship to junior operators and technicians on test procedures, safe handling of engines and proper documentation practices.
Implement test cell housekeeping, consumables replenishment, inventory control for test fittings/adapters and ensure readiness for consecutive test campaigns.
Participate in continuous improvement initiatives to optimize test procedures, reduce test cycle time, improve data quality and implement corrective actions from non-conformances or audit findings.
Validate and enforce customer- and OEM-specific test requirements, work instructions and acceptance criteria during build verification and delivery testing.

Secondary Functions

Assist engineering teams with special instrumentation setups and custom data channel integration for developmental or certification tests.
Support test planning meetings by providing historical test data, run-time estimates and risk assessments for proposed test matrices.
Contribute to health and safety risk assessments (JHAs, PTWs) and update run procedures based on lessons learned and incident reports.
Help manage calibration scheduling and vendor coordination for DAQ equipment, pressure transducers, accelerometers and thermocouples.
Prepare and hand over engines and test cells for scheduled maintenance; verify corrective actions before returning systems to service.
Maintain and improve standard operating procedures, run cards, and emergency checklists with actionable feedback from operations.
Participate in after-action reviews to capture performance data, non-conformance causes and recommended modifications to testing protocols.
Provide subject-matter input for procurement of test cell consumables, sensors and data acquisition upgrades.
Assist in preparing regulatory and customer-facing documentation for certification tests and final delivery dossiers.
Perform shift handovers including briefing the incoming operator on outstanding issues, trends and planned upcoming runs.

Required Skills & Competencies

Hard Skills (Technical)

Proven experience operating jet engine test cells and performing engine ground runs for turbojet, turbofan or turboshaft engines.
Proficiency with industrial control systems: PLCs, SCADA/HMI platforms and test cell control consoles.
Hands-on experience configuring and operating data acquisition systems (DAQ), analog/digital channel setup, and high-speed sampling for engine instrumentation.
Strong ability to read and interpret engine performance charts, thermodynamic data, compressor/turbine maps, and instrumentation schematics.
Competence with vibration analysis tools (FFT analyzers), accelerometers, and basic rotor dynamics interpretation.
Knowledge of engine systems: fuel control, lubrication, bleed air, starting systems, ignition, and thrust reverse systems (as applicable).
Familiarity with sensor calibration techniques and maintaining calibration certificates for torque meters, thermocouples, pressure transducers and tachometers.
Operating knowledge of safety systems: emergency shutdown circuits, fire detection/suppression, purge systems and hazardous energy control (LOTO).
Skilled in troubleshooting electrical, pneumatic and hydraulic support systems for test cells and ground support equipment.
Experience generating test reports, exporting and processing DAQ data, and using software tools for data reduction and visualization (e.g., MATLAB, Python, Excel).
Understanding of regulatory frameworks and quality standards relevant to engine testing (AS9100, FAA/EASA guidance, environmental permitting).
Familiarity with portable instrumentation, borescope support coordination and basic non-destructive inspection awareness.

Soft Skills

Strong situational awareness and calm decision-making under high-pressure conditions.
Clear, concise verbal and written communication for operational briefings and test reports.
Excellent teamwork and ability to coordinate across multidisciplinary teams (engineers, maintenance, safety, customers).
Attention to detail with disciplined documentation and compliance mindset.
Proactive problem-solving and continuous improvement orientation.
Ability to train and mentor junior technicians and promotes a culture of safety-first.
Flexibility to work rotating shifts, extended hours during test campaigns, and occasional weekend work.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED with technical coursework in mechanical, electrical or aerospace fundamentals.

Preferred Education:

Associate degree or technical diploma in Aircraft Maintenance, Aerospace Technology, Mechanical Engineering Technology, or related field.
Additional coursework or certifications in control systems, instrumentation, or data acquisition is advantageous.

Relevant Fields of Study:

Aerospace / Aircraft Maintenance (A&P)
Mechanical Engineering Technology
Avionics / Electrical Technology
Instrumentation & Control Systems

Experience Requirements

Typical Experience Range:

2–5 years operating engine test cells or equivalent hands-on turbine engine ground-run experience.

Preferred:

5+ years experience with complex engine testing programs, multi-engine test cells, and demonstrable experience producing customer-ready run reports.
FAA A&P certification or equivalent, factory engine training (OEM-specific), and certifications in vibration analysis or DAQ/PLC programming are highly desirable.