Instrument Mechanician

Job Purpose

The Instrument Mechanician is responsible for the installation, calibration, maintenance, fault finding, and repair of process instrumentation and associated control systems to ensure accurate measurement, stable process control, safe operations, and optimal zinc production in accordance with statutory and mine standards.

Key Responsibilities

Safety, Health & Statutory Compliance

• Perform all work in compliance with Mine Health and Safety legislation, mine standards, and instrumentation procedures.
• Apply permit‑to‑work, isolation, lock‑out / tag‑out, and hazardous area requirements.
• Use appropriate PPE, calibrated tools, and approved test instruments.
• Identify and report unsafe conditions, defects, and near misses.
• Participate in toolbox talks, risk assessments, and incident investigations.

Instrumentation Maintenance & Calibration

• Carry out planned, predictive, corrective, and breakdown maintenance on instrumentation.
• Calibrate and maintain instruments including:
• Flow, level, pressure, temperature, and density transmitters
• Weigh feeders, belt scales, and load cells
• pH, ORP, conductivity, and analytical instruments
• Perform loop checks, functional testing, and commissioning support.
• Ensure instruments operate within required accuracy tolerances.

Fault Finding & Diagnostics

Fault find and repair:

• Field instruments, junction boxes, and field cabling
• Instrument air systems, valves, and analyzers
• Basic PLC and DCS I/O related to instrumentation
• Analyse recurring instrument failures and provide feedback to supervision.
• Support plant during abnormal operating conditions and breakdowns.

Process Control Support

• Support PLC, SCADA, or DCS systems by:
• Diagnosing instrument‑related alarms and process deviations
• Assisting with control loop performance checks
• Work closely with electrical and operational teams to stabilise plant processes.
• Support plant start‑ups, shutdowns, and maintenance windows.

Preventive Maintenance & Housekeeping

• Conduct routine inspections and condition monitoring of instruments.
• Maintain high standards of housekeeping in panel rooms, instrument racks, and field installations.
• Ensure instruments are protected from dust, moisture, corrosion, and mechanical damage.

Documentation & Reporting

• Accurately complete job cards and work orders in the CMMS (SAP / Pragma / equivalent).
• Maintain calibration certificates, loop diagrams, and instrument histories.
• Provide clear shift handover information on plant and instrument status.

Teamwork & Mentorship

• Work effectively with electricians, technicians, operators, and engineers.
• Assist with mentoring apprentices, assistants, or learners where required.
• Participate in training, refresher courses, and skills development initiatives.

Minimum Qualifications

• Trade Test Certificate – Instrument Mechanician / Instrumentation Technician
• Grade 12 / NQF Level 4
• Valid Instrumentation Authorisation (as per mine requirements)
• Medically fit for mine work

Advantageous

• National Diploma in Instrumentation / Process Control
• PLC / SCADA / DCS training or exposure
• Hazardous area instrumentation certification

Experience Requirements

• 3–5 years post‑trade experience in instrumentation

Experience in:

• Mining or mineral processing plants (zinc advantageous)
• Continuous process environments
• Shift or shutdown maintenance operations

Technical Competencies

• Instrument calibration and diagnostics
• Understanding of control loops and process measurements
• Interpretation of P&IDs, loop drawings, and datasheets
• Instrument air and analyser systems
• Basic PLC I/O and alarm troubleshooting
• Use of calibration and testing equipment