About Us:

At Tomball Controls, we specialize in manufacturing custom fuel tanks, custom sound attenuated enclosures, and access platforms for emergency power generators.

We are proud to serve clients across various industries, providing them with high-quality power packaging solutions to meet their specific requirements. With years of experienced team members and a commitment to excellence, we have built a reputation for delivering reliable and durable products on time and within budget.

Job Description:

We are seeking an experienced and highly motivated Test Technician Supervisor for our location in Von Ormy, TX (south San Antonio, TX). The ideal candidate will have hands-on experience operating and load testing diesel generator systems, a strong understanding of electrical and mechanical safety, and experience leading technicians in a field-service environment.

The Test Technician Supervisor is responsible for safely leading and performing load bank testing of diesel-powered generator systems in accordance with manufacturer requirements, customer specifications, applicable electrical standards, and company safety procedures.

The Test Technician Supervisor must possess a strong working knowledge of diesel generator operation, electrical distribution systems, load bank connections and operation, generator controls, and electrical and mechanical safety hazards.

A primary responsibility of this position is the continuous monitoring of generator and load bank performance and the ability to recognize abnormal operating conditions that could result in equipment damage, catastrophic failure, fire, electrical incident, or personnel injury.

The Test Technician Supervisor must have the judgment and authority to reduce load, remove load, or immediately terminate a test whenever operating conditions become unsafe or fall outside acceptable parameters. Meeting a testing schedule or completing a test shall never take priority over personnel safety or protection of customer equipment.

Key Responsibilities:

Load Bank Testing

• Lead and perform load bank testing of diesel-powered generator systems.
• Review generator nameplate information, manufacturer's requirements, customer specifications, and test procedures before beginning work.
• Determine appropriate load bank configuration and loading requirements based on generator capacity and test objectives.
• Safely connect and disconnect load banks using approved cables, cam-locks, lugs, bus connections, or other approved connection methods.
• Verify correct voltage, phase rotation, frequency, grounding, and connection configuration before applying load.
• Inspect all temporary connections, cables, terminations, and load bank equipment prior to energizing.
• Operate load banks and apply load in controlled increments.
• Continuously monitor generator and load bank operation throughout the test.
• Record required operating parameters at appropriate intervals.
• Perform load testing for the required duration and at specified load percentages.
• Properly unload and shut down the test when testing requirements have been completed or when abnormal conditions are identified.
• Safely disconnect and secure all temporary testing equipment following completion of the test.

Critical Operating Judgment

The Test Technician Supervisor is responsible for recognizing conditions that indicate a generator or load bank may be operating outside safe or acceptable limits. Recognizing a developing problem and terminating the test before equipment failure occurs is more important than completing the scheduled test.

The Test Technician Supervisor must be capable of identifying warning signs including, but not limited to:

• Abnormal or rapidly changing voltage.
• Frequency instability or significant frequency deviation.
• Excessive or rapidly increasing amperage.
• Voltage or current imbalance.
• Unusual changes in generator output.
• Excessive engine coolant temperature.
• Rapidly increasing coolant temperature.
• Low, dropping, or unstable oil pressure.
• Abnormal fuel pressure or fuel-system indications when monitored.
• Excessive exhaust temperature when monitored.
• Abnormal engine noise.
• Excessive or unusual vibration.
• Unusual smoke or changes in exhaust appearance.
• Fuel, oil, coolant, or other fluid leaks.
• Electrical arcing, sparking, smoke, or burning odor.
• Overheating cables, lugs, cam-locks, bus connections, or other electrical components.
• Load bank overheating or abnormal operation.
• Generator alarms or protective-device indications.
• Unusual electrical or mechanical sounds.
• Unexpected changes in engine speed.
• Any condition indicating potential engine, alternator, switchgear, load bank, or electrical-system failure.

