PLC Testing Engineer

Job Summary

We are seeking a Senior PLC Firmware Test Engineer with strong experience in validating PLC firmware used in power plant controllers. The role involves testing firmware that controls critical power generation processes, ensuring functional correctness, real-time performance, safety, and regulatory compliance.

The candidate will work closely with firmware developers, control engineers, and system architects to validate controllers used in thermal, hydro, gas, or renewable power plants.

Experience : 5-7 Years

Location : Bangalore

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Key Responsibilities

Analyze power plant controller requirements, functional specifications, and firmware design documents

Prepare and review test strategy, test plans, and test cases for PLC firmware

Execute functional, integration, system, regression, and stress testing

Validate:

o Control logic and sequencing

o Interlocks, permissives, and alarms

o Start up, shutdown, and emergency operating scenarios

o Fault handling and fail safe behavior

Perform real-time testing for scan cycle behavior, I/O response, and timing constraints

Conduct Hardware in the Loop (HIL) and bench level testing using real PLC hardware

Validate controller behavior for Boiler, Turbine, Generator, and Balance of Plant (BoP) systems

Test industrial communication protocols, including:

o Modbus RTU / TCP

o PROFINET

o EtherNet/IP

Identify, log, and track defects using JIRA / Azure DevOps, and support root cause analysis

Collaborate with control, firmware, and hardware teams to resolve issues

Support Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and customer audits

Prepare test execution reports, defect metrics, and test closure documentation

Guide and mentor junior engineers in PLC and power domain testing

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Mandatory Technical Skills

Strong experience in PLC firmware or controller testing

Hands-on exposure to power plant controllers

Knowledge of PLC programming languages:

o Ladder Logic

o Function Block Diagram (FBD)

o Structured Text (ST)

Understanding of:

o Real-time controller behavior

o Redundancy and failover concepts

o Alarm and diagnostic mechanisms

Strong test documentation and defect management skills

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Power Plant Controller Knowledge (Essential)

Understanding of power generation processes

Exposure to:

o Start up and shutdown sequences

o Interlocks and protection logic

o Emergency trip scenarios

Familiarity with safety critical control behavior

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Good to Have Skills

Knowledge of IEC standards:

o IEC 61131

o IEC 61508 (Functional Safety)

o IEC 61850 (Power systems advantage)

Exposure to SCADA / DCS / HMI integration

Basic scripting or automation using Python

Experience with certification, compliance, or regulatory testing

ISTQB / Embedded / Automation testing certification

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Soft Skills

Strong analytical and debugging skills

Ability to communicate effectively with cross functional teams

High attention to quality and detail

Ownership mindset and ability to work in safety critical environments

Mentoring and technical guidance capability