Instrumentation Technician – Gyratory Crusher

Instrumentation Technician – Gyratory Crusher

Job Purpose

To install, maintain, calibrate, troubleshoot, and optimize all instrumentation, monitoring, and automation systems associated with primary gyratory crushers. The role ensures accurate sensor performance, reliable process monitoring, and the integrity of digital enabled crusher health and performance systems.

Key Responsibilities

• Instrumentation Maintenance & Calibration
• Maintain and troubleshoot TIMS (Tank Instrumentation Monitoring System) sensors, ensuring correct real‑time monitoring of lubrication system flow, pressure, and temperature.
• Inspect, test, and calibrate sensors involved in lubrication, hydraulic pressure, temperature, vibration, and oil monitoring, which are critical to crusher health.
• Ensure sensor accuracy to support predictive maintenance strategies used in intelligent gyratory crushers equipped with advanced monitoring technologies.

Automation & Control System Support

• Support operation and troubleshooting of Metso Mainshaft Positioning systems, which automatically adjust crusher settings based on feed conditions and operational parameters.
• Maintain and validate data from digital monitoring platforms used in TSUV next‑generation crushers, ensuring correct communication and sensor inputs.
• Assist with configuration, maintenance, and fault analysis of intelligent crusher systems generating high‑frequency operational data (over 50 data points per second).

Fault Finding, Diagnostics & Reporting

• Diagnose instrumentation‑related issues such as sensor drift, wiring faults, pressure signal loss, incorrect temperature readings, and lubrication flow anomalies.
• Use predictive diagnostics and anomaly detection provided by intelligent crusher monitoring systems to identify early warning signs of failure.
• Document fault findings, calibration records, and maintenance actions for reliability tracking.

Compliance, Safety & Equipment Integrity

• Follow strict lockout/tagout procedures when opening cabinets, disconnecting sensors, or working on instrument panels; verify residual energy before performing work.
• Ensure instrument enclosures and panel doors remain properly sealed to prevent dust and moisture contamination, especially around relay contacts.
• Assist in maintaining system integrity during crusher shutdowns and startups, including pre‑startup inspection of hydraulic and sensor loops.

Skills & Competencies

Technical Competencies

• Proficient in industrial instrumentation involving pressure, temperature, flow, vibration, and hydraulic monitoring.
• Skilled in troubleshooting instrumentation for automated crusher systems (Metso; TIMS).
• Strong understanding of digital monitoring and predictive maintenance systems used in intelligent gyratory crushers.
• Competent in reading P&IDs, loop diagrams, wiring schematics, and OEM instrumentation manuals.

Operational Competencies

• Ability to analyse real‑time crusher performance data and correlate sensor outputs to mechanical/electrical equipment behaviour.
• Skilled in identifying early-warning conditions in lubrication, hydraulic, and structural systems through sensor diagnostics.
• Capable of supporting commissioning, shutdown calibrations, and instrumentation inspections under time‑critical conditions.

Qualifications & Experience

• Instrumentation Technician Trade Test / National Diploma in Instrumentation or equivalent.
• 3–5 years experience in mining or heavy industrial instrumentation.
• Experience working with primary gyratory crushers and their monitoring/automation platforms (e.g., Metso, TSUV sensing systems)