Test Termination Authority

The Test Technician Supervisor has the authority and responsibility to immediately reduce load or terminate a load bank test whenever unsafe or abnormal conditions are observed. The technician must:

• Understand normal operating characteristics of the generator being tested.
• Establish acceptable operating parameters before applying load.
• Continuously compare actual operating conditions against those parameters.
• Recognize trends that indicate a developing problem before a protective shutdown or catastrophic failure occurs.
• Reduce load when necessary to stabilize an abnormal condition.
• Remove load immediately when continued operation could damage equipment or create a safety hazard.
• Initiate an emergency shutdown when required.
• Notify the appropriate supervisor, customer representative, or responsible personnel when a test is terminated.
• Clearly document the reason for terminating the test.
• Never continue a test solely to satisfy a scheduled load percentage or test duration when equipment operation is questionable.

The Test Technician Supervisor is expected to err on the side of protecting personnel and equipment. When in doubt about the safety or condition of the generator, the appropriate action is to unload and evaluate the situation rather than continue testing.

Electrical Safety Responsibilities

The Test Technician Supervisor must have a thorough understanding of the electrical hazards associated with generator and load bank testing. Responsibilities include:

• Recognizing electrical shock, arc-flash, arc-blast, and arc-fault hazards.
• Following applicable OSHA, NFPA 70E, company, and customer safety requirements.
• Establishing appropriate work boundaries around energized equipment.
• Using properly rated PPE and electrical test equipment.
• Verifying equipment status before making or removing connections.
• Following lockout/tagout procedures when applicable.
• Confirming absence of voltage before performing work where required.
• Ensuring proper phase identification and rotation.
• Ensuring proper grounding and bonding.
• Inspecting all cables and connections before and during testing.
• Monitoring connections for excessive heat, discoloration, arcing, or other indications of failure.
• Maintaining proper separation and routing of temporary power cables.
• Never bypassing safety devices, protective systems, or load bank interlocks without an approved procedure.

Mechanical and Environmental Safety

The Test Technician Supervisor must recognize hazards associated with operating diesel generators and load bank equipment, including:

• Rotating engine components.
• Cooling fans and belts.
• Hot exhaust systems and engine components.
• Pressurized cooling systems.
• Diesel fuel and fuel-system hazards.
• Lubricating oil and hydraulic pressure hazards where applicable.
• High-temperature radiator discharge air.
• Generator vibration.
• Exhaust gases and carbon monoxide.
• Fire hazards.
• Noise exposure.
• Weather and environmental conditions.
• Inadequate ventilation.
• Improperly positioned or secured load bank equipment.

The Test Technician Supervisor must continuously evaluate the work area and stop testing when environmental or mechanical conditions create an unacceptable risk.

Crew Leadership

• Supervisor assigned technicians during generator load bank testing operations.
• Conduct or participate in pre-job safety meetings and review the JHA/JSA.
• Ensure all technicians understand the testing procedure and identified hazards.
• Assign responsibilities according to technician qualifications and experience.
• Supervise proper load bank connections and disconnections.
• Ensure technicians understand expected generator operating parameters and test-termination criteria.
• Maintain control of the testing operation throughout the job.
• Stop work when unsafe conditions are identified.
• Lead by example in all safety practices.
• Communicate effectively with customers, supervisors, project managers, and other contractors.

Generator and Load Bank Knowledge

The Test Technician Supervisor must demonstrate a working knowledge of:

• Diesel generator operation.
• Three-phase electrical systems.
• Generator voltage and frequency characteristics.
• Generator nameplate ratings.
• Load bank ratings and operating requirements.
• Resistive and reactive load banks when applicable.
• Load bank connection methods.
• Generator control panels and basic protective functions.
• Generator alarms and shutdown systems.
• Voltage regulation and frequency control.
• Electrical distribution and temporary power connections.
• Proper loading and unloading procedures.
• Normal versus abnormal generator operating conditions.

The Test Technician Supervisor is not necessarily expected to diagnose or repair every generator problem. The technician must, however, be able to recognize when generator performance is abnormal, understand the potential consequences, and take appropriate action to protect personnel and equipment.

Documentation

• Complete accurate load bank test reports.
• Record generator identification and nameplate information.
• Record voltage, amperage, frequency, kW, power factor, and other required readings.
• Record load percentages and test duration.
• Document alarms, abnormal conditions, test interruptions, and test termination.
• Clearly document the reason a test was stopped when applicable.
• Report equipment concerns to the appropriate personnel.
• Obtain required customer signatures and complete all required test documentation.

Qualifications:

Minimum Qualifications

• Demonstrated experience operating and/or testing diesel generator systems.
• Demonstrated experience connecting and operating generator load banks.
• Strong understanding of three-phase electrical systems.
• Ability to read electrical one-line diagrams and generator documentation.
• Working knowledge of generator controls and protective functions.
• Strong understanding of electrical and mechanical safety hazards.
• Ability to recognize abnormal generator operation and determine when a test should be reduced or terminated.
• Ability to safely use electrical test instruments.
• Ability to Test Technician Supervisors in a field-service environment.
• Valid driver's license and acceptable driving record.
• Ability to travel to customer sites and work extended hours when required.

Preferred Qualifications

• Experience with industrial diesel generators and generator paralleling systems.
• Experience with Caterpillar, Cummins, Kohler, Generac, MTU, Detroit, and other major generator manufacturers.
• Experience with large industrial load banks.
• Experience with resistive and reactive load banks.
• NFPA 70E training.
• OSHA safety training.
• CPR/First Aid certification.
• Experience working around medium-voltage electrical equipment.
• Previous field-service or Test Technician Supervisor experience.

Safety Expectations:

Safety and equipment protection are the highest priorities of this position.

The Test Technician Supervisor is expected to maintain constant awareness of electrical, mechanical, thermal, fire, and environmental hazards throughout the testing process.

The Test Technician Supervisor must understand that generator load testing intentionally places a significant load on equipment and that conditions can change rapidly. The technician must continuously monitor the equipment and be prepared to unload or terminate the test before a developing problem becomes an equipment failure.

The Test Technician Supervisor has the authority and responsibility to STOP THE TEST whenever conditions become unsafe, abnormal, or outside acceptable operating parameters.

No test percentage, test duration, customer request, production schedule, or completion deadline takes priority over the safety of personnel or protection of equipment.

Key Performance Expectations:

A successful Test Technician Supervisor will:

• Safely perform generator load bank testing.
• Demonstrate strong knowledge of load bank connections and operation.
• Understand normal generator operating characteristics.
• Continuously monitor generator performance during testing.
• Recognize early warning signs of potential equipment failure.
• Make sound decisions regarding load reduction and test termination.
• Prevent avoidable catastrophic equipment failures through proper observation and judgment.
• Maintain control of the test operation and field crew.
• Communicate concerns immediately and effectively.
• Produce accurate and complete test documentation.
• Protect customer equipment and personnel at all times.
• Know when to stop the test.

Physical Requirements:

• Ability to work around operating diesel generators and energized electrical equipment.
• Ability to work outdoors and in industrial, construction, and mechanical environments.
• Ability to work in hot, cold, wet, dusty, and noisy environments.
• Ability to climb ladders and stairs.
• Ability to stand, bend, kneel, crawl, and work in restricted areas.
• Ability to safely handle heavy electrical cables and testing equipment using appropriate lifting and material-handling procedures.
• Ability to wear required PPE for extended periods.

Equal Opportunity Employer/Minorities/Women/Veterans/Disabled

• Tomball Controls is an Equal Opportunity and Affirmative Action Employer. Tomball Controls is committed to ensuring equal employment opportunities for all job applicants and employees. Employment decisions are based upon job-related reasons regardless of an applicant's race, color, religion, sex, sexual orientation, gender identity, age, national origin, disability, marital status, genetic information, protected veteran status, or any other status protected by law.